THESE INJECTORS WILL ONLY WORK IF YOU USING A MEGASQUIRT SYSTEM

This is guide is for modifying your KLDE fuel rails and installing Nissan Injectors along with how to shave them.

Why use Nissan injectors? These are by far the most affordable option for using a larger injector on these engines and can utilize the stock rails. These Injectors can be purchased usually on ebay or forums complete in rails with connectors or found individually reconditioned or new.
To date, the only other option is 2nd Gen Rx7 Secondary Injectors and Custom injector setups that include custom built fuel rails witch are both expensive.

Nissan Injectors Modification

Modify OEM Rails for Nissan Injectors, Shave Nissan Injectors, Wiring Nissan Injectors, Testing Nissan Injectors

The biggest hurdle when turbo charging the KL V6 engine is the injectors.  To date the only drop in injectors that are larger then stock are the Millenia S injectors, this from the supercharged millenia Model. 

The OEM KL (DE,ZE,G4) injectors are 220cc, good for about 4psi of boost, fuel pressure set to 60psi.

The OEM Millenia S Injectors are 280cc, Good for about 8psi of boost , fuel pressure set to 50psi.

Both these injectors are not an ideal size for turbo charging the KL, they will required increased fuel pressure to allow moderate amounts of boost, while they peak at 90% or higher duty cycle.   The higher the duty cycle, the increased stress thats put on the injector..  injectors at 90% Duty cycle can stop working or stick open, Additionally  at this duty cycle your at the limitations of the boost you can run.

This is where Nissan Side feed injectors come into play, they are affordable and only require modification of the fuel rail to be used. Below is the documentation of the modifications needed.   Additionally, these injectors can be shaved, turning them into larger injectors very easily at no additional cost.

Injector Shaving                    Injector Wiring               Injector Testing

First, the top of the rails will need to be shaved down 0.205″, this is important being the Nissan’s are shorter then stock.

Second, each injector housing will need to be bored to 0.990″ to fit the Nissan injector.

Third, the hats that hold down the injector will need the holes bored out to 1/4″

This is a comparison of the stock injector vs a Nissan injector.
1.You will need to use the Top O-ring from the Nissan injector in this Installation, so leave it on.
2.You will need to use the Bottom O-Ring from the stock Injector in this installation so swap them onto the Nissan’s.
3. It is recommended to use the Black pintle caps from the stock injector on the Nissan injector for correct spray pattern, be sure to get them in the correct spray position

Use some Vaseline to coat the O-rings of the Injectors and push them in and then put the hats on using the stock screws to secure them.

Attach the wiring harness and it is recommended to test the injectors with an external fuel pump and a cleaning solution to test for leaks and correct spray pattern.

Shaving the Injectors

Shaving an Injector will increase its flow volume.

Using a hand file or sand paper, carefully sand/file down the head of the injector.

Keep sanding/filing untill you start to see the center section lifting off.

When the center section starts to lift off, you can use a pick or piers to peel it away.

You will be left with a small pinhole, use some steal wool to clean up the head of the injector and they are now shaved.

Injector Wiring

How to Wire your injectors for Megasquirt / MSPNP2

The following diagram demonstrates how to wire the injectors.  Megasquirt fires the injectors in batch, so they will be wired bank 1 and bank 2. If your running a MS3 or other system with sequential injection, yours will be wired independently.