Turbo City EFI: A Bolt-On Upgrade

Fuel injection is a highly sought-after upgrade for many 4x4 enthusiasts. It promises improved fuel economy, enhanced reliability, and the elimination of frustrating engine stalls during challenging off-road manoeuvres like steep ascents, descents, or side-hilling. For those looking to modernise their vehicles without embarking on an overly complex or costly project, finding a straightforward, cost-effective solution is paramount. When embarking on a project, such as a Land Cruiser build, the vision for the powertrain often solidifies. While initial ideas about tyre sizes might evolve – dreaming of larger rubber for tackling tougher terrain – the core desire for a robust engine and a reliable transmission usually remains. In this case, the project vehicle received a healthy 1987 Chevrolet 350 V8 engine, coupled with a Turbo 350 automatic transmission, simplifying the driving experience by keeping both hands on the wheel and vital controls.

The Quest for a Bolt-On Solution

With the engine and transmission securely in place, the next critical decision revolved around the fuel and air delivery system. Fortunately, the chosen 1987 model 350 engine came equipped with factory fuel injection, negating the need for modifications such as changing intake manifolds or blocking off fuel pump openings. The primary objective was to find a fuel injection kit that was as close to a 'bolt-on' as possible. The idea of spending countless nights scavenging parts from a scrapyard or dealing with aftermarket systems requiring specialised tools, extensive tuning, or constant maintenance was unappealing. The desire was for a system that used readily available parts, ensuring ease of maintenance and accessibility to replacement components from any reputable auto parts store. This presented a significant challenge, and the search for such an ideal system involved extensive research and consultation with industry professionals.

Introducing Turbo City's Fuel Injection Kit

After a rigorous three-week endeavour, numerous conversations with colleagues across various automotive sectors, and countless phone calls, the search narrowed. The team discovered a promising candidate: a fuel injection kit from Turbo City, based in Orange, California, which claimed to be a genuine 'bolt-on' unit with only minor modifications required. This universal kit is designed to be adaptable to a range of applications, necessitating only basic fabrication skills that most enthusiasts can manage. Examples of these minor modifications include rerouting fuel lines, adjusting or fabricating a simple throttle linkage, and connecting vacuum lines.

What Makes it a Bolt-On Kit?

The specific kit ordered, part number 970-100, begins its life as a stock General Motors throttle body unit. It incorporates commonly used and readily available components and sensors, such as the knock sensor, O2 sensor, weather-tight connectors, and the Engine Control Unit (ECU). Turbo City then applies its expertise to enhance these components. They develop custom computer chips in-house to boost power and efficiency while maintaining factory-level reliability. Furthermore, they manufacture their own wiring harnesses. While these harnesses are supplied pre-packaged, all sensors arrive pre-connected and clearly labelled, significantly simplifying the installation process. The ease of installation is often described as a 'piece of cake'. The most involved aspect typically lies in strategically locating the ECU and all the necessary sensors, a process that will be detailed further.

Installation Walkthrough

Once the fuel injection system was physically bolted onto the engine, the installation process, for the most part, took approximately 4 to 5 hours of focused work. Initial short tests were conducted to ensure the system was receiving power. With about five gallons of fuel added to the tank, the moment of truth arrived. A deep breath, crossed fingers, and a turn of the ignition key resulted in a satisfying VROOOOM! The engine fired up and ran on the first attempt, a remarkable achievement for such a significant powertrain modification. While a slightly rough idle and some initial black smoke were observed, these were quickly rectified by diagnosing and replacing a faulty EGR valve – a component that was part of the original engine and not a fault of the Turbo City kit. Following this, the vehicle was ready to cruise the boulevards in style, powered by fuel injection.

Comparing the Benefits

Compared to other kits evaluated, the Turbo City fuel injection system offered a compelling array of advantages. The installation was not only straightforward but also remarkably quick. The kit provides all the necessary components for a direct bolt-on fit, and the accompanying instructions are clear and comprehensive. Over several months of use, the fuel injection system has performed flawlessly, even when subjected to varying altitudes, demonstrating its robust and reliable nature. These factors solidify the Turbo City kit as an excellent choice for those seeking a true bolt-on fuel injection upgrade.

Important Installation Considerations

It is crucial to acknowledge that installation procedures can vary significantly depending on the specific make and model of the vehicle. As a fundamental safety precaution, always begin any installation involving electrical or fuel systems by disconnecting the vehicle's battery. This often-overlooked step is paramount for safety. Subsequently, carefully assess both your vehicle and the fuel injection system to plan the optimal mounting locations for all sensors, the wiring harness, and the ECU. In this particular Land Cruiser build, the sensors were strategically placed on the firewall, positioned above and to the sides of the distributor. The wiring harness provided is quite long, offering the option of shortening it. However, to mitigate the risk of damaging an expensive harness or causing a short circuit, the decision was made to avoid splicing wires. Instead, the harness was neatly looped and secured out of the way of heat sources and moving parts using Adel clamps and existing vehicle mounting points.

Component Placement and Wiring

Once the ideal locations for all components were determined, the installation could commence in any order. The initial step involved bolting the throttle body onto the intake manifold. Following this, the installation of sensors, including the O2 sensor and knock sensor, began. With the wiring harness laid out across the engine, the optimal position for the ECU was identified and marked. The glove box was chosen as the mounting location for the ECU, offering protection from the elements and the potential for overheating. With the ECU's intended position established, the firewall was marked from the interior to indicate where the wiring harness would need to pass through. A section of the firewall, slightly larger than the harness, was then cut to allow the wires to pass through without risk of chafing. After this, the connectors from the harness were routed through the firewall to the ECU. The ECU was then plugged in and secured to the floor of the glove box using a 1/2-inch rubber bushing. This mounting method elevated the computer, ensuring adequate airflow and isolating it from vibrations and jolts experienced during off-road excursions. With the ECU mounted and the harness connected, the majority of the wiring harness was secured with Adel clamps.

Fuel Pump and Line Installation

A more intricate aspect of the installation involved fitting the low-pressure, electric fuel pump. The pump must be installed below the level of the fuel tank. For the Land Cruiser, with its fuel tank located inside the vehicle, beneath the passenger seat, this was relatively straightforward. The chosen mounting location was on the side of the frame rail, positioned above the forward rear spring mount, offering good protection. The next challenge involved identifying the correct fuel lines from the six metal tubes protruding from the gas tank. Despite the absence of fuel tank schematics from the dealership, a process of elimination and consultation with contacts eventually helped decipher the feed and return lines. Once this hurdle was overcome, the electrical wires and all fuel lines were connected and secured with Adel clamps and hose clamps.

Final Connections and Testing

With all components mounted and secured, power was supplied to the system by connecting the appropriate wires to the battery and available slots in the fuse box. It's important to note that at this stage, no wires had been trimmed or shortened. After all connections were made, the negative battery cable was reattached to the battery, and a careful watch was kept for any signs of smoke – thankfully, none appeared. The next step involved verifying correct voltage to specific system areas and measuring resistance on particular sensors to ensure everything was functioning as expected. After thorough checking and rechecking, the engine was started. The system operated precisely as planned, and the engine was run through its paces. With all systems operating correctly, time was taken to protect any exposed wires with wire loom. Additionally, some wires were lengthened or shortened to improve aesthetics and protection. Following these final adjustments, the Land Cruiser embarked on its inaugural drive, experiencing the benefits of its new fuel injection system.

Troubleshooting Common Issues

While the Turbo City kit is designed for ease of installation, some common issues might arise. A rough idle or stalling could indicate a vacuum leak. Carefully inspect all vacuum line connections and ensure they are secure and properly routed. Black smoke, as experienced in the installation example, often points to an issue with the EGR valve or an overly rich fuel mixture, which might require ECU recalibration or sensor adjustment. Ensure all sensors are correctly installed and making good contact. A check engine light could illuminate for various reasons, often related to sensor readings. Consulting the kit's diagnostic codes or a generic OBD-II scanner (if applicable to the system) can help pinpoint the problem. Always double-check wiring connections; loose or incorrect wiring is a frequent culprit for system malfunctions.

Advantages of Fuel Injection Over Carburetion

The transition from carburetion to fuel injection offers several significant advantages for off-road vehicles:

Frequently Asked Questions (FAQs)

Q1: Is the Turbo City EFI kit truly a direct bolt-on?
While Turbo City markets it as a bolt-on kit, minor modifications such as rerouting fuel lines and adjusting throttle linkage are typically required. However, these are generally manageable for most DIY enthusiasts.

Q2: What kind of performance improvements can I expect?
Owners often report improved throttle response, smoother idle, better fuel economy, and increased power due to more precise fuel delivery and the custom ECU tuning.

Q3: Is this kit compatible with my specific vehicle?
The kit is designed as a universal system, but compatibility will depend on your engine and vehicle's existing setup. It's always recommended to consult with Turbo City or review their specifications to confirm compatibility with your application.

Q4: How difficult is the fuel pump installation?
The fuel pump must be mounted below the fuel tank's level. The complexity will depend on your vehicle's fuel tank location and the available space for mounting.

Q5: Can I use my existing fuel lines?
In many cases, you will need to adapt or replace your fuel lines to connect to the new fuel injection system components. Rerouting existing lines or installing new ones is often part of the process.

Q6: Where is the best place to mount the ECU?
The ECU should be mounted in a location that is cool, dry, and protected from excessive heat and vibration. The glove box, as demonstrated, is a common and effective choice.

Conclusion

The Turbo City fuel injection kit presents a compelling option for 4x4 owners seeking to upgrade from carburetion. Its design, which incorporates readily available GM components and custom tuning, combined with a well-documented and manageable installation process, makes it a strong contender. While minor fabrication is expected, the overall ease of installation and the significant improvements in performance, reliability, and drivability—especially in challenging off-road conditions—justify the effort. For those prioritising a straightforward path to modernising their vehicle's fuel delivery, the Turbo City EFI kit stands out as a practical and effective solution.

Contact Information:
Turbo City
1137 West Katella Avenue
Orange, California 92867
Voice: 714-639-4933
Fax: 714-997-1196
Email: [email protected]
Web Site: http://www.turbocity.com