http://www.superchevy.com/how-to/0306vet-rochester-fuel-injection-system/ Rochester RX: Part II Air Meets Fuel As We Continue To Explore The Mysteries Of The Rochester Fuel Injection System
John Nelson May 7, 2003 2/45
Here's our nearly complete '60 Rochester fuel injection unit, looking good as new. This view shows off the air meter side of the unit, which is the part of the system we'll be focusing on in this installment.
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This simplified diagram shows the basic function of the air meter. Air passing through the intake creates a vacuum. This vacuum passes through a tube to the main control diaphragm, which adjusts the moveable pivot and lever system, and allows the correct amount of fuel to be fed to the injectors.
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In this view of the air meter, Rochester expert Chuck Smith has slid the throttle valve shaft into place and inserted the butterfly valve in its proper position.
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After replacing the two butterfly valve screws, Chuck completes the throttle valve shaft assembly by installing the throttle linkage. It's held in place by a roll pin (1). The set screw (2) should be adjusted until the butterfly shows proper clearance...
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...which is .003-inch, as measured with a feeler gauge.
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The idle speed screw is then replaced. Chuck screws it in all the way before backing it out two full turns. This gets you in the ballpark, but the final adjustment will have to wait until the completed unit is back on the car.
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The air/fuel ratio screw is backed out two turns from fully seated. As with the idle speed screw, final adjustment will have to wait until the unit is replaced.
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At this point, the air meter can be bolted onto the intake manifold (aka the "doghouse"), using the proper gasket (arrow), of course.
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The air diffuser is then screwed to the air meter. This cone creates a venturi effect, which in turn creates the vacuum signals that control the Rochester F.I. fuel meter system. Note the O-ring on the meter (arrow), which needs to be fully seated in its groove.
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Our next step is to reassemble and reinstall the choke unit. As you can see in this diagram, the enrichment vacuum tube passes through the choke. During cold starts, the choke cuts off the vacuum from the air meter with a check ball. This puts the fuel enrichment diaphragm in a "more fuel" position. As the choke thermostat heats up, the check ball allows vacuum to pass through, returning the system to normal operation.
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Our first order of business is to replace the smaller signal control valve in the choke housing...
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...followed by the aforementioned check ball...
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It's all held in place with this steel cap...
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...which is tapped into place with a hammer and a small drift.
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The other, larger signal control valve and its spring are helped in place with a brass cap.
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The choke housing is then screwed into place on the air meter, again using the proper gasket.
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After a thorough cleaning, the original electric choke unit itself is then replaced. It's especially important to make sure that the lever (arrow) is free of corrosion.
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In this shot, our choke assembly is nearly complete. The electric choke unit has been screwed into its housing, with its ground wire in place (1). The pivot assembly has been installed onto the choke (2), while the choke "cam" has been screwed to the air meter (3). The rod that connects them is in place (4), and the choke idle screw has been replaced (5). Chuck sets the screw to contact the low spot in the cam; final adjustment will have to be made when this unit is installed. He then sets the adjustment on the choke unit itself at 1-1/2 notches "rich," or counterclockwise.
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At this point, the air meter is almost complete, and it's time to move on to the injector assemblies. The injector nozzle consists of, from left to right, the nozzle head, a nozzle disc (which allows the proper amount of fuel to enter the nozzle), a nozzle screen to help keep the disc clean (the correct side must be facing down or fuel won't flow), and the nozzle body. Chuck makes sure each nozzle assembly is working properly by spraying carb cleaner through it. Parts are replaced as necessary.
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Every nozzle head is fitted with a small O-ring before being inserted into the nozzle block.
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The nozzle assemblies are run through the block and into these brass fittings (arrow), which correspond to the holes in the intake manfold.
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The bolt holds the block to the manifold, while the small metal place holds the injectors in place.
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Chuck then flips our Fuelie unit over to install the fuel lines, commonly known as "The Spider." Here, he's fitted the center of the Spider into its rubber grommet and made sure that the lines clear the throttle linkage.
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Each line is then connected to its corresponding injector block. These lines look just as they should. According to Chuck, several of the lines had been bent closer to the doghouse in a misguided attempt to make the system look better. He carefully bent them back to their proper position.
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The main fuel line (arrow) is then installed, allowing go-go juice to flow from the fuel meter to the Spider.
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Coming into the home stretch, it's time to connect the air meter and the fuel system. The "H" shaped system of metal tubes and rubber hoses allow vacuum from the air meter to reach the injector nozzles, which helps the fuel to atomize.
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In this photo, the vacuum tube to the main control diaphragm has been installed. Chuck is fastening one end to the air meter; he's pointing at the other end, which attaches to the T-fitting atop the fuel meter, with a screwdriver.
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Looking underneath the unit, we can see how the vacuum tube to the main control diaphragm is routed (1). We've also installed the vacuum enrichment tube (2), which is connected to the fuel enrichment diaphragm (3), routed under and through the injector vacuum tubes...
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...and connect to the appropriate fitting on the choke housing (arrow).
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The remainder of the throttle linkage is then installed. The throttle linkage bell crank is held onto its shaft with a cotter pin (behind the throttle spring); the throttle rod bolts to the linkage on one end and the throttle valve linkage on the other.
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This fitting is then replaced onto the doghouse; it won't be reconnected until the unit is back in the car.
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After putting the intake manifold gaskets in place, Chuck reunites the fuel injection unit and the manifold.
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And finally, the ballast tube is routed across the front of our great-looking and almost-ready-to-go Rochester fuel injection unit. In Part Three, we'll finish up with two critical, but often overlooked components: the Rochester system's high-pressure fuel pump and the unique distributor that drives it. See you then!
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YOU MUST READ THIS BOOK!
In Part One, we extolled the virtues The Chevrolet Ramjet Fuel Injection System, which is being reproduced by Corvette America. (Route 322, Box 427, Dept. VM, Boalsburg, PA 16827; 800/458-3475, www.corvetteamerica.com). In preparing to write Part Two of "Rochester Rx" I referred to this pamphlet again and again to make sure I understood how the unique system works. Each subsystem is explained in detail, and the line drawings are top-notch; several have been used in this story. It's fascinating and useful reading, for the do-it-yourselfer the merely curious, and for those seeking to know everything about vintage Corvettes. Like we said before, when it comes to taking care of a Rochester F.I. system, you can't have too much information.
Sources
Chuck Smith Performance Services
Valley Center, CA 92082,
GaryHodgesRamjet.com Corvette and Chevrolet Carburetor and Rochester Fuel Injection Specialist. Gary Hodges Ramjet, Ltd., providing the finest in carburetor and fuel injection parts for Corvette, Chevrolet, muscle-cars and hot rods. Rochester fuel injection parts, Carter Carburetor parts...
GaryHodgesRamjet.com Corvette and Chevrolet Carburetor and Rochester Fuel Injection Specialist. Gary Hodges Ramjet, Ltd., providing the finest in carburetor and fuel injection parts for Corvette, Chevrolet, muscle-cars and hot rods. Rochester fuel injection parts, Carter Carburetor parts...
www.garyhodgesramjet.com
Gary Hodges Ramjet, Ltd.
Rochester Fuel Injection Parts & Units Distributors & Parts
One of my favorite college instructors called the Rochester
fuel injection system the "Rottenchester dribble system." S E R V I C E
ROCHESTER FUEL INJECTION UNIT REBUILDING & RESTORATION
GaryHodgesRamjet.com Corvette and Chevrolet Carburetor and Rochester Fuel Injection Specialist. Gary Hodges Ramjet, Ltd., providing the finest in carburetor and fuel injection parts for Corvette, Chevrolet, muscle-cars and hot rods. Rochester fuel injection parts, Carter Carburetor parts...
www.garyhodgesramjet.com
An electric fuel shut-off safety solenoid (to protect against hydraulic compression damage) is necessary on all years units. They can be nicely hidden under plenum. We stronglyurge a safety solenoid on ALL fuel injection systems. Solenoids are aircraft style for gasoline usage.
We strongly suggest that your distributor be rebuilt with your unit to ensure total proper operation. P A R T S
AIR CLEANERS, AIR FILTER ELEMENTS, HOSES, CLAMPS & RELATED
57 FI Air cleaner assembly–repro. Includes element, lid,
stud, and wing nut, with tab!............................................................ 1150.00
58-62 FI Air Cleaners—repro-complete (element included) ...................... Please Ask
57-9 FI Passenger Car Air cleaner assembly .................................................... OUT
58-61 FI Air Filter Element--washable ................................................................75.00
62 FI Air Filter Element, Foam, correct thickness & porosity--Ours fits, too!.35.00
62-65 FI Air Filter Element, Washable!! really nice elements!! ....................... 110.00
58-65 FI Clamp, Air Cleaner Duct Hose Clamp 4 3/4" CORRECT.....................29.00
58-61 FI Hose, Low-horse FI, 4-3/4" (short hose only) ................................ 25.00 63-64 FI Hose Ribbed, Air Cleaner to Unit, thick-type .............................. 85.00
57 FI Air filter element-nice replacement, black-Fits great............................18.00 62 FI Bracket, strap and stud, air cleaner adapter mt. to air meter............... 25.00
58-62 FI Air Cleaner Adapter, available, ask often in stock................................ASK
CHOKE & RELATED
63-65 FI Cover, Choke, with spring--perfect!................................................. 140.00
57-61 FI Cover, Choke, with wire assembly, bakelite....back in stock!..... 220.00
62 FI Cover, Choke, with wire assembly, bakelite......back in stock!... 240.00
57-65 FI Screw, Fast Idle Cam (pivot mounting)....................................... 10.00
57-62 FI Screw, fast idle speed control......................................................... 6.00
63-65 FI Spring & Seal Kit,chokeshaft............................................................. 7.00 57-65 FI Spring, fast idle cam control........................................................... 12.00
57-65 FI Fast idle cams, many variations, specify which needed.. price varies
62-65 FI Baffle, inside choke housing.............................................................. 8.00
57-61 FI Choke housing (enrichment housing) small parts & rebuild parts Ask
63-65 FI Choke housing, correct repro., nice!........................................... 250.00
57-62 FI Choke wiring harness repair kits, cover to resistor...................... 25.00
DISTRIBUTOR PARTS, REBUILD KITS & RELATED
57 FI Cap, nice replacement................................................................... 35.00
58-65 FI Cap, nice replacement single window........................................... 35.00
58-62 FI Cap, Dual Window (& 62 340 HP)--NOS, very limited supply!.......... out
58-62 FI Cap, Dual Window (& 62 340 HP)................................................ COMING 58-65 FI Advance weights NOS 737 VERY limited supply................. (pair) 40.00
57-65 FI Rotors (available, prices vary) ..................................................... Ask!
57-65 FI Cross Shaft (specify dist. number & year)........................................ 90.00
57-65 FI Gasket, Dist. Base to Intake &Spacer.........................................(pair) 8.00
57-65 FI Gasket, FM Cable Drive Adapter--our own repro................................ 6.00
58-65 FI Gasket, Dist. Plate--our own repro................................................ 6.00
58-65 FI Gasket, Dist., Upper to Lower Housing--our own repro...................... 5.00
58-65 FI Gasket Kit, Distributor (5-piece kit)........................................... 30.00
57-65 FI Gear set,distributor Cross Shaft......................................................275.00
58-65 FI I.D. Plate, Distributor, with YOUR numbers........................................ Ask!
57-65 FI Oil Line Kit (specify year & distributor number- pass. too)............... 65.00
57 FI Rebuild Kit, Distributor,seals, gaskets, O-ring (specify dist. number 65.00
57 FI Rebuild Kit, Dist. Deluxe--above plus bearing & fasteners
(specify number) ................................................................ 100.00
58-65 FI Rebuild Kit, Distributor--all seals & gaskets (specify year/model)..... 60.00
58-65 FI Rebuild Kit, Dist., Deluxe--above plus fasteners
(specify dist. number) ...................................................................... 65.00
58-65 FI Shaft, Dist. Main...............................................................................CALL
58-61 FI Shaft, Dist. Main, 1110915 only--NEW!..................................... 150.00
59-65 FI Spacer--our own repro, with two gaskets,..................................... 40.00
58-61 FI Tach drive cap (when not using tach drive)................................... 40.00
57-65 FI Tach drive cable adapter coupler—NEW!...................................... 55.00
63-65 FI Vacuum Advance Canister, NOS Delco, varies with application)....CALL
63-65 FI Vacuum Advance Canister, Properly calibrated 201&236. ... OUT
FUEL INJECTION UNITS, DISTRIBUTORS & REBUILD KITS
UNITS AND DISTRIBUTORS FREQUENTLY IN STOCK............................................. Call Currently available, 4800, 4960, 4900, 7320, 7360......................................... call for details!
57-62 FI Rebuild Kit, includes leg gaskets now with VITON seals!.................. 220.00
57-59 FI Rebuild Kit, includes one-piece plenum gasket (if desired)................. 250.00
63-65 FI Rebuild Kit, includes leg gaskets, lid gasket now with VITON seals!.....230.00 FUEL LINES, FILTERS, ELEMENTS
57-58 FI Filter assembly, element, bracket, and studs...........................................Out
57-58 FI Fuel Filter Element NEW NEW NEW!!!!!!!! GF 130 reproduction.... 120.00
58L-61 FI Fuel Filter Element new stock........................................................... 9.00
62-65 All GF90 Filter, Silver............................................................................ 48.00
63-65 All GF90 Filter, Black with silkscreen................................................. 48.00
57-58 FI Fuel Line, Fuel Pump to Unit (2 pieces with fittings)......................... 50.00
59-61 FI Fuel Line, Fuel Pump to Unit (complete with fittings)...................... 45.00
62 FI Fuel Line, Fuel Pump to Unit ..................................................... 45.00
63-65 FI Fuel Line, Chrome WITHOUT filter ........................CALL.....................OUT GASKETS -- FI, DISTRIBUTOR & RELATED
57-65 FI Gasket, Air Cleaner Adapter to Air Meter--our own repro.................. 8.00
57-65 FI Gasket, Air Meter to Plenum--our own repro....................................... 5.00
58-65 FI Gasket, Distributor Plate--our own repro............................................ 6.00
57-65 FI Gasket, Distributor Base to Intake & Spacer--our own repro. (pair) 8.00
58-65 FI Gasket, Distributor Housing Upper to Lower--our own repro.............. 5.00
57-65 FI Gasket, FM Cable Drive Adapter--our own repro............................. 6.00
57-65 FI Gaskets, Nozzle (seals nozzle to block) Viton.............(set of 8) 15.00
57-65 FI Gaskets, Nozzle Block, for 4360, 4520 OR all 4800-7380..(set of 4) 15.00
57-59 FI Gasket, Plenum (fits 57-62) ONE-PIECE ................................... 50.00
60-62 FI Gaskets, Plenum Leg (4)--our own repro (will fit 57-59).................. 20.00
63-65 FI Gaskets, Plenum Leg (4)--our own repro .................................... 20.00
63-65 FI Gasket, Plenum Lid (rubber).................................................... 20.00
57-65 FI Gasket Set, Intake Manifold-two styles, 57-62E, 62L-65................ 40.00 HARDWARE -- BRACKETS, SPRINGS, STUDS, CABLE
57-65 FI Bellcrank Mounting Stud oversize diameter, neat...................... 20.00
57 FI Bellcrank Mounting Stud, unit , standard diameter(neat!)............... 20.00
57-60 All Bolt Set, Intake Manifold AP Head, set of 12 ............................... 18.00
61-63 All Bolt Set, Intake AP, set of 11 bolts & 1 filter bracket stud kit .............20.00
63-65 All Stud, GF90 Bracket, or 61-62 Surge Tank Bracket. ....................... 8.00
58-62 FI Capacitor Mounting Bracket..................................................... 18.00
58-62 FI Coil Bracket........................................................................................ 30.00
58-63 FI Cranking Signal Valve--rebuilt orig. --Exchange only,
must have core first--sorry!.................................................... 140.00
57-65 FI Fitting, Vacuum Take-off, Plenum (vac. advance).................... 20.00
57-65 FI Bellcrank Mounting Studw, etc.)...................................................... 20.00
63-65 FI Fitting, Power Brake Plenum vacuum fitting, New!
Dead-on Accurate!!............................................................... 40.00
57-58 FI Cable Assembly, Fuel Meter Drive, hex nut-specify year)................165.00
59-65 FI Cable Assembly, Fuel Meter Drive, knurled nut--new repro.............165.00
57-58 FI Nut, Hex, for drive cable (wide ’57, narrow ’58) (specify year)......... 35.00
57-65 FI Cable, Fuel Meter Drive, Inner only (specify length: 6-5/16" or 6-3/4") (deluxe)made correctly! Pontiac too!....................................(each) 45.00
57-62 FI Choke cover to resistor wiring harness (repair kits) ....................... 25.00
63-65 FI Flags, Plenum -- Limited Supply.................................................. OUT
57-65 FI Fuel Meter Shield -- Correct...................................................... 22.00
58-63 FI Fuel Meter COVER!!! NEW!!! All (Incl. 64 7375)........................... 395.00
64-65 FI Fuel Meter COVER!!! NEW!!! All with 7380 unit......................... CALL
57-65 FI Hardware Kit (fasteners, etc.)--correct type...................................... 55.00 58-65 FI Hose Clamp, Air Intake, 4-3/4" hose--CORRECT!........................... 29.00
57-61 All Hose Clamp, Heater Fresh-Air, 4" hose (all Corvette........................25.00
57-62 All Hose, Heater Fresh-Air, 4”......................................................... 40.00
57-65 FI Hose Kit, Idle Air (specify year)................................................. 50.00
57-65 FI Internal "Axle" Link--SUPERB REPRO!..................................... 285.00
57-65 FI Kit, Drive Cable Repair, fiber washers and O-ring.......................... 10.00
57-63E FI Main Diaphragm Covers, New! Excellent!!!....................................185.00
57 FI Micro switch rub shield ......................................................................OUT 57-65 FI Nozzle Block--SUPERB REPRO! (57-62 or 63-5)............... (each) 125.00
57-65 FI Nozzle Block Gaskets (block to plenum).........................(set of 4) 15.00
57-65 FI Nozzles--excellent repro (specify year & unit number)... (set of 8) 435.00
57-65 FI Nozzle Seals (seals nozzle to block)................................. (set of 8) 15.00
57-65 FI Nozzle Screens....................................................... (each).. 15.00
57-65 FI Nozzle Top Section (to replace cracked tops).............. (each)........ 25.00
57-65 FI Oil Line Kit, Distributor (57-59 passenger also)................................ 55.00
57-65 FI Oil Filler Caps (Specify needs--Price varies) In stock..................... Ask
64-65 FI PCV Restriction, front of plenum .............................................. 20.00
57-65 FI Piezometer Ring--New! ................................................................ Ask 57-65 FI Plug 1/4 pipe for plenum hex New!............................................... 10.00
57-65 FI Pump Shaft & Seal .....--repro (high pressure pump) with viton........95.00
57-65 FI Pump Seal (Viton seal)................................................................... 25.00
57-65 FI Ratio Lever--New!...................................................................... ASK
57-65 FI Return Spring, Primary Accelerator (specify year)............................ 22.00
1958 FI Extension NEW!!!!!! return spring to bracket.....................................10.00
57-58 FI Return Spring Bracket............................................................. 22.00
59-62 FI Return Spring Bracket............................................................. 22.00
63-65 FI Return Spring Bracket.............................................................. 22.00
57-61 FI Tach Drive Unit for low HP FI Cars.............................................. Out
57-65 FI Tags, Plenum available!......................................................On back order
57-65 FI Foil tag, correct lacquer "candy yellow-gold" dated............................40.00
57-62 FI Throttle Rod Kit, Bellcrank to Air Meter (New! Better!)................... 45.00
63-65 FI Throttle Rod, Bellcrank to Air Meter--NOS.............................................. out
59-62 FI Throttle Control Rod, Bellcrank to Firewall Accelerator with swivel and with
swivel and sleeve...............................................................................55.00
63-65 FI Throttle Control Rod, Bellcrank to Firewall Accelerator
with swivel and sleeve--63-65....................................................... 55.00
57-65 FI Screw, Fast Idle Cam to air meter mounting.................................. 10.00
57-62 FI Screw, Fast Idle Speed................................................................... 6.00
59L-65 FI Siphon breaker (inside fuel meter)................................................. 35.00
57-65 FI Solenoid, safety fuel shut-off--prevent hydraulic cylinder compression (kit)
(will fit all)........................ '57-62 $150......... '63-65 175.00 ................. 59-65 FI Spacer, Exhaust, 2" or 2-1/2"......................................................... Ask
57-58 FI Spacer, Exhaust--New! (says Top)................................................ 65.00
57-62 FI Spider bracket to plenum............................................................. 12.00
57-65 FI Spider, individual lines, ferrules, and nuts -- WE HAVE EM!............... Ask
57-65 FI Fuel Spider Assembly--New reproduction (price varies, specify year
and unit) in stock ............................................................................... Ask
58-65 FI Spill Valve (thumb tack type)--New! (the best!) ............................ 140.00
57-65 FI Stud, Intake Base Plate to Plenum--New!..... each 5.00 or set of 8... 35.00
57-65 FI Spring-enrichment housing spring--NEW NEW NEW!!!!!!................. 15.00
58-62 FI Water Outlet (thermostat housing) aluminum “233” repro ................ 65.00
63-65 FI Water Outlet (thermostat housing) cast 3782370 repro .................... 65.00
MANUALS
1957 FI Service Manual (special edition with intro. to 58-61)........................... 40.00
58-62 FI Service Manual ........................................................................... 15.00
63-65 FI Service Manual ............................................................................ 15.00
53-62 FI Shop Manual, ST-12 excellent FI section! ......................................... 30.00
63-65 FI Shop Manual, ............excellent FI section! ........................................ 30.00
64or65 FI Shop Manual supplement to the 1963 ............................................... 15.00 REBUILD KITS
57 FI Rebuild Kit, Distributor--seals, gaskets, O-ring (specify dist. number.. 65.00
57 FI Rebuild Kit, Dist., Deluxe-plus bearing, and fasteners........................100.00
58-65 FI Rebuild Kit, Dist., Deluxe-plus fasteners (specify dist. number).......... 65.00
57-62 FI Rebuild Kit, FI Unit, includes leg gaskets Viton seals....................... 220.00
57-59 FI Rebuild Kit, FI unit with 1 piece plenum gasket Viton seals ............ 250.00
63-65 FI Rebuild Kit, FI Unit, includes leg gaskets & lid gasket Viton sea...... 230.00
57-63 All Rebuild Kit, Fuel Pump........................... .................................................Ask ******PLEASE NOTE!! Many if not most of the aftermarket pumps run too much pressure!
Check your specifications for your vehicle, but rarely any run over 6.5PSI !! TAGS: Super quality fuel meter foil tags available, however not offset '64-65 tags!
TEE SHIRTS! GET RAMJECTED!!! NEW! NEW! ROCHESTER FUEL INJECTION TEE SHIRTS!!!
NEW! 57-61 RIBBED TOP, AND 63-65 UNITS ON BACK...DELUXE!! $20.00
M, L, AND XL, LADIES TOO. 2XL $22.00 BLACK, GRAY, WHITE
BUTTON UP WITH COLLAR SHOP SHIRTS TOO! L,XL, 2XL..............$40.00 OR, GET RAMJETTED WITH A COOL DUAL FOUR SHIRT. SEE CARB SECTION!
57-62 FI Balance Tubes....................................................................................... 95.00
57-62 FI Elbow, Balance Tube............................................................................. 20.00
57-62 FI Forward Balance Tube Clip............................................................................20.00
57 FI 4800, 4960 Forward Balance tube clamp..............................................25.00
63-65 FI Choke Tube, Chrome ........................................................................... 22.00
57-65 FI Idle Air Tubes!!!!!! New Reproduction!! State year and unit...............ASK
.
63-65 FI Oil Filler Tube, Chrome (caps too!)....................................................... ASK
56-62 All Tube, Oil Filler....................................................................................... 25.00
63-65 FI Clean Air Tube, Exhaust Manifold to Air Meter Adapt. w/hose............ 45.00
64-65 FI Breather tube crank case to air cleaner 7380......................................140.00
62-65 All Stud, Clean Air Tube to Exhaust manifold.............................................10.00
63-65 FI Tube, Choke--Inside Exhaust Manifold, Driver’s Side,
stainless steel....................................................................................... 15.00 VALVE COVERS
59L-67 Corvette Valve Covers NEW REPRO (with minor casting flaw
through O) (we have restored them) ................................... Out
_____________________________________________________________________________ T O O R D E R , C A L L 5 0 3 . 5 8 8 . 3 8 8 3 ALL PRICES SUBJECT TO CHANGE, AND DO NOT INCLUDE SHIPPING
YES! WE ACCEPT VISA & MASTERCARD CREDIT CARDS GARY HODGES RAMJET, LTD. 5 0 3 . 5 8 8 . 3 8 8 3
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