How I Fuel Injected my 250 6 cylinder

I was asked by a couple of guys on how I fuel injected my 250 in my Bronco. First I'm cheap, so I did all the work myself, and second, I'm an engineer, so I want everything perfect or I won't do it. I started out with the Holley Projection 1D that Holley made for many years for the 258 AMC eninge in the Jeep. I spoke to Holley and they said that they had sold over 10000+ of these and were, and are, still very populer. They stock all the parts for them still, because of this. It flow 300 cfm which is just about perfect for these engines. And because of there size, fit perfect with an adapter, and have plenty of room for a large air cleaner. I decided early in the build to make my own fuel injection fuel tank. My son has the 23 gal one in his Bronco, and first, I didnt want to go with a 2in body lift, and second, I dont like how low they sit(my son has hit his a couple of times out on the rocks, not good). So I'll start with pics and narrate them from here:

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00064-20110709-1152.jpg

pic of the throttle body

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00106-20110811-1028-1.jpg

here it is completed

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00084-20110716-1230.jpg

here is the adapter that I made, it has a 2in hole to match the throttle body

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00085-20110716-1230.jpg

here it is installed

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00083-20110716-1227.jpg

I already have a ported head, so I just opened up the bore to 2in's to match the adapter and throttle body

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00065-20110709-1520.jpg

here is the start of the tank being setup to make the intake fuel pump. I discovered that a late model mustangs tank is the same height as our Bronco tank, so this was an easy mod to do.

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00066-20110709-1520.jpg

here is the hole i cut so it would put the pickup right in the middle of the tank but still miss the sender. Just a safety note here, if you dont have a way of cleaning the tank completely, DONT DO THIS!!!!!! OR ATTEMT THIS MOD!!!!!

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00067-20110709-1521.jpg

this is the completed setup, note the the fuel line are pointed in the right dirrection. I welded the locating ring to the tank for a no leak installation

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00104-20110811-1021-1.jpg

this is where I mounted the fuel filter and fuel pump relay. Notice that I used Ford fuel line fittings. I also used the plastic fuel lines from the mustang, this made this part very easy and if I have a problem on the trail, I could fix it easily.

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00103-20110811-1019-1.jpg

better pic of the fuel pump assy, again I used this for easy of repair. You can go to any auto parts store and get a fuel pump for a Ford!!!!!!

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00105-20110811-1021-1.jpg

Its hard to see the fuel lines, but this more for where I went through the fire wall with all the wiring. 2 1in holes and a couple of rubber grommets is all it took

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00109-20110811-1031-1.jpg

One weird thing is the air cleaner mounting, so instead of looking for a chevy part(NO WAY is a chevy part going on my Bronco!!!!) I made an air cleaner bottom

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00112-20110811-1032-1.jpg

this is how it turned out, not bad

http://i225.photobucket.com/albums/dd190/cumminsgenman/IMG00107-20110811-1028-1.jpg

this is where I put the temp sender, works perfect

Well guys this is all I did, and it turned out awesome. I couldn't be more happy. It starts cold, it idles perfect, and I can go up or down any hill. Off camber is where it really shines. Mileage is up 3 mpg and the power is up, just plain awesome. I have also added the O2 sensor kit and it has really helped when I go from the sea to the mountains to play on the Naches trail. I had a holley 350 cfm carb on it before and would NEVER GO BACK!!!!

Now to get you really going. I'm so happy with this setup that I'm now doing a direct port injected head. I cant tell or show you much, but I can tell you that it will now have computer controlled ignition along with full authority fuel injection that will be installed in my wifes Bronco that I doing for her. If you have any question go ahead and ask, and maybe I can help you out.

COOL ! Nice work.

Nice write-up! Please tell me exactly where your fuel tank came from (year, model). Also how did you clean the tank before cutting/welding? That makes me Nervous.

250 efi

That is a super clean job. I don't know how I missed this and am anxiously awaiting the next level.

The bronco tanks is just a stocker. I believe it came out of my son's 72. The mustang fuel tank came out of any 87-93 fastback, and I used the mounting ring and pump assy. I took my bronco tank to the local radiator shop and they boiled it out. It came back super clean, and was worth the 30 bucks to do it. The mustang tank, I just used my steam cleaner and went for it. Now one thing I did was, fill the Bronco tank with argon, while I was welding on it, just for extra insurance.

cool, cool

Dude I am so stoned to see the multi port.I got a 200 thinking of building.can't wait to see your write up on that

Nice job on the 250. another victory for TBI!! I love mine on the 302..

250 efi headers

What brand headers are those? Any thoughts on the benefits, fitment and quality appreciated.

I was wondering when someone would notice the header. I bought this one from mustangs unlimited, along with the port divider. It is a 2 y type into a 2.5in collector. It fits fine as lone as you dont run anything bigger then a 157 flywheel. I run a 164 so I added a curved piece to go aound the bell housing. It misses the starter nice also. Does it help, in one word yes. I had one on my 200 and could tell right away, that t was there.
It picked up HP and torque. So I went ahead and put one on the 250. I didnt want a chrome header, but it was the same price. Also made it easy to put the O2 sensor bungin for the fuel injection.

........... So Let me see if I didn't miss something here.. You can go to the wrecking yard and pick up a jeep Throttle body from a Jeep 258 4.0L .. Bring it home... adapter it to the manifold .. Add a elec. fuel pump with ..What Pounds of pressure.. and your good to go .. Did I miss anything.

PAPITT said:

........... So Let me see if I didn't miss something here.. You can go to the wrecking yard and pick up a jeep Throttle body from a Jeep 258 4.0L .. Bring it home... adapter it to the manifold .. Add a elec. fuel pump with ..What Pounds of pressure.. and your good to go .. Did I miss anything.

Click to expand...

Yes you missed something. its a aftermarket setup that was sold by Holley 1D projection. Since they dont sell the kit anymore he's just buying it piece by piece form holley.
I dont think any jeeps ever came from the factory with throttle body injection so your going to be hard pressed to find anything.
basically if your looking to inject your 300 why dont you just get a later model truck that has a injected 300. I usually see plently of them in junkyards.

ok I thought it was just junk yard items.

68broncoPaul said:

So I'll start with pics and narrate them from here:

pic of the throttle body

here it is completed

here is the adapter that I made, it has a 2in hole to match the throttle body

here it is installed

I already have a ported head, so I just opened up the bore to 2in's to match the adapter and throttle body

here is the start of the tank being setup to make the intake fuel pump. I discovered that a late model mustangs tank is the same height as our Bronco tank, so this was an easy mod to do.

here is the hole i cut so it would put the pickup right in the middle of the tank but still miss the sender. Just a safety note here, if you dont have a way of cleaning the tank completely, DONT DO THIS!!!!!! OR ATTEMT THIS MOD!!!!!

this is the completed setup, note the the fuel line are pointed in the right dirrection. I welded the locating ring to the tank for a no leak installation

this is where I mounted the fuel filter and fuel pump relay. Notice that I used Ford fuel line fittings. I also used the plastic fuel lines from the mustang, this made this part very easy and if I have a problem on the trail, I could fix it easily.

better pic of the fuel pump assy, again I used this for easy of repair. You can go to any auto parts store and get a fuel pump for a Ford!!!!!!

Its hard to see the fuel lines, but this more for where I went through the fire wall with all the wiring. 2 1in holes and a couple of rubber grommets is all it took

One weird thing is the air cleaner mounting, so instead of looking for a chevy part(NO WAY is a chevy part going on my Bronco!!!!) I made an air cleaner bottom

this is how it turned out, not bad

this is where I put the temp sender, works perfect

Well guys this is all I did, and it turned out awesome.

Click to expand...

There, I fixed it. Changed all the to [img]