INSTALLATION INSTRUCTIONS FOR PART #20010 RT1/RT2/DOM WATER / METHANOL INJECTION SYSTEMS

Transcription

1 Kit Cntents INSTALLATION INSTRUCTIONS FOR PART #20010 RT1/RT2/DOM WATER / METHANOL INJECTION SYSTEMS Parts UHO Pump (Special High Output) 3 Qt Reservir 10 Ft High Pressure Tubing 3 Ft Wire Lm 18 1/8 Silicne Tubing Electrical Packet 1 Green LED 4 Blue Butt Cnnectrs 3 Small Eyehks 1 Male Cnnectr 1 Female Cnnectr 1 Vacuum T VC-25/MAF Cntrller With Harness 10 Tie Wraps Level switch Upgrade Required Tls Electric Drill w/ Drill Bits Utility Knife Screwdriver Phillips Assrted Wrenches 1/8 NPT Tap Mechanical Packet 1 Nzzle Hlder 1 Reservir Fitting 3/8 NPT t ¼ tube 8 #8x1&1/2 Screws 8 #8 Washers 4 #6x1/2 Screws 1 E-6000 (GOOP) Slenid Upgrade Carb Plate(s) (1 fr RT1, 2 fr RT2) Dual Nzzle Upgrade (RT2 Only) Nzzles 60ML/MN (Yellw) 100ML/MN () 175ML/MN (Green) 225ML/MN (Purple) 375ML/MN () 625ML/MN (Blue) Upgrades Bulkhead 2.5 Galln Reservir SafeInjectin Nitrbster Dual Nzzle Upgrade Bst Juice

2 Intrductin - Please refer t system diagram during install. Fr RT1 systems, nly ne carb plate is used and n T fitting is required. The ptinal Level Switch Upgrade (#40030) is shwn. Installatin- Mechanical Step 1 Reservir Install Install 3/8 NPT t ¼ tube reservir using E6000 sealant. Injectin Status LED Carb Plate(s) The nzzle, nt the reservir, shuld be the highest pint in the system. T Bst Surce Green White Nzzle +12 Vlt Key On Identificatin Chart: Engine Grund Yellw Nt Used Nzzle Clr Nzzle Size Nzzle Clr Nzzle Size Yellw 60 ml/min Purple 225 ml/min 100 ml/min 375 ml/min Green 175 ml/min Blue 625 ml/min Slenid Pump Nzzle Identificatin Chart: Nzzle Clr Nzzle Size Nzzle Clr Nzzle Size Yellw 60 ml/min Purple 225 ml/min 100 ml/min 375 ml/min Green 175 ml/min Blue 625 ml/min White T Fitting (RT2 Only) (Secnd Plate fr RT2 Only) Lw Fluid LED Optinal: The factry windshield washer reservir can be used as the reservir fr yur system, using ptinal part number Drill 9/16 hle in desired bulkhead lcatin. Remve ne nut frm bulkhead and turn the remaining nut until it is at the very end. Feed red tubing thrugh the drilled hle and up and ut f the tp f the reservir. Attach tubing t the bulkhead n the side ppsite the nut. Pull the tubing thrugh the bulkhead hle until the bulkhead seats against the inside f the reservir. Apply E6000 sealant (included) arund bulkhead. Slide the nut yu had previusly remved up nt the tube and thread nt bulkhead. While pulling firmly n the red tubing, tighten the uter nut using a 17mm scket (nly needs t be hand tight). A ratchet is nt needed. Once sealant has set, fill reservir with water and check fr leaks. Cautin****** T avid gravity feeding f fluid with rear munt reservirs, it is essential t use a check valve in-line between the reservir and pump. D nt perate yur rear munt equipped vehicle withut a check valve installed.

3 Cautin******* Whenever the nzzle is munted pst-thrttle plate, t avid siphning fluid at idle, it is essential t use a slenid upgrade inline between the reservir and pump. Ensure there are n kinks in the tubing and insert tubing int quick discnnects at pump and reservir until fully seated. Keep the pump within 2 feet f the reservir. Step 2 Pump Install Munt the pump s the inlet is psitined at the lwest pint f the reservir r lwer. Pump can be munted hrizntally r vertically using the supplied screws and washers. Ensure that n sharp bends in the high pressure tube ccur near the pump. Sharp bends can cause stress n the inlet and utlet prts f the pump, causing leaks. Trim tube with a utility knife r razr blade, making sure t eliminate any burrs r kinks n the end. Insert firmly int the pump abut ½ inch thrugh the light grey lcking cllar. Nte the arrws indicating flw directin n the tp f the pump. T remve the hse, gently and evenly push the light grey lcking cllar int the head unit f the pump, then pull n the hse gently. Cautin****** Pump must be shielded frm rad debris and tire wash. Failure t d s will result in pump failure Step 3 Nzzle Selectin Nzzle sizing is a functin f hrsepwer, which apprximates the engine airflw, and bst, which apprximates intake charge heat. Recmmended starting pints: RT1/DOM RWHP: 375 Nzzle RWHP: 625 Nzzle RT RWHP: 2 X 225 Nzzle RWHP: 2X375 Nzzle Seal the nzzle int the nzzle hlder using the included E6000 sealant. Using a sealant that is nt permanent will allw fr nzzle changes during tuning. Simply remve the nzzle, clean the threads, and reinstall using sealant. Measure the distance frm the reservir utlet t the pump inlet. Cut the ¼ red tubing using utility knife. Make cuts are as square as pssible. Assemble desired nzzle int nzzle hlder using E6000 sealant. The end f the nzzle with the fine mesh screen is t be inserted int the nzzle hlder. Trque ½ turn past finger tight. D nt use Tefln sealants n Snw Perfrmance fittings.

4 RT2 Systems: Find a lcatin fr the T fitting that prevents any kinks r sharp turns in the hse. Cnnect hse frm the OUT prt f the slenid t the T. Cnnect hses frm the T t the nzzle hlders n the carb plates. RT1/DOM Systems: Cnnect hse frm the #1 prt f the slenid t the nzzle hlder n the carb plate. Crrect Incrrect NOTE: If nzzle is munted lwer then the reservir, a Slenid Upgrade (#40060) must be used t prevent draining. Step 4 Nzzle Munting The nzzle(s) munt int the carb plate(s) n either side. Plug the unused prt n the plate(s) with a 1/8 th NPT plug r use it as the prt fr a bst signal t the cntrller. Use a small amunt f E6000 sealant n threads t prevent vacuum/bst leaks. Turn the nzzle(s) and hlder(s) ½ turn past finger tight. Nte that fresh gaskets and lng studs are included fr a clean and secure installatin f the carb plate(s). Cntinual insertin and remval frm quick cnnect fittings will mar the end f the tubing. Over time the internal gripping teeth may lse their hld f the tubing which may create a leak. If this ccurs simply remve the tubing and make a fresh cut using a razr blade. Installatin - Electrical Variable Cntrller Installatin Step 5 Slenid Munting Measure the distance frm the pump utlet t the slenid. Typical munting pints are n the firewall. The slenids can be secured using tie-wraps. Cut the ¼ tubing using utility knife. Make cuts are as square as pssible. Be sure t avid mving r ht parts. Use the included tiewraps t rute lines. Use a small amunt f E6000 sealant and install the included straight fittings int the slenid. Turn ½ turn past finger tight. The figure abve shws the back view f the variable cntrller. Attach cntrller t secure lcatin with easy access in engine bay r passenger cmpartment. The VC series cntrllers are designed t withstand engine bay cnditins, but shuld nt be munted directly t the engine blck. Cnnect vacuum/bst hse frm intake plenum t hse barb n back f cntrller and secure with a tie wrap. Plug wire harness int back f cntrller. Nte the terminal psitins are numbered n the bttm side f wire harness cnnectr. Ensure there are n kinks in the tubing and insert int quick discnnects until fully seated. the Slenid is flw directinal. Be sure t nte which prt is the INLET/PRESSURE prt (2) and which is the OUTLET prt (1). Gently pull n tubing t ensure a gd cnnectin. CAUTION: Discnnect the negative battery terminal while cnnecting wires t prevent electrical fire r damage t cntrller.

5 Cnnect BLACK wire at psitin 1 t a gd grund lcatin. Cnnect GREEN wire at psitin 4 t Pump RED pwer wire. Cnnect RED wire at psitin 3 t +12 vlt key n surce. When selecting a 12V key n surce, try t find a dedicated circuit rated t at least 10 amps. The YELLOW wire at psitin 2 is nt used in bst referenced applicatins. Variable Cntrller Tuning Rtate the MODE switch clckwise t select BOOST mde. Always have a gd electrical grund cnnectin. A pr grund will result in erratic peratin f cntrller. Adjust the START bst level first by turning dial clckwise t ½ t 1/3 the engines max bst. This sets the bst pressure required t activate the injectin system. If bucking r bgging is felt at the nset f injectin, increase the start pint. Begin with the Full pint at the vehicles maximum bst. Often a full pint belw the vehicle s max bst can be used, s lng as n bgging ccurs. Cntrller Operatin Example Pump Output % Start The left line n the chart shws the START dial at 4 psi and the FULL dial at 12 psi. At 4 psig f bst pressure the pump will perate at 10%. At 12 psig f bst pressure, the pump will deliver 100% f injectin pressure. Fr bst pressure readings between the START and FULL settings, the cntrller will linearly adjust the pump pressure as shwn n the graph. Testing the System Full Bst Pressure psi Nte: fr best results, prime pump befre use T clear air frm the pump and insure that the system is primed: Fill reservir with water apprx ¼ full. Remve tubing frm nzzle (r slenid if slenid used in-line between pump and nzzle) and run tube int separate cntainer. Apply 12 VDC t red pump wire fr apprximately 5 secnds r until fluid flw is cnsistent. Pump is nw primed. Recnnect tubing frm pump utlet t nzzle (r slenid). If using check Valve in between the pump and the reservir: Remve the check valve and place a slid piece f tube between the pump and the reservir and prime the system. Then replace Check valve in between the pump and reservir.

6 Step 1 Test Pump and Mechanical System Discnnect all cntrl and SafeInjectin mdules. Discnnect tube frm the utlet prt f the pump. Using a 12 vlt surce, apply pwer t red wire f pump. Pump shuld activate, green LED shuld g n, and fluid level in tank shuld g dwn. It is recmmended t als check the nzzle spray pattern while fllwing this prcedure. Als check fr leaks. Never flw liquid thrugh a SafeInjectin mdule withut all nzzles cnnected. Tuning Quick Reference The pwer ptential f the system is realized thrugh increased bst and/r timing. The large gains n ctane and cling prvided by the system make this pssible, even n standard pump fuel. It is recmmended that reservir always be at least 1/4 full. The Bst Cler adds an alternate fuel surce as well as significantly cls cmbustin. With the Bst Cler, ne des nt need t cl cmbustin with verly rich air/fuel ratis. T minimize cmbustin quench, yu shuld start with an air t fuel rati f :1. Injecting water/methanl lwer than RPM culd result in cmbustin quench. All vehicles are different. If the engine bgs r lses pwer, then it is cming n t early, the quantity is t much, r there is nt enugh methanl in the mixture (50/50 water/methanl recmmended). If yu have t increase the nset t high in the rpm range (detnatin cntrl is needed sner), g t a smaller nzzle. If pump ges n and fluid level desn't g dwn, there is an bstructin in the tube r nzzle. Activatin f the pump fr 1-5 secnd intervals will purge air frm the system after installatin. This can be accmplished during initial use. Step 2 Test Cntrller Begin the testing prcess with bth dials n the variable cntrller at their lwest settings (cunter-clckwise). Turn ignitin key n s that the system has 12 vlt pwer. If the pump runs, inspect grund wires fr secure cnnectin. Pump shuld be ff at this pint, apply light air pressure int vacuum tube cnnectin n back f cntrller. Pump shuld activate while lw pressure is applied but nt enugh t cmpletely atmize fluid. Cautin****** Prlnged quench may cause lwer engine damage ver a perid f time. Maintenance Remve nzzle(s) and clean screen filters at least nce per year using carb cleaner. The Bst Cler has been designed t perate with high cncentratins f methanl. Oil r ther additives are nt required fr system lubricatin. Fr best perfrmance, cling, and system life it is recmmend that Snw Perfrmance Bst Juice (#40008) be the exclusive fluid used in the system.

7 Fluid Level Switch Lw Fluid LED Instructins Lcate desired level switch munting psitin. Suggested placement is 1/5 f max reservir height. Carefully drill side f reservir using 13/16 bit. A step bit is recmmended fr best drilling results. Hle must be free f nicks r shavings fr prper sealing. Remve rubber seal frm level switch. Insert seal int reservir until fully seated. Gp can be used arund the edges f the hle. Lubricate exterir f level switch with water and insert int seal until fully seated. Psitin level switch s GT symbl is at six clck psitin. Wait 30 minutes fr Gp t cure, then test fr leaks. With fluid level abve level switch, flat shuld be angled up. With fluid level belw level switch, flat shuld be in hrizntal psitin. Cnnect ne black wire frm level switch t grund. Cnnect ther black wire frm level switch t white wire frm LED. Cnnect red wire frm LED t +12 vlt key n pwer surce. SNOW PERFORMANCE FUEL SYSTEMS