INSTALLATION INSTRUCTIONS FOR PART #20140 STAGE 3 N54 BMW BOOST COOLER WATER/METHANOL INJECTION SYSTEM

Transcription

1 INSTALLATION INSTRUCTIONS FOR PART #20140 STAGE 3 N54 BMW BOOST COOLER WATER/METHANOL INJECTION SYSTEM Parts List UHO (Special High Output) Pump 2.5 gal Reservir 20 ft. 1/4 OD Tubing 3ft.Black Wire Lm 36 1/8 Silicne tubing Electrical Packet 2 Wire Splices 2 Butt Cnnectrs Vacuum T 3 Small Eyehks 1 Male Cnnectr 1 Female Cnnectrs 10 Tie Wraps Arm Switch 3 Duble Sided Tape Stage 3 MPG-MAX Cntrller Required tls - Electric drill w/ drill bits - Adjustable wrench - Utility knife - Screw driver Phillips - 5/16 pen end wrench (fr nzzle) -1/8-27 NPT Tap Mechanical Packets 1 Nzzle Hlder 7 #8x1&1/2in. Screws 4-#8 Washers 4 #6x1/2in. Screws 1 Reservir Fitting 3/8 NPT t ¼ tube 1 Dual Nzzle Upgrade 2 Slenid Upgrades 1 Tube E6000 GOOP Sealant Nzzles 60ML/MN (#1) 100ML/MN (#2) 175ML/MN (#3) 225ML/MN (#4) 375ML/MN (#5) 625ML/MN (#6) Upgrades Bulkhead 2.5 Galln Reservir Slenid Hse Adaptr r Bung SafeInjectin Nitrbster Carb Plate Level Switch

2 Intrductin: The Stage 3 MPG-MAX N54 System is designed t deliver precise amunts f water-methanl in a wide range f perating cnditins. The cntrl mdule fr this system has integrated sensrs and is a fully standalne unit that will wrk n virtually any frced-inductin engine. This system can deliver 5%-15% gains in ecnmy alng with cler cmbustin temperatures, lwer intake air temperatures, and pint ctane gains ver regular pump gas. Please refer t the System Diagram belw during install. If using SafeInjectin, als nte the diagram n page 20. Installatin- Mechanical Step 1 Reservir Install Install 3/8 NPT t ¼ tube reservir fitting with the 6000 sealant. Munt reservir in trunk cmpartment using screws and washers prvided. Nte lcatin ptins fr the included lw level warning light sensr. 3QT reservir munted in the trunk cmpartment. (Pht curtesy f Supreme Pwer) Manifld Inlet Air Flw Intercler Pwer Slenid Black Slenid Red 2 Green Pwer Slenid Blue Tied ut f the Way Clear Bst Tube White - T Pump Red Wire Pump 3 QT Reservir Black There are many lcatins suitable fr the tank. Keep in mind that tubing will be ruted frm the tank t the pump, and the tank shuld be munted in a lcatin that allws fr easy filling. The lw level sensr (P.20) is typically munted near the bttm f the tank n ne f the sides. Fr rad racing r lng range applicatins, a 2.5 galln reservir is available. 2.5 galln reservir munted in the truck cmpartment. Nte the included munting straps. (PN# 40014) 1 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. 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. 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. Tube can be ruted under the flr carpeting f the trunk cmpartment t the pump, r the pump can be munted near the tank abve the trunk flr. Sme clearancing f the grves at the edge f the cmpartment may be needed fr flush fitment. 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 if pssible. Run the tube frm the utlet f the pump t the first slenid IN fitting. Cautin****** Pump must be shielded frm rad debris and tire wash. Failure t d s will result in pump failure Step 3 1 st Slenid/Tube Install and Ruting - Under Car The picture at right shws an ideal place t drill in rder t rute the water/methanl tube and pump/level switch wiring under the car. The tube is nly ¼ uter diameter (OD), s a small hle is all that is needed. This is an ideal pump lcatin under the flr f the trunk cmpartment. Nte the gentle angles f the tube t and frm the pump. The prvided wire lm can be used t cver the tubes fr a stealthier lk. (Pht curtesy f Mark Weinberg) 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. The tube frm the pump cnnects t the #2 prt f the first slenid. Install the 1/8 The picture at left shws the under-bdy tray remved. The existing brackets fr factry lines are ideal fr ruting the water/methanl line and wiring. Snw Perfrmance tubing is rated fr high temperature envirnments, but keep it away frm ht r mving cmpnents such as suspensin members and exhaust systems. NPT straight fitting int the #2 prt f the first slenid using a small amunt f E6000

4 sealant n threads. Tighten ½ turn past finger tight. The slenids can be munted n the firewall r next t a strut supprt in the engine bay. Use the included tie-wraps t secure the slenids in place. Slenids munted high n the firewall f a 335i. Slenids can be munted vertically r hrizntally. (Pht curtesy f Mark Weinberg) The slenids have tw black wires. On the first slenid, ne wire cnnects t grund, while the ther will cnnect t the cntrller utput wire t the pump (white). On the secnd, ne cnnects t the green cntrller utput and ne ges t grund. Step 4 Nzzle Selectin Nzzle sizing is a functin f hrsepwer, which apprximates the engine airflw, and bst, which apprximates intake charge heat. The fllwing are sme general guidelines. Engines running stck t mild bst (up t abut 16 psig) and making HP will use a 100ML/MN nzzle and 175 ML/MN nzzle. (Black and Green clred nzzles respectively) Engines making mild t high bst (up t 20 psig) and HP will use a 100 ML/MN nzzle and a 225 ML/MN nzzle. Engines making in excess f 500HP will use a 175ML/MN nzzle and a 375ML/MN nzzle. Larger 625ML/MN nzzles are available fr high heat/hp applicatins Seal the nzzle int the nzzle hlder using included GOOP 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. 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 1/2 turn past finger tight. D nt use Tefln sealants n Snw Perfrmance fittings. Crrect Incrrect

5 Step 5 Nzzle Munting Step 6 Nzzle/ Pwer Slenid Cnnectin The nzzles are installed 90 t the directin f airflw. On rund intake tubes, this is 360 arund the tube meaning the nzzles can be munted in any directin. This will ensure maximum cling as the nzzle sprays in a cne pattern. The nzzle tips shuld be flush with the inside wall f the tube r prjecting slightly int the airflw fr gd spray pattern. Remve the air inductin piece at the frnt f the engine bay fr easy access t the intake plumbing. Nzzle Munted n N54 intake plumbing pre-manifld inlet. Drill and tap (11/32" pre-drill, 1/8-27 NPT tap) air inlet tube as shwn. Be sure t remve the tube in rder t prevent shavings frm entering the engine. Use cmpressed air r a rag thrugh the tube t ensure that all shavings are remved. The nzzles are munted using their external 1/8 NPT threads. Tighten the nzzle and nzzle hlder assemblies ne half turn past finger tight using E6000 sealant t seal the threads. The nzzles can be munted clse tgether fr ease f installatin. The #1 prt f the first slenid cnnects t the included T fitting. One utlet frm this T will then cnnect t the #2 prt f the Pwer slenid. The Pwer slenid is usually lcated clse t the first slenid, as shwn n P. 7. The ther utlet frm the T fitting cnnects t the smaller f the tw nzzles. The #1 prt f the Pwer slenid then cnnects t the larger nzzle. Measure the distances frm the Pwer slenid and T fitting utlets t their respective nzzle hlders. Cut the ¼ tubing using a sharp utility knife r razr blade. Make cuts are as square as pssible. Ensure there are n kinks in the tubing and insert int the quick discnnects until fully seated. Gently pull n tubing t ensure a gd cnnectin. Als ensure that engine mvement will nt stress the tubing r fittings r bring the tube int clse cntact with ht parts/surfaces. Have tubing cnnect t quick cnnect fittings at shallw angles. Having an immediate sharp bend may unseat the tubing frm the internal -ring. Nzzles shwn munted in Stett inlet pipe. Nte the shallw cnnectin angles f the tubes. Be sure that the tips f the nzzles are flush with the inside wall f the tube r prjecting int the airflw slightly. (Pht curtesy f Mark Weinberg) 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.

6 Installatin - Electrical Variable Cntrller Installatin Bst Line Cnnectin The bst line can be cnnected as shwn in the picture (right). The T cnnects t the black silicne tubing, which then cnnects t the clear tubing using a tie-wrap. Stage 3 cntrller munted using Mark Weinberg s custm Bezel. The cntrller can als be munted in the glve cmpartment r n the dash bard. The Stage 3 N54 cntrller has an integrated wiring harness fr ease f install and a clean appearance. Refer t the main wiring diagram and listing belw fr installatin. T pwer the system, yu may use either the cigarette lighter circuit r the fuse bx behind the glve cmpartment. If yu chse t use the fuse bx, then use the spt belw the 30 amp fuse in the middle f the bx. CAUTION: Discnnect the negative battery terminal while cnnecting wires t prevent electrical fire r damage t cntrller. Cnnect BLACK wire t a gd grund lcatin. A gd grund is critical t prper system peratin. Cnnect GREEN wire t the pwer slenid wire. The ther wire n the pwer slenid cnnects t grund. Cnnect RED wire t a 12 vlt key-n pwer surce. Often the Cigarette lighter is ideal. There are n key-n pwer surces in the engine bay itself. Cnnect the clear tubing t the black silicne line. This line can be T ed int any accurate manifld bst pressure surce. A bst gauge line that is tapped int the intake manifld is ideal. See the next page fr an ideal lcatin. Cnnect the WHITE wire t the red pwer wire f the pump. The BLACK wire n the pump ges t a gd chassis grund. Tuning the Stage 3 MPG-MAX System The Stage 3 N54 system allws fr a large range f tuning. It has tw fully prgressive stages f injectin t cver nt nly high lad/high perfrmance driving, but als mderate driving such as ging up a hill r accelerating away frm a stplight. The bst data is displayed n the LCD screen, alng with the system s utput as a percentage f pump capability. All functins f the cntrller are accessed using the tw push buttns t the left and right f the LCD screen. Pressing buttn 1 will scrll between screens, while pressing buttn 2 will affect whatever setting is n the screen. Hlding dwn buttn 2 while pwering up the unit will engage metric units (BAR). Hlding dwn buttn 1 while pwering up will set standard units (PSI). Once this has been dne nce, it is nt necessary t specify units again. The cntrller cmes pre-set t standard units.

7 Display and Cntrl Screens: Screen 1 B INJ P This is a display nly screen. It displays bst, pulse-width (PW), and water/methanl injectin as independent bar graphs. Bst PSI Screen 2 EFI Pulse % This display screen shws bst in psi and pulse-width as a percentage. PSI %PW % Injectin Screen 3 This screen displays bst in psi, while pulse-width and injectin are shwn as a percentage. PSI PW Screen 4 This screen displays bst in psi and pulse-width as a percentage. Cntrl = Bth Change Screen 5 This is the first setup screen. It allws yu t select BOOST, EFI, r BOTH, using buttn number tw. Select BOOST. Screen 6A EFI Start% Increase Screen 7A This screen sets the bst pressure required t start injectin thrugh the MPG-MAX nzzle. This shuld be set as described in the tuning examples n page 16. Screen 7B This screen decreases the bst required t start injectin thrugh the MPG-MAX nzzle. Press buttn 2 t decrease this value. Screen 7C Bst Full Increase This screen sets the bst full pint when maximum injectin thrugh the MPG-MAX nzzle will be reached. In mst N54 applicatins, this shuld be set at a bst achieved in mderately hard driving. Screen 7D This screen sets the bst full pint when maximum injectin thrugh the MPG-MAX nzzle will be reached. Screen 8A Nt used in an N54 applicatin. Bst Start Increase Bst Start Decrease Bst Full Decrease PW/Bst Cntrl Inc Nt Used in an N54 applicatin. Screen 6B Nt used in an N54 applicatin. Screen 6C Nt used in an N54 applicatin. Screen 6D Nt used in an N54 applicatin. EFI Start% Decrease EFI Full% Increase EFI Full% Decrease Screen 8B Nt used in an N54 applicatin. PW/Bst Cntrl Dec Pwer Mde EFI Screen 9 Change POWER MODE This screen selects between BOOST and EFI (fuel injectr PW) t determine which will cntrl pwer mde. Select BOOST. Screen 10A Pwer Start Increase This screen sets the bst start pint that triggers the pwer mde. Once this value has been reached, the secndary pwer nzzle will start injecting autmatically in additin t the MPG-MAX nzzle. Typical start pints are abut 60% f maximum bst. When pwer mde engages, the small red light next t the number 2 buttn will light.

8 Screen 10B This screen decreases the start pint that will trigger pwer mde. Screen 10C Pwer Full Increase This screen sets the full pint when maximum injectin in pwer mde will be reached. When the value is reached, bth nzzles will be injecting at 100% fr maximum cling and ctane gain. Typical full pints are 80%-90% f maximum bst. Screen 10D Pwer Start Decrease Pwer Full Decrease This screen decreases the full pint when maximum injectin in pwer mde will be reached. Other cntrller infrmatin: The cntrller has a read nly mde. If yu wish t bserve bst and EFI data withut injectin, prceed t a display screen, then press and hld buttn 2. Then press and hld buttn 1. Finally, release bth buttns simultaneusly. This will tggle between read nly mde and nrmal peratin. Tuning Examples: The fllwing are sme general guidelines fr cmmn applicatins f the Stage 3 N54 system: Lw/Stck Bst Applicatin: This vehicle makes a peak bst f psig: Injectin Mdes: BOOST fr MPG stage, and BOOST fr Pwer stage. Bst Start: 3 psig Bst Full: 6psig Pwer Start: 7 psig Pwer Full: 12 psig As bst ges abve nrmal cruising cnditins, we get a small amunt f injectin. In the event that high levels f thrttle are used and bst ges t 7psig, the system will inject thrugh bth the Pwer and MPG nzzles. Only at 12 psig des the system inject maximum vlume thrugh bth nzzles Mderate/High Bst Applicatin: This car runs a mre aggressive tune, and makes 17 psig. It is running stck turbs. In this case the system uses a larger nzzle, and the settings reflect that: Injectin Mdes: BOOST fr MPG stage, and BOOST fr Pwer stage. Bst Start: 3 psig Bst Full: 6 psig Pwer Start: 9 psig Pwer Full: 15 psig Under mderate thrttle, bst will trigger a small amunt f injectin fr cling and efficiency. As mre bst builds under higher thrttle psitins, the system will add mre injectin. In the event that bst reaches higher levels (such as in a race r in a WOT situatin n the street) the system will utilize bth stages f nzzles simultaneusly fr maximum ctane gain and cling.

9 Testing the System 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. Step 1 Test Pump and Mechanical System Electrically discnnect all cntrl and SafeInjectin mdules. Using a 12 vlt surce, apply pwer t the red wire f pump. Pump shuld activate 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. D nt pump fluid thrugh a SafeInjectin unit withut all nzzles cnnected. This can verflw the unit and cause damage. Be sure nt t flw t much fluid int the intake during testing. If necessary, have nzzles spray int a separate cntainer. Step 2 Test Cntrller Turn ignitin key n s that the system has 12vlt pwer. If the pump runs, inspect grund wires fr secure cnnectin and repair as needed. Set the cntrller t inject based n BOOST with a start at 1 psig. The pump shuld be ff at this pint. Start the vehicle and apply pressure t the bst line with a hand pump. A few psig will be sufficient t start injectin. The cntrller shuld display an injectin % and a bst reading shuld als be visible (if yu are in the prper display screen). 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. 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). Cautin****** Prlnged quench may cause lwer engine damage ver a perid f time. If pump ges n and fluid level desn't g dwn, there is an bstructin in the tube r nzzle. Activatin f the pump in 1-5 secnd cycles will purge air frm the system after installatin. This can be accmplished during initial use

10 Maintenance Remve nzzle(s) and clean screen filters 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, and can cause damage t the system. Cntaminants in the fluid such as dirt can damage the system. Ensure that dirt and debris d nt fall int the tank. D nt use Tefln tape r paste t seal cnnectins. These sealers are nt as effective as the Gp sealant prvided and can break dwn ver time, clgging cmpnents. Fr best perfrmance, cling and system life it is recmmend that Snw Perfrmance Bst Juice, part #40008, be the exclusive fluid used in the system. 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. LED can be munted in a ¼ hle. Fluid Level Switch (ptinal) Red Lw Fluid LED Black Black 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.

11 SafeInjectin (Optinal) SafeInjectin is a flw mnitring system designed t warn the driver in the event f an abnrmal flw situatin. If flw drps belw the useradjustable set pint f a specified length f time, it will utput a 12V signal. This signal can be used t change mapping in many systems, using part number t cut the signal that triggers an aggressive map. It will als illuminate the prvided LED light. SafeInjectin Mechanical Installatin: Place the SafeInjectin mdule inline between the pump and the T fitting n the water/methanl tube. Chse a lcatin that allws easy access t the SafeInjectin mdule cntrlls. Be sure t cnnect the methanl tube at shallw angles t the cnnectrs n the SafeInjectin mdule. Never flw liquid thrugh the SafeInjectin mdule withut all nzzles in place. Ding s can damage the unit. 1 2 Bst Line t Manifld Surce (P.12) Cntrller Green: T Pwer Slenid/ SafeInjectin Purple SafeInjectin Electrical Installatin: The SafeInjectin mdule has 5 wires n it: The Red ges t a 12V key-n pwer supply. The Black ges t grund. Black: Grund Red: 12V Key-On Pwer Blue Wires: Tied ut f Way SafeInjectin Green: T Output Device and/r LED SafeInjectin Yellw: T Optinal Flw Gauge SafeInjectin Purple: T Cntrller Green Grund The Purple wire cnnects t the Green wire frm the cntrller. The Yellw wire is fr the ptinal digital flw gauge. The Green wire is the utput wire. This wire will carry a 12V signal in the event f a lw flw situatin, r an verflw situatin. Output Optins Pump The SafeInjectin unit mnitrs the flw f water/methanl in the system. When flw drps belw the unit s adjustable set pint fr the specified perid f time, the fault trigger will g t a high state f 12 vlts. In additin t the supplied LED, this trigger can be used t cut the signal t anther device such as a Prceed r JB3 unit. See page 23 fr details. White: Pump Red Wire Black: Grund The trigger signal can deliver up t 1.5 amps t drive a slenid r relay. The system als includes an amber LED light. This can be used t warn the driver f a lw flw situatin. Red: 12V Key-On

12 Operatinal Settings Adjustable Lw Flw Limit: The left dial n the SafeInjectin unit cntrls the lwest allwed flw. It is adjustable frm 100ML/MN t 600ML/MN. The dial is set t 100ML/MN when it is turned fully cunter-clckwise. It is set t 600ML/MN when it is turned fully clckwise. Be very gentle when adjusting the dials, as they are very precise and d nt require excessive frce. Many systems functin belw 600ML/MN. A 175 nzzle will flw 250 ML/MN at nminal pump pressure fr example. A typical N54 applicatin will utilize a minimum flw f 300ML/MN. Optinal: #30200 Map Switch Relay This relay harness allws the SafeInjectin system t cut the pwer signal t a Prceed r JB3 unit. This will send the unit back int a lwer tune t prtect the engine. SafeInjectin Relay T White Wire frm Cntrller Sample Time: The SafeInjectin unit has a user adjustable delay (Sample Time) that can be used t cntrl the speed at which the trigger signal is activated. The delay is adjustable frm 0.1 secnds (full cunter clckwise) t 1.5 secnds (full clckwise). This delay prevents a 12V signal frm being sent during a slw ramp up f injectin r when injectin is gradually being reduced. A typical N54 applicatin will use a Sample Time f apprximately.8 secnds. Tuning Tip: Red Wire Terminal 86 SafeInjectin Green Wire SafeInjectin Green Wire Black Wire Terminal 85 Grund Green Wire Terminal 87A T Prceed r JB3 If the min flw is set at a high value and the time delay is set at a lw value, the system may send ut a 12V utput as injectin gradually ramps up, due t the system nt yet passing the selected lw flw value at lw bst/airflw levels. Adjust the time delay upward t cmpensate fr this. CAUTION: NEVER RUN SAFEINJECTION WITHOUT A NOZZLE. DOING SO WILL DESTROY THE FLOW METERING CAPABILITY OF THE UNIT. Electrical Installatin: The Green wire frm the SafeInjectin harness cnnects t the Red wire n the relay. This wire is n the ppsite side f the relay frm the Black grund wire. Cnnect the Black wire t a slid grund pint. The Yellw wire f the relay cnnects t the white wire frm the cntrller. The Green wire frm the relay cnnects t the Prceed r JB3 unit. If cnnecting t the JB3, be sure t put in an inline 1.2k 1/4 watt resistr t prvide the prper vltage signal. Withut a resistr, the signal n the green wire will be 12V. Cautin****** Only use the SafeInjectin unit t mnitr the flw f ne nzzle. Mnitring tw nzzles will damage the flw metering system. SNOW PERFORMANCE FUEL SYSTEMS