INSTALLATION INSTRUCTIONS FOR PART #48002 WATER / METHANOL INJECTION SYSTEM DURAMAX 6.6L DIESEL

Transcription

1 Cntact Us: Phne Office (719) Fax (719) Tech Supprt Line (Tll Free) (866) Web INSTALLATION INSTRUCTIONS FOR PART #48002 WATER / METHANOL INJECTION SYSTEM DURAMAX 6.6L DIESEL Mail Snw Perfrmance, Inc 1017-A East Highway 24 Wdland Park, CO Ntes The cntents f this dcument are subject t change withut prir ntice. N part f r this entire dcument may be reprduced in any frm withut prir written permissin f Snw Perfrmance, Inc under the cpyright except fr private use. The names, addresses and telephne numbers mentined are current as f Nvember 1, Nte that this infrmatin is subject t change. Please refer t fr current infrmatin. 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Incrprated

2 CONTENTS Kit Cntents 3 Intrductin 4 Nzzle Identificatin Chart 4 Installatin Mechanical 5 Installatin Electrical 10 Variable Cntrller Installatin 10 Variable Cntrller Tuning 11 Cntrller Operatin Example 12 Testing the System 12 Tuning Quick Reference 13 Maintenance 14 Fluid Level Switch 15 Slenid Upgrade (ptinal) 16 Install Ntes 17 Warranty Infrmatin 18 Cntact Us 22 LIMITATION OF LIABILITY REPAIR OR REPLACEMENT OF A DEFECTIVE PRODUCT IS THE ORIGINAL RETAIL PURCHASER S EXCLUSIVE REMEDY UNDER THIS WARRANTY. DAMAGE OR INJURY TO THE ORIGINAL RETAIL PURCHASER, TO HIS OR HER VEHICLE, CARGO, OR PROPERTY, AND/OR TO ANY OTHER PERSON OR PROPERTY IS NOT COVERED BY THIS WARRANTY. THIS WARRANTY IS EXPRESSLY MADE IN LIEU OF ANY AND ALL OTHER EXPRESS WARRANTIES, WHETHER ORAL OR WRITTEN. SNOW S SOLE LIABILITY IS LIMITED TO THE REMEDY SET FORTH ABOVE. IN NO EVENT WILL SNOW BE LIABLE FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL, INCIDENTAL, SPECIAL, EXEMPLARY, OR PUNITIVE DAMAGES OR FOR ANY OTHER DAMAGES OF ANY KIND OR NATURE (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS OR LOST SALES). SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. Nn-Warranty Repair/Retest Prducts returned due t damage r misuse and Prducts retested with n prblem fund are subject t repair/retest charges. Prduct will be returned t custmer at custmer s expense. A credit card number must be prvided in rder t btain an RMA (Return Merchandise Authrizatin) number prir t returning Prduct. Have a questin? FAQ: CAUTION Yu must cmpletely read thugh these instructins befre installing and perating this prduct. Failure t d s can result in damage t this prduct and the vehicle. 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

3 Warranty Warranty Plicy Snw Perfrmance, Inc. warrants that the Prduct shall cnfrm t and perfrm in accrdance with published technical specificatins and shall be free f defects in materials and wrkmanship fr 90-days prviding: 1. Yu are the riginal purchaser and prvide prf f purchase. 2. Fr 1-year warranty, the Warranty Card that came with system (nt applicable t separate parts purchases) is returned t Snw within 45-days f purchase. If valid warranty card nt n file with Snw, the standard 90 day warranty applies frm date f purchase. 3. Fr Lifetime warranty,, the Warranty Card that came with system (nt applicable t separate parts purchases) is returned t Snw within 45-days f purchase and Bst Juice injectin fluid is used exclusively.* 3. An RMA # has been attained and is displayed n package cntaining returned part. 4. Parts Warranty ~ 90 day warranty n parts purchased separately if used in cnjunctin with a Snw System. N warranty implied if used with a nn-snw part/system. Subject t Snw s inspectin f the prduct, Snw will remedy defects in materials and/r wrkmanship by repairing r replacing, at Snw s ptin, the defective prduct withut charge fr parts r labr, subject t the limitatins and exclusins described in this warranty. This warranty des nt cver prblems caused by nrmal wear and tear including aesthetic xidatin f surfaces, accidents, unlawful vehicle peratin, r mdificatins r repairs t prduct nt perfrmed r authrized by Snw. This includes any prduct that is disassembled r taken apart fr any reasn. * Bst Juice usage evidenced by invices/ receipts. In additin, this warranty des nt cver prblems resulting frm cnditins beynd Snw s cntrl including, but nt limited t, theft, misuse, verlading, r failure t assemble, munt r use the prduct in accrdance with Snw s written instructins r guidelines included with the prduct r made available t the riginal retail purchaser. In the event f failure, Snw will repair r replace the part at Snw's sle discretin. Failures resulting frm misapplicatin r misuse f the Prduct, failure t adhere t any specificatins r instructins, r failure resulting frm neglect, abuse, accidents, r act f nature are nt cvered under this warranty. Parts UHO Pump (Ultra High Output) 3 Qt Reservir 10 ft High Pressure Tubing 3 ft Black Wire Lm 18 1/8 Silicne Tubing Electrical Packet 1 Green LED 2 Blue Butt Cnnectrs 2 Small Eyehks 1 Large Eyehk 1 Male Cnnectr 3 Female Cnnectrs 1 Arm Switch 1 Bst T VC-100 Cntrller With Wiring Harness 10 Tie Wraps Fuse hlder 20 amp fuse Required Tls Electric Drill w/ Drill Bits Utility Knife Screwdriver Phillips Assrted Wrenches 1/8 27 NPT Tap Kit Cntents Mechanical Packets 1 Nzzle Hlder 1 3/8 NPT t ¼ tube 8 #8x1&1/2 Screws 8 #8 Washers 4 #6x1/2 Screw 1 Dual Nzzle Upgrade 1 Bulkhead 1 E-6000 (GOOP) Nzzle Nzzles Upgrades/Optins 2.5 Galln Reservir 7 Galln Reservir Slenid Upgrade Hse Adaptr r Bung Bst Juice Level Switch Warranty service may be btained by calling , getting an RMA (Return Merchandise Authrizatin), delivering the part t Snw alng with prf f purchase. Custmer agrees t insure the Prduct r assume the risk f lss r damage in transit, t prepay shipping charges t Snw, and t use the riginal shipping cntainer r equivalent. Shipping fr Warranty replacement parts shipped utside the cntinental US will be charged t custmer. Nn-Warranty Repair/Retest Prducts returned due t damage r misuse and Prducts retested with n prblem fund will be returned t custmer at custmer s expense. 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

4 Intrductin This kit prgressively injects water-methanl accrding t manifld bst pressure. The system is applicable fr turb diesels making ver 25 psig f bst pressure. The cntrller utilizes a heavy-duty design that can read up t 100 psig f bst. It has tw dials t set the start and full pints t tailr the delivery t yur engine s needs. Prgressively injecting accrding t bst pressure allws fr the mst pwer ver the widest range f RPMs. These kits allw fr great hrsepwer increases and EGT reductins expect abut 70hp and 250 degree F EGT drp using a 50% mixture f water/methanl. Please refer t the system diagram during install. Install Ntes Pump Setting (psig) Nzzle Size (ml/min) Bst / Vacuum setting Misc: Disclaimer Nzzle Identificatin Chart: Nzzle Number Nzzle Size Nzzle Clr Nzzle Size 1 60 ml/min ml/min ml/min ml/min ml/min ml/min D nt use this prduct until yu have carefully read the fllwing agreement. This sets frth the terms and cnditins fr the use f this prduct. The installatin f this prduct indicates that the BUYER has read and understands this agreement and accepts its terms and cnditins. Perfrmance prducts by their nature are designed t increase hrsepwer and perfrmance nt engineered in the riginal vehicle and the increased stress culd result in damage t related systems. This is a high perfrmance prduct use at yur wn risk. Snw Perfrmance Inc., Its agents, emplyees r wners shall nt be under any liability whether in cntract r therwise whether r nt resulting frm ur negligence r cntents f infrmatin supplied fr any damage r lss resulting frm such infrmatin. The BUYER is respnsible t fully understand the capability and limitatins f his/her vehicle accrding t manufacturer specificatins and agrees t hld the SELLER harmless frm any damage resulting frm failure t adhere t such specificatins. The SELLER disclaims any warranty and expressly disclaims any liability fr persnal injury r damages. The BUYER acknwledges and agrees that the disclaimer f any liability fr persnal injury is a material term fr this agreement and the BUYER agrees t indemnify the SELLER and t hld the SELLER harmless frm any claim related t the item f the equipment purchased. Under n circumstances will the SELLER be liable fr any damages r expenses by reasn f use r sale f any such equipment. The BUYER is respnsible t bey all applicable federal, state, and lcal laws, statutes, and rdinances when perating his/her vehicle, and the BUYER agrees t hld SELLER harmless frm any vilatin theref. The SELLER assumes n liability regarding the imprper installatin r misapplicatin f its prducts. It is the installer's respnsibility t check fr prper installatin and if in dubt, cntact the manufacturer. 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

5 Slenid Upgrade (ptinal) The ptinal Slenid Upgrade (#40060) is required if the nzzle is t be installed after the intake thrttle plate (as shwn), r the fluid reservir is munted higher then the nzzle. It is highly recmmended fr trunkmunt reservirs. Finger thread the tw 1/8 NPT quick cnnect fittings int prts labeled (2 r IN) and (1 r OUT) n the slenid. Tighten an additinal half turn past finger tight. Nte: Slenid must be installed Pre-pump t ensure crrect peratin. Cut high pressure line at lcatin slenid is t be installed. Insert ends f cut line int quick cnnect fittings f slenid. The prt labeled (2 r IN) is the inlet and the prt labeled (1 r OUT) is the utlet. Gently pull n line t check secure cnnectin. If line pulls ut, re-insert farther int fitting t engage lcking clips. If high pressure line remval is required, firmly press in metal fitting ring t disengage lcking clips while pulling hse frm fitting. Cnnect ne f the BLACK wires frm slenid t the RED psitive pump wire r the WHITE wire frm the cntrller. Nte that cnnecting the wire t any ther pwer surce ther then the pump/cntrller wire will result in imprper peratin f slenid. Cnnect the secnd BLACK wire t a secure chassis grund lcatin. The included rcker switch has 2 prngs. The prng with the piece f plastic cming ut with it is cnnected t 12VDC key n pwer, while the ther prng cnnects t the RED cntrller wire Nte that while the diagram shws bth nzzles, ften nly ne is needed. See page 8 fr details. Installatin - Mechanical Step 1 Reservir Install Install straight fitting with sme included E6000 sealant and munt reservir as high in engine cmpartment as pssible using #8x1½ sheet metal screws and washers prvided. Nte that the nzzles shuld be the highest pint in the system, nt the reservir. Optinal: The factry windshield washer reservir can be used as the reservir fr yur system. Drill 9/16 hle in desired bulkhead lcatin. Bulkhead Fitting Installed in Washer Tank. Remve ne nut frm bulkhead and turn the remaining nut until it is at the very end. 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

6 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 a liberal amunt f 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. 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. Fluid Level Switch (ptinal) Instructins Lcate desired level switch munting psitin. Suggested placement is 1/5 f max reservir height. Red Lw Fluid LED Black Black 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. 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

7 1. The engine be run withut water/methanl fr at least 5 minutes after injectin befre turning the engine ff. 2. The armed switch is turned t the ff psitin when the engine is ff. Cautin: D nt attempt t inject water/methanl until the engine has reach perating temperature. A cld engine is mre susceptible t quench and pr perfrmance. 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. 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. 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. Cautin****** Pump must be shielded frm rad debris and tire wash. Failure t d s will result in pump failure 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

8 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: WHP 625 ml/min nzzle WHP 375 & 625 ml/min nzzle WHP 2 X 625 ml/min nzzle 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. If pump ges n and fluid level desn't g dwn, there is an bstructin in the tube r nzzle. Activatin f pump fr shrt perids (1-5 sec.) will purge air bubbles 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. Tuning Quick Reference If cmbustin quench ccurs as evidenced by engine bucking, reduce the injectin quantity r raise the nset bst level. This can be dne by: Crrect Incrrect 1. Using a smaller nzzle(s). 2. Intrducing injectin later at a higher start setting. Als, fresh methanl less than 1 mnth ld when expsed t atmsphere and using a greater methanl cncentratin up t 50% - will reduce cmbustin quench. 100% water will cl cmbustin and EGTs and will increase pwer apprximately HP. 75/25% water/methanl will cl EGTs and pwer will increase apprximately HP. 50/50% water/methanl will cl EGTs and increase pwer apprx 70+ HP. NOTE: If nzzle is munted lwer then the reservir, a Slenid Upgrade (#40060) must be used t prevent draining. Cautin: T avid pling in the intake and pssible engine damage upn start-up, it is recmmended that: 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

9 Fr the middle line, the chart shws the Start dial at 6 psi and the Full dial at 13 psi. At 6 psig f bst pressure the pump will perate at 10%. At 13 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 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 a 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 the check valve in between the pump and reservir. Step 4 Nzzle Munting The nzzle assembly shuld be installed 90 t the directin f airflw. On rund intake tubes, this is 360 arund the tube meaning the nzzle can be munted in any directin. This will ensure maximum cling as the nzzle sprays in a cne pattern. Chse and mark munting lcatin fr nzzle placement. Nzzles can be munted virtually anywhere n the tube ging frm the intercler utlet t the intake inlet, s lng as it has a clear spray pattern int the tube and airflw. Ensure that the tip f the nzzle is flush with the inner wall f the tube r prtruding slightly int the airflw. Remve the selected piece befre the intake and drill and tap (11/32" pre-drill, 1/8-27 NPT tap) fr ne r tw nzzles. Step 1 Test Pump and Mechanical System Discnnect pump frm cntrller. 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. The nzzle is munted using its external 1/8 NPT threads. Tighten the nzzle and nzzle hlder assembly ne half turn past finger tight using E6000 sealant n the threads. 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc

10 Step 5 Nzzle Cnnectin Measure the distance frm the pump utlet t the nzzle hlder. Cut the ¼ tubing using utility knife. Make cuts are as square as pssible. Always have a gd electrical grund cnnectin. Pr grund will result in erratic peratin f cntrller. Ensure there are n kinks in the tubing and insert tubing int quick discnnects until fully seated. Gently pull n tubing t ensure a gd cnnectin. Variable Cntrller Tuning VC-100uC Start Psi Full Psi Installatin - Electrical Variable Cntrller Installatin 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 bst line (use the included bst T ) 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. 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. Cnnect GREEN wire at psitin 1 t Pump RED pwer wire. Cnnect green LED per wiring diagram. Cnnect RED wire t inline switch and cnnect t a +12V key n surce Use a tie wrap t keep silicne vacuum/bst line n hse barb in high bst applicatins. Adjust the Start Psi bst level first by turning dial clckwise t 1/3 rd t ½ the engines max bst utput. This sets the bst pressure required t activate the injectin system. Typical start pints are between 12 and 25 PSI. Next, adjust Full Psi t the engines max bst utput. Nte - ver lapping the settings, where the Full dial is lwer then Start, will result in max injectin at the nset pint. A typical applicatin making 35 psig f bst shuld set the start at abut 18 and the full at abut 30. Cntrller Operatin Example Pump Output % Start Full Bst Pressure psi 2010, Snw Perfrmance, Inc 2010, Snw Perfrmance, Inc