Diesel Installation Instructions

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Marcus Reeves
6 years ago
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1 Diesel Installation Instructions Note: please read instructions completely before installation to ensure a safe/easy installation. Installation is broken down in 3-parts. 1. Pump/Tank/Nozzle - (mechanical) 2. Electrical I - Mechanical Mechanical BOM Contents - Pump - Tank - Nozzles (2) - 8' tubing 1/4" O.D. - (2) Fittings pump in/out (3/8" NPT - 1/4" O.D., elbow adapter) - (10) Tie wraps - (2) Nozzle holders (1/4" NPTF - for nozzle, 1/4" O.D. tube compression for tube) - "t" for dual nozzle Required tools - Drills(s)

- Tap (1/4" NPT) - Teflon sealant (pipe sealant) - Thread sealant - loctight permanent (for nozzle) - Adjustable wrench - Utility knife - Screw driver - phillips Instructions - Please refer to

2 - Tap (1/4" NPT) - Teflon sealant (pipe sealant) - Thread sealant - loctight permanent (for nozzle) - Adjustable wrench - Utility knife - Screw driver - phillips Instructions - Please refer to mechanical diagram. - Mount tank as high in engine compartment as possible using sheet metal screw provided. - If windshield washer reservoir is utilized,mount quik-connect bulkhead in the bottom using Goop sealant or similar methanol resistant adhesive/sealant. The following procedure will allow the use of a nut on both sides : After drilling the appropriate sized hole in bottom of reservoir, 1.Attach tubing to threaded end of fitting. 2.Pull tubing through the reservoir fill opening. 3. Slide the nut on the tubing. 4. While pulling on the tube, thread the nut on the fitting after applying sealant. - Mount pump so pump is positioned lower than bottom of tank. Pump can be mounted horizontally or vertically using (4) supplied screws. - It is recommended that the pump not be mounted on fire wall for passenger compartment noise considerations. - Assemble desired nozzle into nozzle holder using pipe sealant. Torque at least 1/2 turn past hand tight. - If nozzle is mounted lower than the reservoir, a solenoid must be used. Note: - Nozzle sizing is a function of flywheel horsepower ( FWHP), which approximates an engines airflow, and boost, which approximates intake charge heat. Recommended starting points: HP (flywheel) Fuel (ml/ min) Water/Methanol (25%) Water/Methanol (15%)

1200 8673 2166 1255 1250 9035 2257 1307 1300 9397 2347 1359 1350 9397 2347 1411 1400 10120 2528 1463 1450 10482 2618 1515 1500 10844 2708 1567 Diesel Engines: 1) For TOWING/LOWER EGT s, inject a qty

2) For POWER/LOWER EGT s, inject at least 25% of total fuel(assumes a 50/50% water/ methanol mix) ( eg. 400HP, inject at least 722ml/min.). More than 30psig usually requires 25-35% of total fuel.

3 Diesel Engines: 1) For TOWING/LOWER EGT s, inject a qty of at least 15% of total fuel ( assumes a 100% water or 20/80% methanol/water)( eg. At 300HP, inject at least 320 ml/min.) EGT decreases of are common with this qty. 2) For POWER/LOWER EGT s, inject at least 25% of total fuel(assumes a 50/50% water/ methanol mix) ( eg. 400HP, inject at least 722ml/min.). More than 30psig usually requires 25-35% of total fuel. Note: - All nozzles are rated at 60psi pump pressure. Increasing pressure increases flow: 175ml/min 200psi=240ml/min 225ml/min 200psi=310ml/min 375ml/min 200psi=520ml/min 200psi=865ml/min Note: Introducing water/methanol before 15 psi boost could result in quenched combustion and engine misfire. - Drill and tap (7/16" pre-drill, 1/4-18 NPT), metal air inlet tube as close as possible to intake. - Mount nozzle assembly at 90 degrees to the direction of airflow. - Install nozzle assembly using sealant. - If nozzle is accessible without removing assembly, JB Weld or permanent sealant/bond is preferred to ensure enduring seal. - Cut tubing to desired length and install by pushing tube completely (approx. 1/4") into quick connects of both the nozzle assemblyto-pump outlet, and pump inlet-to-tank. Use tie wraps to help route tubes and to ensure tubes don't contact moving or hot parts in engine compartment. II - Electrical

4 Electrical BOM Contents Stage 2 Diesel Hobbs: Stage 1 & 2 Diesel (variable controller): - Relay - Variable Controller - Relay connector - LED - Green - LED - green - Connectors - Boost pressure switch - Tie Wraps (10) - Connectors - Corrugated Wire Loom - Tie wraps (10) - "Armed" switch

5 - Corrugated wire loom - Fuse and fuse holder - "Armed" switch - Fuse and fuse holder Required tools - Drill - Screw driver-phillips - Wire cutter/stripper/crimper Instructions Diesel - Please refer to electrical diagram. - Mount variable controller on firewall. - Attach 1/8 hose ( supplied) to post on controller. Other end attaches to manifold boost source. - Select location of LED (green-on when pump activated) in dashboard of vehicle. Run red and black wires to LED and make required connections (refer to wiring diagram). - Wire relay according to diagram using supplied connectors. - Do not route wires near hot or moving parts. Use corrugated wire loom and tie wraps (supplied) to protect and route wires. Instructions Stage 2 Hobbs - Please refer to electrical diagram. - Mount relay on firewall using supplied sheet metel screw. - Mount presure switch to manifold boost source. - Select location of LED (green-on when pump activated) in dashboard of vehicle. Run red and black wires (red from relay post #87, black supplied.) to LED and make required connections (refer to wiring diagram). - Wire Relay according to diagram using supplied connectors. - Do not route wires near hot or moving parts. Use corrugated wire loom and tie wraps (supplied) to protect and route wires. Testing the system (Important: please disconnect the wiring harness from the Variable Controller on stage-1 systems before testing. Running 12v back through the controller could damage the components) 1. To test pump and mechanical system: - Using a 12v source, apply 12v to the pump red wire (disconnect wire at pump). Pump should activate and fluid level in tank should go down. Also check for leaks. - If pump goes on but fluid level doesn't go down, there is an obsturction in the tube or nozzle. - If the pump doesn't go on, there is a ground problem or a faulty pump. - All pumps are tested before shipment. - Activation of pump for short periods (2-5 sec.) will not cause engine damage. 2. To test LED vs. pump "on": - Apply a 12v source to green wire on the Variable Controller harness - please ensure that the harness is disconnected from controller or damage to controller may occur (pole #87 of relay if Hobbs option). Pump should activate and LED should go on. Check LED ground and wiring if not. If wiring and ground OK, check LED with 12v source. 3. To set boost pressure switch activation point: - The stage-2 diesel kit comes with a Hobbs switch preset to 35psig ( 60psig optional). Note: it is not recommended to inject full qty. before 15psig or combustion quench will occur. III Variable Controller - Tuning Tips Instructions Tip: Use a tie wrap to keep rubber vacuum/boost on hose barb in high boost applications. - Begin tuning process with both adjusters at their highest settings (clockwise). - The amount injected can be adjusted by pump pressure which can be changed by turning the allen head in the pump regulator - counterclockwise = less pressure. The stage-1 pump is set at the factory at the highest setting which for this application is 140 psi. - Over lapping the settings - setting full lower than onset will result in max injection at the onset point. Tip: With turbo diesels: with 20psig boost, on at 15psi /full at 20psi works well. With 35psig, on at 20psi/full at 35psi is a good starting point. It is not recommended that full injection take place before 20psig or combustion quench may occur.

6 05/20/04 Operating Tips 1. If combustion quench occurs as evidenced by engine bucking, reduce the injection quantity or raise the onset boost level. This can be done by: 1. lowering the pump pressure by turning the pump regulator adjusting screw counterclockwise.2. Using a smaller nozzle(s). 3. Introducing injection later at a higher boost setting. Also, fresh methanol less than 1 month old when exposed to atmosphere and using a greater methanol concentration up to 50% - will reduce combustion quench. 2. Caution: To avoid pooling in the intake and possible engine damage upon start-up, it is recommended that: 1. the engine be run without water/methanol for at least 5 min. after injection before turning the engine off. 2. The armed switch is turned to the off position when the engine is off. Disclaimer Do not use this product until you have carefully read the following agreement. This sets forth the terms and conditions for the use of this product. The installation of this product indicates that the BUYER has read and understands this agreement and accepts its terms and conditions Performance products by their nature are designed to increase horsepower and performance not engineered in the original vehicle and the increased stress could result in damage to related systems. This is a high performance product use at your own risk. Snow Performance Inc., Its agents, employees or owners shall not be under any liability whether in contract or otherwise whether or not resulting from our negligence or contents of information supplied for any damage or loss resulting from such information. The BUYER is responsible to fully understand the capability and limitations of his/her vehicle according to manufacturer specifications and agrees to hold the SELLER harmless from any damage resulting from failure to adhere to such specifications The SELLER disclaims any warranty and expressly disclaims any liability for personal injury or damages. The BUYER acknowledges and agrees that the disclaimer of any liability for personal injury is a material term for this agreement and the BUYER agrees to indemnify the SELLER and to hold the SELLER harmless from any claim related to the item of the equipment purchased. Under no circumstances will the SELLER be liable for any damages or expenses by reason of use or sale of any such equipment. The BUYER is responsible to obey all applicable federal, state, and local laws, statutes, and ordinances when operating his/her vehicle, and the BUYER agrees to hold SELLER harmless from any violation thereof. The SELLER assumes no liability regarding the improper installation or misapplication of its products. It is the installer's responsibility to check for proper installation and if in doubt, contact the manufacturer.

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