INSTALLATION INSTRUCTIONS FOR PART #50015 DIESEL MPG-MAX WATER / METHANOL INJECTION SYSTEM 6.0L/6.4L/6.7L POWERSTROKE DIESEL

Transcription

1 Kit Cntents INSTALLATION INSTRUCTIONS FOR PART #50015 DIESEL MPG-MAX WATER / METHANOL INJECTION SYSTEM 6.0L/6.4L/6.7L POWERSTROKE DIESEL Parts 7 Galln Reservir UHO Pump (Ultra High Output) 25 ft High Pressure Tubing 3 ft Black Wire Lm 18 1/8 Silicne Tubing Electrical Packet 2 Blue Butt Cnnectrs 3 Small Eyehks 1 Male Cnnectr 3 Female Cnnectrs 10 Tie Wraps 1 Arm Switch 1 Brass Hse Barb 5 Duble Sided Tape 1 Yellw Temp Prbe Cnnectr Diesel Stage 3 MPG Max Cntrller Temperature Prbe Fuse hlder 20 amp fuse Required Tls Electric Drill w/ Drill Bits 1/8 27 NPT Tap Screwdriver Phillips Assrted Wrenches Mechanical Packets 1 Nzzle Hlder 4 #8x1&1/2 Screws 4 #8 Washers 2 Dual Nzzle Upgrades 2 Slenid Upgrade 7 Galln Fitting Set: 90 Elbw 3/8 1/8 Reducer 1 Temp Prbe Cmpressin Fitting 3/16 1 E-6000 (GOOP) 1 175ml/min Nzzle 1 375ml/min Nzzle 1 625ml/min Nzzle Upgrades/Optins 2.5 Galln Reservir Hse Adaptr r Bung Bst Juice Level Switch

2 Intrductin The Snw Perfrmance Bst Cler Diesel Stage 3 MPG-MAX water/methanl injectin system prvides mre pwer, cler EGTs, and excellent fuel ecnmy increases. The MPG-MAX system des nt require a sustained high lad state in rder t prvide maximum fuel ecnmy gains. The MPG-MAX system uses a new injectin management cntrller that allws fr a small spray f water/methanl t be injected acrss the pwer curve. This prvides an increase in cmbustin efficiency which prvides mre pwer withut injecting mre diesel fuel. This increase in efficiency translates int an increase in fuel ecnmy. Typical fuel ecnmy increases are 10%-15% r 1-3 MPG. The MPG-MAX system has a secndary utput that is used t activate a Pwer Mde. This intrduces a secnd phase f injectin. A larger nzzle(s) is used t inject mre fluid t make mre pwer. The Pwer Mde activatin pint is adjustable fr best perfrmance. Because the MPG-MAX system injects mre frequently, the fluid cnsumptin rate will be higher than ther Bst Cler systems. The MPG-MAX system has been cupled with the Snw Perfrmance 7 Galln Reservir t prvide a large fluid tank that fits well int the bed f a truck. This will prvide the lngest range pssible and includes the necessary installatin hardware. Refer t the fllw installatin diagram. Cmpletely read thrugh this instructin manual befre attempting installatin. Cntact Snw Perfrmance fr any questins r cncerns. Nzzle Identificatin Chart: Nzzle Number Nzzle Size Nzzle Number Nzzle Size 1 60 ml/min ml/min ml/min ml/min ml/min ml/min

3 Nte: The diagram shws three nzzles, but in mst applicatins tw nzzles will prvide the ptimal flw. See page 8 fr details. Nte: The prvided rcker switch is used n the cntrller pwer supply. The prng with the piece f plastic cming ut with it cnnects t 12VDC key n pwer, the ther prng cnnects t the RED wire n the cntrller. Installatin - Mechanical Step 1 Reservir Install Install 90 degree elbw int reducer bushing using E6000 sealant. Turn ½ turn past finger tight. D nt use Tefln sealants n Snw Perfrmance fittings. Install reducer bushing int reservir utlet using E6000 sealant. Turn ½ turn past finger tight. Cautin****** T avid gravity feeding f fluid with rear munt reservirs, it is essential t use a slenid in-line between the reservir and pump. D nt perate yur rear munt equipped vehicle withut a slenid 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. Cautin: Munt pump away frm direct rad spray and debris. 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. Test fit reservir in desired munting lcatin. Typical placement is tucked up alng the side f a pickup bed r in a bed munted tl bx. Check the area under the bed near the desired munting lcatin. Nte the lcatin f fuel tanks, fuel lines, and wiring. Mark the lcatin f the fur aluminum munting strap tab blt hles. Drill thrugh bed with apprpriately sized drill bit. USE CAUTION WHILE DRILLING. Munt reservir with aluminum munting straps using apprpriate hardware. 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. The pump can be munted under the truck bed if in a place prtected frm rad spray 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: HP MPG MAX POWER MODE 350 > WHP 175 ml/min 375 ml/min WHP 175 ml/min 625 m/min 500 < WHP 175 ml/min ml/min

4 Seal the nzzle int the nzzle hlder using 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. 6.0/6.4L Assemble desired nzzle int nzzle hlder using included 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. 6.7L specific 1. Remve clamp frm intercler-t-intake tube and remve tube. Crrect Incrrect 2. Drill and tap plastic tube as shwn. 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 placed n the charge pipe between the intercler utlet and the intake inlet, at a lcatin where they have an unbstructed spray pattern int the airflw. Remve selected piece and drill and tap (11/32" pre-drill, 1/8-27 NPT tap) fr tw nzzles. Nte that NPT is a tapered thread, and be cautius nt t ver-tap thin walled pipes. Test fit nzzles int the pipe. Even a thin-walled pipe as fund n 6.0L and 6.4L Pwerstrkes will be sufficient fr a secure fitment. 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 included E6000 sealant t seal the threads. Step 5 Nzzle and Slenid Cnnectin Slenid is flw directinal. Be sure t nte which prt is the INLET/PRESSURE prt (2 r IN) and which is the OUTLET prt (1 r OUT).

5 The main utlet line cming frm the Reservir cnnects t the first slenids inlet. The utlet f this slenid cnnects t the inlet f the pump. The utlet f the pump cnnects t the Unin T. One utlet f the tee ges t the small MPG-MAX nzzle and the ther utlet f the tee cnnects t the secnd slenid. The utlet frm the secnd slenid will cnnect t the POWER MODE nzzle(s). Measure the distance frm the pump utlet t the injectin lcatin. 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 until fully seated. Gently pull n tubing t ensure a gd cnnectin. Use tie wraps t help rute tubing and t ensure it desn't cntact mving r ht parts in the engine cmpartment Step 6 Install EGT Prbe Drill and tap exhaust manifld pre-turb. If this is perfrmed with the exhaust manifld still n the engine, start the engine and let it idle while drilling and tapping. This will prevent shaving frm entering the exhaust and turb. During tapping, cat tap with heavy grease s it will cllect any metal shavings. 6.7L EGR tube munt. Temp prbe must prtrude int exhaust. D nt kink prbe r use pliers t bend. Munt the Temp Prbe using the 3/16 cmpressin fitting (prvided). Installatin Electrical Variable Cntrller Installatin 6.0/6.4L specific Remve the passenger side tire and wheel. Remve the plastic fender liner by remving the 8-black plastic quick fasteners. With the liner remved, drill and tap the exhaust manifld frm the side. Steering clumn munt. 12vdc key-n surce (passenger kick panel) Attach cntrller t secure lcatin with easy access in driver s cmpartment using supplied tape. Cnnect black silicne tubing frm intake plenum bst surce (use the included brass hse barb) t clear tubing cming frm the cntrller and secure with a tie wrap. 6.7L specific 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 WHITE wire t Pump RED pwer wire. Cnnect GREEN wire t ne BLACK wire frm slenid. Cnnect ther BLACK wire t grund.

6 Cnnect RED wire t inline switch and then cnnect t +12V key n surce. Wire the Yellw K type temp prbe cnnectr t temp prbe installed in Step 6 abve. The YELLOW wire cnnects t the POSTITIVE terminal, the RED wire cnnects t the NEGATIVE terminal f the cnnectr. Cnnect t the lead frm cntrl mdule. Cntrller Operatin Always have a gd electrical grund cnnectin. Pr grund will result in erratic peratin f cntrller. The cntrller has an LCD display screen. The display sftware allws fr seven different display mdes and three cntrl/setup screens. T cntrl the screen selectin, the unit has tw peratr buttns; ne t the left f the screen (buttn 1) and ne t the right f the screen (buttn 2). Pressing and releasing buttn 1 will cause the display t sequence t the next screen. Buttn 2 is nly active in the cntrl/setup screens, and is used t change the current cntrl setting f the setup screen displayed. The system memry will remember the current display setting even if the unit is turned ff. The cntrller will turn n at the last used display setting. Additinally, buttn 2 is used fr the Injectin ON/OFF functin. Pressing and hlding buttn 2, then pressing buttn 1, then releasing bth buttns will change the system t read nly withut changing the display screen. The pump will nt activate in read nly. All screen display functins will remain active even when the injectin is turned ff. Screen 1 This mde displays pressure (P), temperature (T) and injectin percentage (Inj) as three independent bar graphs. P Inj T Screen 2 This mde displays the bst pressure and EGT temperature in PSI and degrees F. Screen 3 This mde displays the bst pressure and EGT temperature in BAR and degrees C. Screen 4 This mde displays the bst, EGT and injectin in Standard units. Screen 5 This mde displays the Bst, EGT and Injectin in Metric units Screen 6 This display shws bth digital and bar graph readings fr bst and EGT in Standard units. Screen 7 This display shws bth digital and bar graph readings fr bst and EGT in Metric units. Screen 8 This is the setup screen fr the cntrl mde. Pressing the right buttn (# 2) will tggle the setting between MPG and TOW. If TOW is n, the 2- D matrix value fr the injectin is used. If MPG is n, bst alne will determine injectin. Screen 8A MPG MODE START - UP. Pressing and releasing buttn 2 will increase the injectin activatin pint. Typical activatin pints are psig. Screen 8B Bst EGT Bst EGT PSI DegF T %Inj BAR DegC %Inj PSI DegF Bar DegC Injectin Mde Change MPG Mde Start PSI Up MPG Mde Start PSI Dwn MPG MODE START - DOWN. Pressing and releasing buttn 2 will decrease the injectin activatin pint. MPG Mde 100% PSI Up

7 Screen 8C MPG MODE 100% - UP. Pressing and releasing buttn 2 will increase the maximum injectin pint. Typical 100% pints are psig. Screen 8D MPG MODE 100% - DOWN. Pressing and releasing buttn 2 will decrease the maximum injectin pint. Screen 9-(TOW MODE ONLY) This screen is used t select between LOW, MED, and HI bst mde. Fr vehicles making 8-18 psig f bst, use LOW mde. Fr vehicles making psig f bst, use MED mde. Fr vehicles making 25+ psig f bst, use HI mde. Screen 10-(TOW MODE ONLY) This screen is used t increase the injectin gain setting. Pressing and releasing buttn 2 will increase the gain setting. The gain affects injectin in Tw mde nly, and 5%-10% changes make a significant impact n injectin. Screen 11-(TOW MODE ONLY) This screen is used t decrease the injectin gain setting. Pressing and releasing buttn 2 will decrease the gain setting. Screen 12-(MPG MODE ONLY) POWER MODE START - UP. Pressing and releasing buttn 2 will increase the Pwer Mde injectin activatin pint. Set Pwer mde t start 6-10 psig befre maximum bst. Screen 13-(MPG MODE ONLY) POWER MODE START - DOWN. Pressing and releasing buttn 2 will decrease the Pwer Mde injectin activatin pint. Variable Cntrller Tuning MPG MODE MPG Mde 100% PSI Dwn Bst Range Change Inj Gain Increase Inj Gain Decrease Pwer Mde Start Up Pwer Mde Start Dwn IN MPG mde, injectin is a functin f bst pressure nly which is desirable when a mre immediate injectin is desired. With the MPG mde functin activated, an injectin start and full pint must be selected. Tggle t Screen 8. Select MPG mde. Tggle t Screen 8A/B. Adjust the start pint up r dwn. Typical start pints are psig. Tggle t Screen 8C/D. Adjust the full 100% pint up r dwn. Typical 100% pints are psig. Tggle t Screen 9. Select bst level. See Cntrller Operatin: Screen 9. Tggle t Screen 12/13. Adjust the POWER MODE activatin pint up r dwn. Initially set the POWER MODE start pint t activate 6-10 psig f yur maximum bst pressure. If the max bst pressure is 40 set the POWER MODE start pint t psig. If the max bst pressure is 50 set the POWER MODE start pint t 40 psig. A typical applicatin making 40 psig f bst shuld use the HI bst range and leave gain at 100%. MPG Start shuld be apprximately 21 psig, 100% shuld be apprximately 29 psig, and POWER MODE shuld be set at 31 psig. Tw MODE When Tw mde is enabled, the cntrller will measure EGTs and bst pressure t calculate the injectin rate. Based n these tw inputs, the cntrller uses pre-mapped 2-D matrix t determine hw much fluid t inject. Because the cntrller is pre-prgrammed, there are n start and full pints t adjust. Tggle t Screen 8. Select Tw mde. Tggle t Screen 9. Select bst level. See Cntrller Operatin: Screen 9.

8 Tggle t Screen 12/13. Adjust the POWER MODE activatin pint up r dwn. Initially set the POWER MODE start pint t activate 6-10 psig f yur maximum bst pressure. If the max bst pressure is 30 set the POWER MODE start pint t psig. If the max bst pressure is 40 set the POWER MODE start pint t 30 psig. ADJUSTING THE CONTROLLER The MPG MAX phase f injectin is meant t inject a small amunt f fluid during mderate lad cruising. Starting the MPG MAX phase as early as pssible ffers the largest range f benefit. If cmbustin quench ccurs as evidenced by engine bucking r bgging, t much fluid is being injected t sn. T prevent quench try each f the fllwing: Tggle t Screen 8A. Adjust the MPG MODE START pint t cme n at a higher bst level. Change ut MPG MAX nzzle t the next size smaller. If quench ccurs when the POWER MODE activates try each f the fllwing: 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). 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 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. Tggle t Screen 12. Adjust the POWER MODE START pint t cme n at a higher bst level. Tggle t Screen 11. Adjust the GAIN dwn t reduce verall injectin amunt if in Tw Mde. Change ut POWER MODE nzzle(s) t the next size smaller. 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 With the nzzles remved frm the intake, place the cntrller in bst nly mde by disabling the EGT Cntrl mde. Set gain t 100.

9 Using a hand pump, apply psig f pressure t the bst line t the cntrller. Pump shuld activate, fluid shuld flw, and tank level shuld g dwn. Tuning Quick Reference If cmbustin quench ccurs as evidenced by engine bucking, reduce the injectin quantity. This can be dne by: 1. Using a smaller nzzle(s). 2. Using Screen 9 and Screen 10 t adjust the gain. 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 apprx HP. 75/25 water/methanl will reduce EGTs and pwer will increase apprximately 40 HP. 50/50 water/methanl will reduce EGTs and increase pwer apprximately 70+ HP. Cautin: T avid pling in the intake it is recmmended that: 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. 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. Fluid Level Switch (ptinal) Instructins Red Lw Fluid LED Black Black 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