INSTALLATION INSTRUCTIONS FOR PART #47002 WATER / METHANOL INJECTION SYSTEM UNIVERSAL TURBO DIESEL

Transcription

1 Kit Cntents INSTALLATION INSTRUCTIONS FOR PART #47002 WATER / METHANOL INJECTION SYSTEM UNIVERSAL TURBO DIESEL 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 Bst T Fitting 1 Green LED 2 Blue Butt Cnnectrs 2 Small Eyehks 1 Large Eyehk 1 Male Cnnectr 3 Female Cnnectrs 1 Arm Switch VC-100 Cntrller W/ Harness 10 Tie Wraps Fuse hlder 20 amp fuse Mechanical Packets 1 Nzzle Hlder 1 3/8 NPT t ¼ tube 8 #8x1&1/2 Screws 8 #8 Washers 4 #6x1/2 Screws 1 Dual Nzzle Upgrade 1 Bulkhead 1 E-6000 (GOOP) Nzzle Nzzles Required Tls Electric Drill w/ Drill Bits Utility Knife Screwdriver Phillips Assrted Wrenches 1/8 NPT Tap Upgrades/Optins 2.5 Galln Reservir 7 Galln Reservir Slenid Upgrade Hse Adaptr r Bung Bst Juice

2 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 F EGT drp using 50/50 water/methanl injectin fluid. Please refer t system diagram during install. Wiring diagram Installatin Mechanical Step 1 Reservir Install 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 Install straight fitting and included E-6000 sealant and munt reservir in engine cmpartment using #8x1½ sheet metal screws and washers prvided. Nte that the nzzles, nt the reservir, shuld be the highest pint in the system. Optinal: The factry windshield washer reservir can be used as the reservir fr yur system. Drill 9/16 hle in desired bulkhead lcatin. Nte that the bulkhead can be munted hrizntally t direct tube tward pump. Bulkhead Fitting Installed in Washer Tank. Remve ne nut frm bulkhead and turn the remaining nut until it is at the very end.

3 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 E-6000 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 pump s the pump 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. 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. The pump can be munted n the flr next t the reservir. Cautin****** Pump must be shielded frm rad debris and tire wash. Failure t d s will result in pump failure

4 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 nzzles Seal the nzzle int the nzzle hlder using included E-6000 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. 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. Remve the pipe just befre the intake itself and drill and tap (11/32" predrill, 1/8-27 NPT tap) fr ne r tw nzzles. Nzzles can be munted almst anywhere n the charge pipe between the intercler utlet and the intake itself, as lng as they are at a 90 degree angle t the directin r airflw, and have a clear spray pattern int the pipe with n bstructins. Ensure that the nzzle tip is flush with the inner wall f the pipe r prtruding slightly. Assemble desired nzzle int nzzle hlder using E-6000 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 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 E-6000 t seal the threads. NOTE: If nzzle is munted lwer then the reservir, a Slenid Upgrade (#40060) must be used t prevent draining.

5 Step 5 Nzzle Cnnectin Measure the distance frm the pump utlet t the nzzle hlder. 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. Installatin - Electrical Variable Cntrller Installatin Use tie wraps t help rute tubing and t ensure it desn't cntact mving r ht parts in the engine cmpartment. Have tubing cnnect t quick cnnect fittings at shallw angles. Having an immediate sharp bend may unseat the tubing frm the internal -ring and create a leak. 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. 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 bst line (using included bst T fitting) t hse barb n back f cntrller and secure with tie wraps. 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 at psitin 3 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 the inline switch and cnnect t a +12V key n surce. Always have a gd electrical grund cnnectin. Pr grund will result in erratic peratin f cntrller.

6 Variable Cntrller Tuning VC-100uC Start Psi Full Psi Testing the System Step 1 fr best results, prime pump befre use Use a tie wrap t keep rubber vacuum/bst line n hse barb in high bst applicatins. Adjust the Start Psi bst level first by turning dial clckwise t ½ t 1/3 rd f the engines max bst utput. This sets the bst pressure required t activate the injectin system. Typical start pints are PSIG. Next, adjust Full Psi t the engines maximum bst utput. Nte - Setting the Full dial lwer then Start, will result in max injectin at the nset pint. A typical applicatin making 35 psig shuld set the Start at 18 psi and the Full at 30 psi. Cntrller Operatin Example Pump Output % Start Full Bst Pressure psi 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 2 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. Fr the middle line, the chart shws the Start dial at 6psi and the Full dial at 13psi. At 6psig f bst pressure the pump will perate at 10%. At 13psig 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. If pump ges n and fluid level desn't g dwn, there is an bstructin in the tube r nzzle.

7 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 3 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 very light air pressure int vacuum tube cnnectin n back f cntrller with the start dial gently turned cunter-clckwise. 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: 1. Using a smaller nzzle(s). 2. Intrducing injectin later at a higher start setting. Cautin****** Prlnged quench may cause lwer engine damage ver a perid f time. Cautin: T avid pling in the intake and pssible engine damage upn start-up, 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. 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.

8 Fluid Level Switch (ptinal) Red Lw Fluid LED 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. Slenid must be munted pre pump. 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. 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. 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. SNOW PERFORMANCE FUEL SYSTEMS