Gasoline Installation Instructions

Transcription

1 Gasoline 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 3. Level Swith (optional) I - Mechanical Mechanical BOM Contents - Pump - Tank - Nozzles - 6' tubing 1/4" O.D. - (2) Fittings pump in/out (3/8" NPT - 1/4" O.D., elbow adapter) - (5) Tie wraps - Nozzle Holder Required tools - Drills(s) - Tap (1/4" NPT)

2 - Teflon sealant (pipe sealant) - Adjustable wrench - Utility knife - Screw driver - phillips - Thread Sealant - loctight permanent (for nozzle) Instructions - Please refer to mechanical diagram. - If auxiliary tank is utilized, the battery will have to be relocated to the trunk for most applications to free up necessary space for a tank. - Mount tank as high in engine compartment as possible using sheet metal screw provided. - 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 then the reservoir, a solenoid must be used. Note:

3 - Nozzle sizing is a function of flywheel horsepower ( FWHP), which approximates an engines airflow, and boost, which approximates intake charge heat. Recommended starting points: Gasoline Engines: 1) Naturally aspirated and nitrous applications injection qty 10% of total fuel at peak FWHP (eg. With 300HP, inject 214 ml/min) 2) 5-9 psig boost - 15% 3) psig - 18% 4) psig - 20% 5) psig - 22% 6) % HP (flywheel) Fuel (ml/ min) Water/Methanol (25%) Water/Methanol (15%) 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

4 Note: - Nozzle size may have to be adjusted up or down depending on the air fuel ratio (smaller nozzle if starting at less than 12.5:1) and concentration of methanol (smaller if less than 50% methanol is used). - Introducing water/methanol before 4-5 psi boost could result in quenched combustion and engine misfire. - Drill and tap (7/16" pre-drill 1/4-18 NPT), throttle body or metal air inlet tube. Ensure that nozzle is before throttle plate. - Mount nozzle 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

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6 Electrical BOM Contents Stage 1: Stage 2: - Relay - Variable Controller - Relay connector - LED - Green - LED - green - Connectors - Boost pressure switch - Tie Wraps - Connectors - Corrugated Wire Loom - Tie wraps (5) - Corrugated wire loom - Allen wrench (to set pressure switch) Required tools - Drill - Screw driver-phillips - Wire cutter/stripper/crimper Instructions: Stage 1 - Please refer to stage 1 electrical diagram. - Mount Relay on firewall using supplied sheet metal screw. - Mount pressure switch close to manifold vacuum/boost source. - Attach supplied 1/8" hose to post on pressure switch. Other end attaches to manifold vacuum 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. Instructions: Stage 2

7 - Please refer to stage 2 electrical diagram. - Mount variable controller. Firewall is recommended away from heat and in an easy to access location. - Attach 1/8" tygon hose to port on controller. The other end attaches to the manifold boost source. - Select location of LED (green-on when pump activated) in dashboard of vehicle. Wire LED per the wiring diagram. - Wire controller per the stage 2 wiring 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 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 pole #87 of relay. 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: - Begin with turning the allen screw on pressure switch all the way counterclockwise (this will activate water/methanol at low 2-3 psi boost). Adjust set screw clockwise until desired activation point is reached (5-6 psi recommended). Note: 2mm Allen wrench supplied with kit. Stage 1 Tuning Tips - Begin tuning with the onset pressure at the lowest setting (adjust the pressure switch all the way counterclockwise). - Continue tuning at 1/2 turn (clockwise) intervals until no hesitation/misfiring occurs at injection onset and a steady flow of power is felt (usually about RPM). - Increase base timing in 2 degree increments until the first hint of detonation - then back off 2 degrees (use 3rd gear pulls from 2000RPM). - The kit enables the use of increased timing which provides for over 50% of the potential power increase( denser intake charge the remainder). All other factors being the same, if base timing is not increased over the non-boost Cooler settings, power increase will be less. - After tuning, ensure that reservoir has adequate fluid at all times. It is recomended that reservoir always be at least 1/4 full. Stage 2 Variable Controller Tuning Tips 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 lowest settings (counter-clockwise). - The amount injected can also be adjusted by pump pressure which can be changed by turning the Allen head in the pump regulator - counterclockwise = less pressure. It is set at the factory at the highest setting. - Adjust the onset boost level first by turning setscrew clock wise to the desired setting. - Next, adjust the full injection boost level clockwise until a smooth power curve is felt with no misfiring. - Over lapping the settings - setting full lower than onset will result in max injection at the onset point. Tip: With centrifugal superchargers: with 10psig boost, on at 3psi /full at 6psi works well. With 20 psig, on at 5psi/full at 12psi is a good starting point. MAF Variable Controller Tuning Tips

8 - Begin tuning process with both adjusters at their lowest settings (counter-clockwise). - The amount injected can also be adjusted by pump pressure which can be changed by turning the Allen head in the pump regulator - counterclockwise = less pressure. It is set at the factory at the highest setting. - Adjust the onset MAF voltage level first by turning setscrew clock wise to the desired setting. - Next, adjust the full MAF voltage level clockwise until a smooth power curve is felt with no misfiring. - Over lapping the settings - setting full lower than onset will result in max injection at the onset point. Tip: Usually on at 2.7V and full at 4.5V is a good starting point. III Fluid Level Switch Instructions - After mounting reservoir, mount red LED in dash next to the green ignition LED is usually easiest. - Wire LED per diagram with one wire to ground, the other to one wire of the level switch. - Connect other level wire to a 12v key-on source. - With key-on source, the red LED should be on with no fluid in the reservior. Upon filling the reservior, the red LED should be off. - The system is designed to indicate when there is less than 1 of fluid in the reservior. It is recommended that reservior be re-filled before red LED is activated.