INSTALLATION INSTRUCTIONS FOR PART #20001 FORCED INDUCTION BOOST COOLER WATER / METHANOL INJECTION SYSTEMS Parts UHO (Ultra High Output) Pump 3 Qt Reservir 10 ft High Pressure Tubing 3ft Wire Lm 18 1/8 Silicne Tubing Electrical Packet 1 Fuse Hlder 1 20AMP Fuse 1 Green LED w/resistr 2 Blue Butt Cnnectrs 1 Large Eyehk 2 Small Eyehks 1 Male Cnnectr 1 Female Cnnectrs 1 Relay w/ Harness 10 Tie Wraps 1 Pressure Switch 1 Vacuum T Required Tls: -Electric Drill W/ Drill Bits -Adjustable Wrench -Utility Knife -Screw Driver -5/16 Open End Wrench -1/8-27 NPT Tap Mechanical Packets 1 Nzzle Hlder 1 Reservir Fitting 3/8 NPT t ¼ tube 8 #8x1&1/2 Screws 8 #8 Washers 4 #6x1/2 Screws 1 E-6000 (GOOP) Nzzles 60ML/MN (1) 100ML/MN (2) 175ML/MN (3) 225ML/MN (4) 375ML/MN (5) 625ML/MN (6) Upgrades Bulkhead 2.5 Galln Reservir Slenid Hse Adaptr r Bung Nitrbster Dual Nzzle Carburetr Plate Bst Juice Level Switch
Install 3/8 NPT t ¼ tube reservir fitting using E6000 sealant in the bttm f the reservir. Bst Switch Red Injectin Status LED White Thrttle Plate The nzzle, nt the reservir, shuld be the highest pint in the system. NO3 Prng T 12V Key- On Pwer Bst Line T Engine Bst Surce +12 Vlt Key On Engine Grund Wire Cnnectin Green Yellw Red Wire T COM Prng 20A Fuse The bst switch has three prngs. The prng labeled NO3 is fr 12V key-n pwer, and the prng labeled COM cnnects t the relay s red wire. Nte that that are tw red wires n the relay harness. The red wire immediately next t the green wire is fr the LED indicatr light. The red wire with its wn dedicated terminal cnnects t the bst switch which in turn cnnects t 12V key-n pwer. Nzzle Identificatin Chart: Nzzle Number Nzzle Size Nzzle Number Nzzle Size 1 60 ml/min 4 225 ml/min 2 100 ml/min 5 375 ml/min 3 175 ml/min 6 625 ml/min Red Installatin- Mechanical Step 1 Reservir Install Red Pump T Battery Psitive (+) Lw Fluid LED Level Switch Air Flw Optinal: The factry windshield washer reservir can be used as the reservir fr yur system, using ptinal part number 40080. Drill 9/16 hle in desired bulkhead lcatin. Remve ne nut frm bulkhead and turn the remaining nut until it is at the very end. 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 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. Cautin******* Whenever the nzzle is munted pst-thrttle plate, t avid siphning fluid at idle, it is essential t use a slenid upgrade inline between the reservir and pump.
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****** Pump must be shielded frm rad debris and tire wash. Failure t d s will result in pump failure 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: 250-350 RWHP: 175 ml/min nzzle. 350-475 RWHP: 375 ml/min nzzle 475-600 RWHP 625 ml/min nzzle Seal the nzzle int the nzzle hlder using the included E6000 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. 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. 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. 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.
Crrect Incrrect 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. Be sure that the nzzle tip is flush with the inside wall f the tube, r even prjecting int it slightly t ensure n interference in the spray pattern. Make sure the nzzle is the highest pint in the system as well. Drill and tap (11/32" pre-drill, 1/8-27 NPT tap) air inlet tube as clse as pssible t thrttle bdy/thrttle plate. NOTE: If nzzle is munted lwer then the reservir, a Slenid Upgrade (#40060) must be used t prevent draining. 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 t seal the threads. Carb Plates are available fr 4150 and 4500 style carburetrs. Yu can munt the nzzle in a plastic r rubber air inlet tube using a Nzzle Munting Adapter (#40110). Weld-in aluminum (#40120) and steel (#40130) bungs are als available. The recmmended nzzle munting pint is befre the thrttle bdy/ thrttle plate. If yu munt the nzzle after the thrttle bdy/thrttle plate (including use f a carb spacer plate) r belw the reservir, a Slenid Upgrade (#40060) must be used t prevent siphning at idle r gravity feed.
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. 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 Required tls - Drill - Screw Driver Crss Tip - Wire Cutter/Stripper/Crimper - Please refer t electrical diagram. Step 1 Pressure Switch Munt the pressure switch using a tie wrap. Hard munting using screws is nt recmmended as diaphragm distrtin culd cause the switch t malfunctin. Attach 1/8 silicne tubing (supplied) t hse barb n switch. Other end f the hse attaches t manifld bst surce. Wire switch accrding t wiring diagram. Step 2 LED Select lcatin f LED (green-n when pump activated) in driver s cmpartment f vehicle. Run RED and BLACK wires t LED and make required cnnectins as indicated in wiring diagram. Nte that the RED wire immediately next t the GREEN wire is used fr the LED, nt the RED wire n the ppsite side f the relay harness frm the GREEN wire. The WHITE wire f the LED cnnects t grund, the RED wire f the LED cnnects t the prper RED wire. Step 3 Relay Optinal Aluminum Bung Shwn 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. Munt the relay n fire wall clse t the pressure switch. Wire relay accrding t diagram using supplied cnnectrs. Either f the cmbined GREEN/RED wires can be used t pwer the pump, injectin status LED, r Slenid Upgrade. The single RED wire is the switched activatin input. It is typically cnnected t the adjustable pressure switch, but can als be cnnected t a nitrus slenid r ther 12V input t cntrl injectin. CAUTION: D nt rute wires near ht r mving parts. Use crrugated wire lm and tie wraps (supplied) t prtect and rute wires.
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 1 Test Pump and Mechanical System Turn key t ON psitin. Bypass the pressure switch by tuching a wire between the tw ples n the switch. 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. If pump ges n and fluid level desn't g dwn, there is an bstructin in the tube r nzzle. Activatin f the pump in 1-5 secnd intervals will purge air frm the system after install. This can be accmplished in initial use. Step 2 Test LED vs. Pump On Apply a 12v surce t ple #87 f relay (single red wire, nt red/green wire). Pump shuld activate and LED shuld g n. Check LED grund and wiring if n activatin. If wiring and grund check ut kay, check LED with 12v surce. Initial Tuning #20001 Set Bst Switch Activatin Pint At the factry setting, the bst switch will start injectin at abut 10 psig bst. Adjusting the set screw clckwise will increase the bst pressure needed t activate injectin. Turning the adjustment screw cunter-clckwise will decrease it. 1 full turn cunter-clckwise will decrease the injectin pint by 1-2 psig. Typical injectin nset pints are at ½ f maximum bst. Intrducing water/methanl befre ½ f maximum bst pressure culd result in quenched cmbustin and engine misfire. Tuning Quick Reference The pwer ptential f the system is realized thrugh increased bst and/r timing. The large gains n ctane and cling prvided by the system make this pssible, even n standard pump fuel. The Bst Cler adds an alternate fuel surce as well as significantly cls cmbustin. With the Bst Cler, ne des nt need t cl cmbustin with verly rich air/fuel ratis. T
minimize cmbustin quench, yu shuld start with an air t fuel rati f 12.0-12.5:1. Injecting water/methanl lwer than 3300-3500 RPM culd result in cmbustin quench. All vehicles are different. If the engine bgs r lses pwer, then it is cming n t early, the quantity is t much, r there is nt enugh methanl in the mixture (50/50 water/methanl recmmended). Cautin****** Prlnged quench may cause lwer engine damage ver a perid f time. Fluid Level Switch (ptinal) Red Lw Fluid LED Maintenance Remve nzzle(s) and clean screen filters 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, and can cause damage t the system. Cntaminants in the fluid such as dirt can damage the system. Ensure that dirt and debris d nt fall int the tank. D nt use Tefln tape r paste t seal cnnectins. These sealers are nt as effective as the Gp sealant prvided and can break dwn ver time, clgging cmpnents. Fr best perfrmance, cling and system life it is recmmend that Snw Perfrmance Bst Juice, part #40008, be the exclusive fluid used in the system. 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.
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. SNOW PERFORMANCE FUEL SYSTEMS