WILD WATER INJECTION

SCHEID DIESEL’S ELECTRIC WATER INJECTION KIT ON A 1,000HP RACE TRUCK

Water injection has been around nearly as long as the diesel engine has been in existence. Instead of intercooling, injecting water into a diesel engine can be used to control combustion and exhaust gas temperatures through a phase change. Known as the latent heat of vaporization of a liquid, when water turns to steam it sucks heat out of the air, which in a turbocharged diesel engine can be quite hot.

2_TRANNY1704 — Scheid Diesel’s water kit is a lot simpler than many other units, and it’s also a lot more powerful. Where other pumps will run at 200-300 psi, Scheid’s runs at 400-600 and can be turned up even more if warranted.

3_TRANNY1704 — Before the water injection kit was installed, we needed a place for the nozzle in the intake. Many aftermarket intake horns have provisions for this, but since Cole Dow had fabricated an intercooler delete pipe for the occasion, one needed to be welded in.

4_TRANNY1704 — After whipping up a piece of aluminum on the lathe, Cole’s brother Cory TIG-welded it onto the engine’s intake piping.

5_TRANNY1704 — Scheid recommended we place the nozzle close to the intake, so the bung was welded, drilled, and tapped and placed right before the v-band for Dow’s dual-feed intake.

As the horsepower per liter of an engine increases, it creates more and more heat. In stock applications, intercooling and proper turbo sizing can control exhaust gas temperatures without any issue, but if you’re the type of person who can’t leave well enough alone, temperatures can become a major issue.

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MELTING PARTS WITH 1,000 HP

Cole Dow has a very quick 9-second diesel race truck that was having EGT problems. With the amount of nitrous he was using (0.063, 0.085, 0.087, and 0.110-inch jets on a Nitrous Express progressive controller) he was seeing exhaust gas temperatures that were off the charts. His 1,600-degree pyrometer would be buried just after launch, and at the far end of the track the needle had wrapped all the way around back to the “0” mark. Not only were EGTs off the chart, Dow also would only get a few runs in before he would melt the center out of the turbo housing, melt the exhaust wheel, or both. Since replacing turbos every few runs wasn’t in his maintenance budget, he decided to do something about it.

600PSI WATER INJECTION

Normal diesel water injection kits run around 200 to 300 psi and are usually marketed with methanol in mind as a power booster. Since Scheid Diesel’s main business is sled pulling, the company took a different approach and built a mammoth electric water-injection kit designed to cool between 800 and 1,400 horsepower at the flywheel on pulling trucks. With 12-nozzle/1,000psi mechanical injection kits being drastic overkill for most applications, they decided the electric kit would make a good gap filler for those who wanted to cool their charge in high-horsepower applications. In Dow’s case, adding water injection also meant that the nitrous could be ramped up quicker for better 60-foot times, and about 150 pounds of intercooler, piping, pump, and water tank could be shed to save weight.

THE INSTALLATION

The Scheid water injection kit’s main objective is to keep things cool in a full-throttle application, which made installation rather painless. The kit includes a tank and pump assembly, a single large nozzle, line, and a Hobbs switch that’s triggered at a specific boost level. Also included is a bottle of cutting oil that is mixed with water to help keep the pump lubricated. Since Dow already had nitrous bottles and a lot of other things going on in his bed, he chose to mount the pump on the floor of the truck beneath the passenger seat.

6_TRANNY1704 — The water injection system is triggered with a Hobbs switch that senses boost pressure and then makes an electrical connection. Since Dow launches at 20 to 30 psi of boost, the switch was adjusted to 40 psi by using an air compressor and multi-meter so the water would come on right after the truck left the line.

7_TRANNY1704 — Dow found a free spot at the back of the P-pump’s AFC housing to boost-reference the pressure switch. Once set, a rubber plug was installed on the set screw to ensure its trigger point remained the same.

8_TRANNY1704 — Cory told us that most race car (or race truck in this case) problems come with wiring, so he crimped and soldered all connections to the water system before installation.

9_TRANNY1704 — Cole drilled a hole in the firewall to run the water system’s high-pressure line to prepare for the installation of the tank/pump assembly. A rubber grommet was also installed to protect the high-pressure line from damage.

10_TRANNY1704 — Since Dow already had a fuel cell and twin nitrous bottles in the bed, he chose to mount the tank and pump assembly on the floorboard of his truck. In the meantime, the extra line was looped in the cab until the owner could get to a hydraulic shop to shorten it.

Pump installation only took a couple of hours, with the majority of the time being spent adjusting the pressure and tuning, as well as welding an extra bung into the intake for the water nozzle. We verified the system was working by spraying it in the air (which is good fun), and then with the pressure maxed out we hit the track.

TESTING AT SACRAMENTO RACEWAY

The previous round of testing had left Dowwith a new turbo to try, a 75mm S400 turbocharger with an undivided housing and 96mm turbine wheel. The big turbine ameant the truck was now harder to spool and needed an additional jet of nitrous (0.030-inch) just to get off the line. With exhaust gas temperatures at 1,200 degrees at the starting line, we knew the water injection had plenty of heat to absorb.

11_TRANNY1704 — The hard-wiring for the pump was installed in order to test it. Once triggered, a single solenoid opens and sends hundreds of pounds’ worth of pressurized water into the engine.

12_TRANNY1704 — Did we say water? Well, it’s almost that. Water is mixed with a cutting agent that creates a milky substance to keep the pump lubricated.

13_TRANNY1704 — Cory jumped the leads on the pump to activate the system while Cole held the nozzle, the result of which was a pretty impressive spray that we felt was bound to cool things off a bit.

14_TRANNY1704 — After we made sure the kit worked, Cory went about wiring in an activation switch on the dash. Things are quite busy on the inside of this truck, which meant Cory had to get creative.

15_TRANNY1704 — With the water system installed, it was time for some late-night testing, first without nitrous, then with everything on kill.

17_TRANNY1704 — With the nitrous activated, the truck hit more than 80 psi of boost, enough to blow off the intake pipe right into the radiator. For next day at the track, Dow welded on a strap and clamp to keep the intake from blowing off again.

18_TRANNY1704 — At the drag strip, the Dodge ran a 9.74 at 139 mph and cut a 60-foot time of 1.39 seconds, which is a new best for the truck. Best of all, it still drove onto the trailer after a number of hard passes.

The nitrous hit immediately off the line just like before, but this time there was a smaller flame, and no turbo-part sparks coming out of the hood stack. The truck still made plenty of heat, but with the water on it built much more slowly. The gauge still swept past 1,600 degrees, but this time it was pointed more down rather than all the way around. Dow estimated his EGT at the end of the track to be in the 2,000-degree range rather than the 2,200-2,400 degrees that was so hard on his turbos. While the truck still ran hotter than he hoped, he made nearly a dozen test passes with no turbo failures, and ran 139 mph back to back, which has been the Dodge’s best speed so far.

THE VERDICT

We talked to Dan Scheid, owner of Scheid diesel, after testing to get his thoughts on the matter. He advised us that bumping the timing a few degrees more (up from 22 degrees) might help, and that we could also drill the water nozzle out to .030 inches if we wanted, which would provide less pressure but more flow. At the track, with the wastegate wide open, the truck hit a scary 86 psi, which is pretty high for a single turbo. At that point, we decided to halt testing until Dow could get the boost to manageable levels with a larger 66mm wastegate. But with a number of fast passes under his belt and no melted turbo parts, we’d have to say using the Scheid water injection kit was a success.DW

SOURCE

DOW BROTHERS RACE CARS
916.812.1678

SCHEID DIESEL
800.669.1593
ScheidDiesel.com

FREQUENTLY ASKED QUESTIONS.

Is water injection approved for public use by regulatory bodies?

When it comes to water injection systems, approval for public road usage is quite a rarity. These systems are primarily designed for motorsport applications and may not meet the requirements set by various regulatory bodies for everyday vehicles.

Regulatory Approval Challenges

Lack of Certification: Many water injection systems do not come with the Allgemeine Betriebserlaubnis (ABE), a certification necessary for legal use on public roads in some countries like Germany.
Designed for Motorsport: The technology caters mainly to racing environments, where regulations differ significantly from public road standards.
Safety and Emissions Concerns: Regulatory bodies, such as the Environmental Protection Agency (EPA) in the U.S. and the European Union’s regulatory authorities, often focus on emissions and safety standards where water injection systems may not comply.

Alternatives

For Street Use: Enthusiasts looking to modify their vehicles should consider alternatives that are explicitly approved for public use or consult with a professional to understand the implications fully.
Consult Local Regulations: Always check specific regional or national regulations, as requirements can vary.

In summary, while water injection systems may enhance performance, they are not typically approved for public road use due to their design focus and lack of regulatory certification.

What is the general conclusion about the effectiveness and practicality of water injection systems?

THE VERDICT

We talked to Dan Scheid, owner of Scheid Diesel, after testing to get his thoughts on the matter. He advised us that bumping the timing a few degrees more (up from 22 degrees) might help, and that we could also drill the water nozzle out to .030 inches if we wanted, which would provide less pressure but more flow. At the track, with the wastegate wide open, the truck hit a scary 86 psi, which is pretty high for a single turbo. At that point, we decided to halt testing until Dow could get the boost to manageable levels with a larger 66mm wastegate. But with a number of fast passes under his belt and no melted turbo parts, we’d have to say using the Scheid water injection kit was a success. DW

Unleashing Performance and Efficiency

Water injection systems offer a significant boost in performance, providing up to 40 percent more power while also enhancing fuel efficiency. These systems not only improve consumption rates but also offer engine protection, making them a valuable addition for racing fans and ambitious tuners. While there are minor disadvantages, these are outweighed by the benefits, especially if the general operating permit is not a concern.

Balancing Power and Safety

Integrating these insights, it’s clear that water injection systems can be both effective and practical. The successful use of the Scheid kit demonstrates that, with proper adjustments and understanding, such systems can safely deliver enhanced performance without compromising the integrity of the engine. With careful tuning and expert advice, the potential for increased power and efficiency is substantial.

How does the system impact engine maintenance or longevity?

By providing engine protection, water injection systems can contribute positively to engine maintenance and longevity.

What is the overall assessment or conclusion about the system?

The overall conclusion is that water injection systems are highly beneficial, offering significant performance gains with few drawbacks.

What are the advantages of water injection for engine tuning?

“WATER INJECTION HAS BEEN AROUND NEARLY AS LONG AS THE DIESEL ENGINE HAS BEEN IN EXISTENCE. INSTEAD OF INTERCOOLING, INJECTING WATER INTO A DIESEL ENGINE CAN BE USED TO CONTROL COMBUSTION AND EXHAUST GAS TEMPERATURES THROUGH A PHASE CHANGE. KNOWN AS THE LATENT HEAT OF VAPORIZATION OF A LIQUID, WHEN WATER TURNS TO STEAM IT SUCKS HEAT OUT OF THE AIR, WHICH IN A TURBOCHARGED DIESEL ENGINE CAN BE QUITE HOT.

A major advantage of water injection is its ability to actively cool the combustion process, significantly reducing engine knock. This allows for an increase in boost pressure and ignition timing safely, without risking damage to the engine. By lowering the thermal load, it ensures optimal efficiency even at higher outside temperatures. The charge air temperature can be reduced below that of the environment, compensating for power loss and ultimately enhancing performance.

’s</Scheid Diesel> water kit is a lot simpler than many other units, and it’s also a lot more powerful. Where other pumps will run at 200-300 psi, ’s runs at 400-600 and can be turned up even more if warranted.

Additionally, water injection reduces specific consumption and lowers exhaust gas temperatures, which protects the turbocharger and extends its life. Even with extreme efficiency, it can make an intercooler unnecessary. This makes it a superb addition to existing tuning measures, such as chip tuning, without sacrificing any boost pressure.

Normal diesel water injection kits run around 200 to 300 psi and are usually marketed with methanol in mind as a power booster. Since ’s</Scheid Diesel> main business is sled pulling, the company took a different approach and built a mammoth electric water-injection kit designed to cool between 800 and 1,400 horsepower at the flywheel on pulling trucks. With 12-nozzle/1,000psi mechanical injection kits being drastic overkill for most applications, they decided the electric kit would make a good gap filler for those who wanted to cool their charge in high-horsepower applications.”

Can water injection replace other components, like an intercooler?

In some cases, the efficiency of water injection is so high that it can potentially replace an intercooler, providing an alternative method for managing heat in the engine system.

How does water injection affect charge air and exhaust temperatures?

By lowering both the charge air and exhaust gas temperatures, water injection helps protect components like the turbocharger and maintains optimal efficiency.

How does water injection affect engine cooling?

Water injection actively cools the combustion process, significantly reducing the thermal load on the engine, which helps in managing the engine’s operating temperature more effectively.

What are the benefits of using water injection in tuning?

Performance Boost

For those who have tuned their engines for high power, water injection can be a game-changer. This technique can lead to a remarkable increase in engine output, especially when paired with a high-performance turbocharger. In some setups, this can result in a power boost of up to 40%, allowing drivers to tap into greater performance without compromising engine integrity.

Heat Management and Engine Protection

Water injection excels in managing heat build-up. By effectively cooling the combustion process, it reduces the thermal load on the engine, safeguarding it from potential damage. This is particularly beneficial for preventing engine knocking and maintaining consistent performance levels even under intensive conditions.

Environmental Impact

Beyond performance, water injection offers environmental benefits. By optimizing combustion efficiency, it reduces fuel consumption and lowers pollutant emissions, making it an environmentally conscious choice for engine tuning enthusiasts.

Complementary Systems

Unlike traditional charge air cooling, water injection does not lead to a loss of boost pressure. This is because it can cool the charge air temperature below ambient levels without relying on external factors like ambient temperature. For the best results, consider combining water injection with an upgraded intercooler to maximize cooling efficiency and power output.

Incorporating water injection into your tuning setup not only enhances performance but also ensures your engine operates under safer thermal conditions. This makes it an invaluable addition for anyone serious about optimizing their diesel engine’s capabilities.

Is water injection compatible or beneficial alongside other tuning measures?

Yes, it complements other tuning efforts by providing enhanced cooling and performance, making it an excellent addition for further engine optimization.

How does water injection contribute to engine protection and longevity?

By managing heat effectively, water injection prevents knocking and potential engine damage, thus safeguarding the engine and enhancing durability.

How does water injection compare to other cooling systems like charge air cooling?

Unlike charge air cooling, water injection maintains boost pressure and can lower charge air temperatures below ambient levels, avoiding performance loss.

How does water injection impact fuel consumption and emissions?

It helps reduce fuel consumption and lowers pollutant emissions, offering an eco-friendly advantage.

How much can water injection increase engine power?

Water injection can significantly boost engine power, potentially increasing output by up to 40% when paired with a high-performance turbocharger.

What are the disadvantages or challenges associated with water injection?

However, incorporating water injection isn’t without its challenges. One of the primary concerns is maintenance; it’s crucial to ensure there is always enough fluid available to prevent the system from running dry. Installing a fluid gauge inside the vehicle can help monitor levels and avoid potential damage. Moreover, the system should allow the piston pressure pump to be switched off when the tank is empty, safeguarding against wear and tear.

Another consideration is the use of methanol. While it’s a popular choice for maximizing power gains, methanol’s availability can be limited, posing a challenge for those seeking to unlock the full potential of their water injection system. Balancing these challenges with the benefits can help achieve the desired performance gains without compromising system integrity.

Are there any challenges related to the use of certain fluids like methanol?

Obtaining methanol can be challenging, yet it’s important for maximizing the system’s potential.

What operational safeguards should be in place?

Ensure the system includes a fluid gauge and the ability to switch off the pump to prevent it from running dry.

What maintenance is required for water injection systems?

Regularly check fluid levels to ensure there is always enough fluid available in the system.

Should water or a water-alcohol mixture be used as a coolant in water injection systems?

Choosing the Right Coolant: Water vs. Water-Alcohol Mixtures

When deciding between using only water or a water-alcohol mixture for water injection, consider several factors that can impact performance and maintenance:

Water Only: If you opt for pure water, ensure it is distilled. Distilled water helps prevent lime deposits that could clog the nozzles and contaminate the combustion chamber. This precaution can save you from potential maintenance issues down the line.
Water and Methanol Mixture: For those seeking the highest performance boost, a mixture of water and methanol is recommended. Typically, this is mixed in a ratio of 70% water to 30% methanol. Methanol not only enhances performance but also helps prevent the formation of oil carbon in the combustion chamber.
Water and Ethanol Mixture: Alternatively, ethanol can be used in a 50:50 ratio with water. While easier to source, the performance increase with ethanol is somewhat lower compared to methanol.

Each coolant option brings its own set of benefits and considerations. Understanding these can help you make an informed choice that aligns with your engine’s needs and your performance goals.

What is water injection and how is it defined?

What is Water Injection?

Water injection is a technique used to enhance engine performance by cooling the fuel-air mixture. This process can lead to more power output and reduced fuel consumption. A common approach involves injecting very finely atomized water or a water-alcohol mixture directly into the combustion chamber. This method is often referred to as WAES (Water Alcohol Emulsion System) technology.

How Does it Work?

Cooling Effect:When water is injected, it absorbs heat as it transitions from liquid to steam, effectively cooling the intake air.
Temperature Control:This cooling effect helps manage combustion and exhaust gas temperatures, making it particularly beneficial for turbocharged diesel engines.

Another variation of this technique involves spraying water onto the charge air cooler from the outside, thereby reducing the temperature of the charge air before it enters the engine. Both methods aim to maximize efficiency and performance, offering flexibility in application depending on the engine design.