Intercooler water mister installation part 1...
04-23-2004, 09:07 PM
#1
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Intercooler water mister installation part 1...
Decided to install the electronic/electric portion of the mister system on the car. The actual hoses, spray/mister nozzles and electric pump will be done when we switch the front bumper assembly to the Caractere one, this will be part 2 in the coming weeks. Side note on the electric pump I'm going to use. I've decided to not use the headlight washer pump because or reliability concerns. I got a fuel pump used in the older VWs in the CSI fuel injection systems. This pump is constantly operating in a CSI system and won't overheat for this task either. It can produce between 68 and 75 psi which should be more than enough for this use.
Instead of using only one mister per I/C, I will try to fit (if able, tight space) two per side to get even more water onto the I/Cs.
Anyways here are some pictures from the electric hookup.
In this picture you can see the cover to the ECU as been removed. You can see the ECU itself the main ECU harness and you can see a grey wire coming out from inside the car where the fuses are. Inside the grey jacket is a multitude of wires for power to the pump, some for the temperature sensors, one for a digital thermometer and one for the fuel injection signal. If you look closely, between the main harness and the ECU itself you can see a little green wire. This wire is the signal wire that goes from the ECU to the injector on the #1, cylinder more on this later.
<img src="http://pictureposter.audiworld.com/46874/h2omist1.jpg">
In this picture you can see all the wires after the grey jacket was removed (above the ABS pump).
You can see a red wire; this wire is the fuel injector signal wire. It will be sliced in and soldered to the green wire from the previous picture. The system does not use boost as a parameter to decide whether to spray or not. It uses the injector's duty cycles and a temperature differential that you set up to your own likings. Once the temperature differential as been reached or exceeded the systems is now armed and waits to see if the demand for the injectors cycle is increased (stepping on the gas pedal). If it detects an increase in duty cycle bang the pump is sent power and the spraying starts until a relief in injector duty cycle is seen. If you look below the ABS pump and over the fender there is a larger green wire that is the power to the pump wire.
<img src="http://pictureposter.audiworld.com/46874/h2omist2.jpg">
In this picture you can see a close up of the remaining wires that were originally in the grey jacket. If you look closely in the techs left hand (the one with the watch) you can see right below his thumb a set of wire terminated by a small circular loop. This is a temperature sensor that will be installed in the clean air in the I/C intake duct, way ahead of the I/C so as to read the outside air temperature. The next one below that is basically the same but also includes a bolt and a two prone wire attached to it. This is the one we are going to install behind the I/C through the I/C fins as to read the internal I/C temperature or air intake temp. The difference between the first sensor and this one is what triggers the pump. If you look further down, dangling there is a black wire, a third temp sensor, this one is hooked up to the digital thermometer in the cockpit. Notice that for a clean finish all the wiring is wrapped up in plastic tubing.
<img src="http://pictureposter.audiworld.com/46874/h2omist3.jpg">
Ok in this picture you see that we are about to pass the wiring out from the ECU box through the fire wall by going through the big rubber tubing that seals the ECU box. You can see the screw driver going in a spare exit hole at the bottom of the big tube and going in towards the ECU. In the fore ground you can see the black digital thermometer wire, the green electric pump wire and in the back ground the red injector signal wire.
<img src="http://pictureposter.audiworld.com/46874/h2omist4.jpg">
Now you can see a close up of the green injector signal wire from the ECU itself already spliced and the red one from the control module in the fore ground.
<img src="http://pictureposter.audiworld.com/46874/h2omist5.jpg">
In this picture, it's the actual soldering of the two wires together.
<img src="http://pictureposter.audiworld.com/46874/h2omist6.jpg">
Another view of the soldered wires before the final touches are done.
<img src="http://pictureposter.audiworld.com/46874/h2omist7.jpg">
This shot is showing the inside of the car and where the control module is located. You can see all the wiring. There is a red wire that is connected to the ignition and one to a relay. The other wires connect to the module through two canon plugs.
<img src="http://pictureposter.audiworld.com/46874/h2omist8.jpg">
Sorry for the quality of this picture and I know it is hard to see but this is where the control module sits when all is finished, you can see some of the wiring at the top right corner. Once everything is put back in place the unit is easy to access with excess wiring to pull it out of its hiding place. It is recessed under neath the steering wheel in that slot where you can store the owner's manual.
<img src="http://pictureposter.audiworld.com/46874/h2omist9.jpg">
Again sorry for the picture quality. Just a look at the digital thermometer. I set it up dead centre over the steering column on the bottom on the dash board. The I/C temp can be read by the one on the right side. the one on the left is the car interior temp. not really needed. Originally this unit was made as an indoor/outdoor thermometer for the home.
<img src="http://pictureposter.audiworld.com/46874/h2omist10.jpg">
Instead of using only one mister per I/C, I will try to fit (if able, tight space) two per side to get even more water onto the I/Cs.
Anyways here are some pictures from the electric hookup.
In this picture you can see the cover to the ECU as been removed. You can see the ECU itself the main ECU harness and you can see a grey wire coming out from inside the car where the fuses are. Inside the grey jacket is a multitude of wires for power to the pump, some for the temperature sensors, one for a digital thermometer and one for the fuel injection signal. If you look closely, between the main harness and the ECU itself you can see a little green wire. This wire is the signal wire that goes from the ECU to the injector on the #1, cylinder more on this later.
<img src="http://pictureposter.audiworld.com/46874/h2omist1.jpg">
In this picture you can see all the wires after the grey jacket was removed (above the ABS pump).
You can see a red wire; this wire is the fuel injector signal wire. It will be sliced in and soldered to the green wire from the previous picture. The system does not use boost as a parameter to decide whether to spray or not. It uses the injector's duty cycles and a temperature differential that you set up to your own likings. Once the temperature differential as been reached or exceeded the systems is now armed and waits to see if the demand for the injectors cycle is increased (stepping on the gas pedal). If it detects an increase in duty cycle bang the pump is sent power and the spraying starts until a relief in injector duty cycle is seen. If you look below the ABS pump and over the fender there is a larger green wire that is the power to the pump wire.
<img src="http://pictureposter.audiworld.com/46874/h2omist2.jpg">
In this picture you can see a close up of the remaining wires that were originally in the grey jacket. If you look closely in the techs left hand (the one with the watch) you can see right below his thumb a set of wire terminated by a small circular loop. This is a temperature sensor that will be installed in the clean air in the I/C intake duct, way ahead of the I/C so as to read the outside air temperature. The next one below that is basically the same but also includes a bolt and a two prone wire attached to it. This is the one we are going to install behind the I/C through the I/C fins as to read the internal I/C temperature or air intake temp. The difference between the first sensor and this one is what triggers the pump. If you look further down, dangling there is a black wire, a third temp sensor, this one is hooked up to the digital thermometer in the cockpit. Notice that for a clean finish all the wiring is wrapped up in plastic tubing.
<img src="http://pictureposter.audiworld.com/46874/h2omist3.jpg">
Ok in this picture you see that we are about to pass the wiring out from the ECU box through the fire wall by going through the big rubber tubing that seals the ECU box. You can see the screw driver going in a spare exit hole at the bottom of the big tube and going in towards the ECU. In the fore ground you can see the black digital thermometer wire, the green electric pump wire and in the back ground the red injector signal wire.
<img src="http://pictureposter.audiworld.com/46874/h2omist4.jpg">
Now you can see a close up of the green injector signal wire from the ECU itself already spliced and the red one from the control module in the fore ground.
<img src="http://pictureposter.audiworld.com/46874/h2omist5.jpg">
In this picture, it's the actual soldering of the two wires together.
<img src="http://pictureposter.audiworld.com/46874/h2omist6.jpg">
Another view of the soldered wires before the final touches are done.
<img src="http://pictureposter.audiworld.com/46874/h2omist7.jpg">
This shot is showing the inside of the car and where the control module is located. You can see all the wiring. There is a red wire that is connected to the ignition and one to a relay. The other wires connect to the module through two canon plugs.
<img src="http://pictureposter.audiworld.com/46874/h2omist8.jpg">
Sorry for the quality of this picture and I know it is hard to see but this is where the control module sits when all is finished, you can see some of the wiring at the top right corner. Once everything is put back in place the unit is easy to access with excess wiring to pull it out of its hiding place. It is recessed under neath the steering wheel in that slot where you can store the owner's manual.
<img src="http://pictureposter.audiworld.com/46874/h2omist9.jpg">
Again sorry for the picture quality. Just a look at the digital thermometer. I set it up dead centre over the steering column on the bottom on the dash board. The I/C temp can be read by the one on the right side. the one on the left is the car interior temp. not really needed. Originally this unit was made as an indoor/outdoor thermometer for the home.
<img src="http://pictureposter.audiworld.com/46874/h2omist10.jpg">
04-23-2004, 09:43 PM
#3
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Very well written. It reminds me of those NOS systems w/the button under the gas pedal...
Since you're going with more misters, won't you need a bigger water supply? Where do you plan on mounting that? Thanks again for the info.
04-23-2004, 09:47 PM
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I still intend to use the W/W reservoir. I only use it for Solo 2 and I will try it while...
Tracking to see how fast the water level drops but because it is misting I don't think it is using all that much.
04-24-2004, 04:08 AM
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Well untill I feel the need for something bigger, IMO there is no need for it. There is not much ...
Room in the engine bay for a big reservoir and putting one in the trunk is a pita. This is the family car after all.
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04-24-2004, 06:16 AM
#9
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Good idea, and very nice write up... but i would just put this on...
I know you have the duel FMIC but this might be less hassle? = )
<img src="http://pictureposter.audiworld.com/52591/car4.jpg">
<img src="http://pictureposter.audiworld.com/52591/car4.jpg">
04-24-2004, 07:43 AM
#10
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A FMIC is only good for much bigger turbo kits and it better be well designed because you may...
Run into all kinds of issues with it. Personally I do not like the looks of any FMIC I have seen so far on the B6, again this is my opinion and no insults intended.