DIY Network

CO2 Intercooler-Sprayer: Trunk-Mounting the Tank From "Tricked Out" episode DTRK-207

	The project car: Dodge SRT-4. In this project, we install a CO2-sprayer system to upgrade the intercooler.
	Media Watch the Video

In this episode of DIY's Tricked Out, host Andrew Totolos, with some assistance from guest expert Dave Markley, kicks the power up a notch on a Dodge SRT-4 by installing a carbon-dioxide intercooler sprayer. This upgrade to the existing turbocharger/intercooler combination serves to cool the air entering the engine's combustion chambers even more than the intercooler alone. And as all engine-mod enthusiasts know, colder air means more power. To begin the project, Andrew and Dave begin assembling some of the kit fittings and install the CO2 tank in the vehicle' strunk.

Materials used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Intercooler kit, including brackets, storage bottle and tubing
Installation kit
Sprayer
Mini fuse-tap
14-gauge wire
Electrician's grabber tool
T-25 torx-bit screwdriver
Drill and drill bits
Painter’s tape and marker
Utility knife
1/4-inch bolts with nuts and washers
Thread-sealant tape
Safety glasses
Alcohol and towels
Metal ties
Metal snips
Eyelet connectors
Vehicle lift or jack stands
Vise

DIY Difficulty Rating for This Project: We gave this a difficulty rating of 4 on a 5-point intermediate-level scale.

advertisement

The Project Car: Dodge SRT-4

This 2005 Dodge SRT-4 has already seen some modifications, and they're all about speed. Outside, the SRT looks essentially stock, but under the hood it’s a different story. The owner has powered up the factory spark and opened up the intake with a polished cold-air kit, plus all the original intake plastic has been replaced with hard pipes.

He's also added an aftermarket front-mount intercooler. Upgraded motor-mount inserts make sure all the power gets to the ground, and spent gas is expelled through dual 2-1/2-inch tuned stainless-steel pipes.

The interior still wears the factory Mopar threads. The only clue to the power lurking under this hood is a turbo timer mounted under the radio.

	Intercooler modifications expert Dave Markley.

The Intercooler-Sprayer System

Dave Markley of Design Engineering, who designed this sprayer and is helping with this installation, describes his sprayer system in which liquid CO2 is stored in a tank secured in the trunk of the vehicle and delivered to the front of the car via a braided stainless-steel line. The flow of CO2 is controlled electronically by a solenoid valve which releases the compressed gas onto the front of the intercooler via perforated tubing.

Cooler air which is delivered to the engine's combustion chambers via an intercooler is denser and more oxygen-rich than ordinary air, hence provides better spark and more horsepower. Dave's CO2 system serves to cool the air even more than the already beefed-up intercooler.

Fittings and Tank Installation

The first step is to assemble some of the sprayer kit's critical fittings. After that, the CO2 tank can be mounted in the trunk.

• To assemble an NPT coupling, apply some pipe-thread tape to the threads (figure A), then screw the two ends together and tighten them down (figure B).

  Figure A

  Figure B

  
  

  	Figure C
  	Figure D
  	Figure F
  	Figure E
  	Figure G

• The next connection is a nipple nut to the tank. There’s no need for sealant here because of the Teflon washer included with the kit to insure a good seal. Tighten the connection securely (figure C).

• Loosely install the tank mounting brackets to the tank (figure D). The tank will be mounted with the nozzle pointing down. The two brackets provided are different sizes and, when everything is installed will orient the bottle in the proper angled position so that liquid CO2 rests in the bottom of the bottle. With the brackets loosely installed, you can take the fittings to the car (figure E).

• In the SRT-4, the trunk is a good location to mount the CO2 storage tank. Pull out the spare-tire cover and the spare tire. Get your fingers up under the rear center trim piece and pop it off.

• Pop up the fasteners that secure the carpet with a panel removal tool, and peel the carpet forward to expose the trunk floor.

• Pick a location that is convenient to a floor-mounted grommet, and set the tank in the place to mark the mounting holes.

• Check underneath the car to make sure you won’t puncture the fuel tank, fuel lines, or any wiring before you drill. Then mark the four mounting bolt locations through the brackets.

• Remove the tank and drill out the holes with a 5/16" bit (figure F).

• After the holes are drilled, put bolts in the holes to find the hole location through the carpet and cut small holes for the bolts and hose to pass through.

• Remove the bottle from the mounts, and bolt the mounts to the floor.

• Once the brackets are secure, install the tank to the brackets (figure G) and tighten it down.

RESOURCES :

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

GUESTS :

Dave Markley
Design Engineering, Inc.
Avon Lake, OH
Phone: 800-264-9472
www.designengineering.com