DIY Network

CO2 Intercooler-Sprayer: Mounting the Solenoid and Sprayer From "Tricked Out" episode DTRK-207

	Intercooler specialist Dave Markley designed the CO2 sprayer system installed in this project.
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In this episode of DIY's Tricked Out, host Andrew Totolos installs a carbon-dioxide intercooler sprayer on a Dodge SRT-4. In this second phase of the project, Andrew is assisted by intercooler expert Dave Markley, and the two of them install the CO2 lines under the vehicle and mount the sprayer to the intercooler up front.

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.

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Supply Lines, Solenoid and Sprayer

With CO2 tank installed in the trunk, the next steps are running the CO2 supply-lines beneath the vehicle, installing the solenoid controller and mounting the sprayer to the intercooler. We placed the car on a lift for this part of the project, but if you don't have access to a lift, you’ll need to get the car up on jack stands. Also, be sure to let the car cool completely before you begin this job.

Important: The feeder hose needs to run from the rear of the car all of the way to the front. When installing the lines, take care to keep the new line away from the exhaust or any moving parts such as suspension components.

Figure A

• Run the short end of the hose line from under the car through the grommet in the trunk.

• Hop in the trunk, and attach the hose line to the tank (figure A).
  

• Back under the car, you’ll want to keep the tubing close to the underside of the body as you work it into place (figures B and C). On the SRT-4, a central wire conduit underneath the car already exists, so you can simply take advantage of that for running the lines. Wherever you run the lines, wire ties can be used to secure them.

• Once you get to the front, work your way to the center. In the SRT-4 the supply line should be run over the front cross member and through the engine bay to the intercooler.

  Figure B

  Figure C

  
  

• For installing the sprayer, you may need to pull the bumper cover off for access to allow for extra space in which to work. If you take yours off, it’s likely simply a matter of a couple of screws in the fender, a few along the top and some light-wiring to unplug.

• The solenoid controller (figure D)comes with the sprayer kit. There’s a valve inside that is operated by an electromagnet, and it allows for the use of an electric switch to open the valve instead of turning the manual valve on the bottle. Attach this fitting to the solenoid valve, then attach the whole valve assembly to the sprayer (figure E).

  Figure D

  Figure E

  
  

• After you attach the two fittings to the solenoid valve, screw the solenoid onto the sprayer and tighten it down. Once the solenoid is attached, attach extension leads to the solenoid so the wiring will be long enough to reach the switches inside the car.

• At the car, hold the sprayer in position and push metal wire ties through the intercooler in two locations. Hold the sprayer in place as you tighten the first two metal ties (figure F), then trim off excess with metal snips (figure G).

  Figure F

  Figure G

  
  

  	Figure H
  	Figure I
  	Figure J

• Add more wire ties as needed for your setup (figure H).

• Attach the CO2 supply line to the 4-AN fitting on the solenoid and use two wrenches when you tighten the fitting to prevent stressing the connection (figure I).

• Finally, run the solenoid extension wires up so they will be accessible once the bumper cover is back in place, and tie them down for support (figure J).

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