DIY Network

CO2 Intercooler-Sprayer: Switch Installation From "Tricked Out" episode DTRK-207

	The sprayer and solenoid installed on the intercooler.
	The optional air-intake cooling component of the CO2 system utilizes a cryogenic bulb, mounted in he airflow system, which cools to -40 degrees Fahrenheit.

In this project, host Andrew Totolos installs a carbon-dioxide intercooler sprayer on a Dodge SRT-4. The sprayer has now been attached to the intercooler. In this third phase of the project, Andrew and Dave Markley work together to wire the solenoid and trigger switches that will control the sprayer from inside the car.

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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Figure A

CO2-System Options

The sprayer is only one part of this versatile intercooler system. The system also offers the option of an air-intake cooling component that can be placed anyplace in the airflow stream--pre-turbo, post-turbo, or on either side of the intercooler. It consists of a segment of air-tube with a cryogenic bulb mounted in its center (figure A) which cools to minus 40 degrees Fahrenheit. The CO2 that circulates to the sprayer can also circulate to these intake coolers which can be used singly or several can be installed to work together.

Figure B

With the CO2-delivery system installed, it’s now time to hook up the wiring for the solenoid and trigger switches. For the configuration Dave chose, the system switches include an arming switch that sends power to both a push-button and floor-pedal activator. The arming switch activates the other two switches (figure B). For safety, the two other switches are non-functional until the arming switch has been engaged.

	Figure C
	Use a grabber tool to pull the wiring from the engine compartment through the firewall grommet.

Installing the Arming and Throttle Switches

• Cut off the excess length from the ground lead running to the solenoid, and use an eyelet connector to attach it to a body ground (figure C).

• Route the signal lead around the engine compartment, and use a grabber tool to pull it through a firewall grommet into the interior of the car.

• Now that the wire is through, the throttle switch can be installed. You have a couple of options as to where to install this switch: either under the gas pedal or to the throttle linkage under the hood. In the SRT-4, we opted to mount it directly under the pedal.

• Hold the bracket and switch up to the accelerator for a trial fitting.
  

• Use an existing bolt to mount the switch so that it is only engaged at full throttle and doesn’t interfere with the normal operation of the pedal (figure D).

• If the bracket needs to be bent, remove the switch, pop it in a vice, and tap it gently with a hammer at different angles until it gets to the shape needed (figure E). It will take a little guesswork to get the bracket just right, so take your time.

  Figure D

  Figure E

  
  

  Figure F

• Once you’re satisfied with the fit (figure F), bolt the throttle switch to the accelerator bracket using the existing bolt, and give it a try. If it’s aligned correctly, you’ll be able to feel the switch beneath the pedal.

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