Just finished installing my Cooling Mist water injection unit. My new mod stands for
Air Intake Heater Delete Water Injection Mod
I did this mod strictly for cleaning the combustion chamber on my Greasecar Truck, so I just needed 1 of the smallest injectors, and the 150 psi Shurflo pump. If you are looking to cool high EGTs, you can add a tee, one or two more injectors and a 250 psi pump.
I took a Cummins oil pan pug, and drilled and tapped it for 1/8" NPT. Then I screwed in the water injection mister in the bottom end of the plug, and the water supply hose barb on the other end of the tapped plug. The mister is on the left side of the drain plug in the pic below. It is a 6.2 GPH injector. On the right is the 1/8 NPT X 1/4 ID hose barb.
I put JBWeld around the mister and the hose barb.
The Water Injection plug is then installed in place of the Air intake Heater. Delete the Air Intake Heater. Remove the red wire from the solenoid. Leave the other wire ( it is said to be blue, but mine was black) on the solenoid. Remove the ground wire and then remove the heater (13/16 wrench). Replace heater with the AIHDWI plug. You may get the DTC P0541. Clear the code and it will not come back.
The water injection is controlled by a boost switch. I mounted the boost switch in the fuse panel wiring area. The boost switch is set to come on at 8 psi. I tee'd into the MAP sensor line. It is 1/4' vacuum hose. I used a brass 1/4" tee and a 1/4" compression fitting to control the boost switch. The water supply hose is .180" ID and 1/4" OD. I couldn't find a barb that fit the .180" ID poly hose, so I just used a piece of 1/4" ID rubber hose to "step down" until I can get to the hardware store tomorrow and get 1/4" ID poly hose. You can see that in the picture after the one below.
The water supply hose and the boost hose is running across the back of the engine, through the firewall into the cab in some wire loom. Those other hose? Those are my other "experiments" (see sig).
I put the water tank and pump in the backseat of the cab. It will partially wedge under the bench seat in my super cab. It is wedged tightly. Filled it with distilled water. The backseat location is temporary but it would keep it from freezing and/or allow it to thaw quicker. The 150 psi Shurflo pump is quiet. It has a check valve, and I installed a fuse. The CV is hard to see in the pic below but it has the orange piece on it. The tank I have is 1.5 gallon. I plan on putting a bigger tank in the bed one day. I have it in the backseat so I can keep an eye on it all for a while.
I put an master ON/OFF switch and a LED light that is wired to the pump in the dash ,so the LED comes on when the pump is spraying. I can see (and hear) when the pump is on, so I can calibrate the boost switch, since the switch has no calibrations. It just has a allen head (5/64") that you turn counter clockwise to have it come on at lower boost levels, and vice versa.
So there you have it. The Air Intake Heater Delete Water Injection Mod. If anyone would like a parts list, PM me. You definitely can piece this together yourself more cheaply than buying the kit, UNLESS you get the kit on a big sale, like I did. The kit, plus plug, switch, LED, wiring, and wire loom was $240.