Water-Methanol Injection Systems
Owner’sManual
with Installation Instructions
Banks
Straight-Shot
& Double-Shot
®
®
Water-Methanol
Injection Systems
Vehicle Specific Applications
THIS MANUAL IS FOR USE WITH SYSTEMs 45150, 45151, 45155,
45156, 45160, 45161, 45170, 45171, 45175, 45176, 45180, 45181
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (800) 438-7693
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
©2013 Gale Banks Engineering
08/30/13 PN 97651 v.1.0
Dear Customer,
If you have any questions
concerning the installation of
your Banks Straight-Shot ® or
Double-Shot ® system, please call
our Technical Service Hotline
at (888) 839-2700 between 7:00
am and 4:00 pm (PT). If you
have any questions relating
to shipping or billing, please
contact our Customer Service
Department at (888) 839-5600.
Thank you.
General Installation
Practices
To avoid serious injury or death, follow
the safety information in this document.
1.
For ease of installation of your
Water-Methanol injection system, familiarize yourself with the procedure by
reading the entire manual before starting work. This instruction manual contains 28 pages of text, illustrations and
parts listing.
2.
Disconnect the ground cable from
the battery before beginning work. If
there are two batteries, disconnect
both.
3. Route and tie wires and hoses a min-
imum of 6 inches away from exhaust
heat, moving parts and sharp edges.
Clearance of 8 inches or more is recommended where possible.
4. When raising the vehicle, support it
on properly weight-rated safety stands,
ramps or a commercial hoist. Follow
the manufacturer’s safety precautions.
Take care to balance the vehicle to
prevent it from slipping or falling. When
using ramps, be sure the front wheels
2
97651 v.1.0
are centered squarely on the topsides;
put the transmission in park; set the
hand brake; and place blocks behind
the rear wheels.
: Do not use floor
jacks to support the vehicle while
working under it. Do not raise
the vehicle onto concrete blocks,
masonry or any other item not
intended specifically for this use.
5. During installation, keep your work
area and components clean to avoid possible dirt entry into the engine.
6. For proper performance from your
Water-Methanol injection system and to
prevent engine damage, it is essential that
your engine’s fuel system be capable of
delivering fuel at the factory’s specification. We have often found vehicles with
inadequate low pressure side fuel delivery that isn’t apparent until performance
modifications are made.
Definitions of ANSI Z535
Safety Standards
: Indicate[s] a hazardous situation which, if not avoided, will
result in death or serious injury.
: Indicate[s] a hazardous situation which, if not avoided, could
result in death or serious injury.
: Indicate[s] a hazardous situation which, if not avoided, could
result in mild or moderate injury.
: Indicate[s] a situation that
requires your immediate attention.
Tools Required:
•
1⁄ 4”
and
3⁄ 8”
Table of Contents
General Installation Practices . . . . 2
drive ratchets
• Inch and metric sockets and
drive extension
3⁄ 8”
• Inch and metric combination or open-end wrenches
• S
tandard and Phillips head
screwdrivers
• Standard and needle-nose pliers
• Pocket or X-Acto knife
• Clean shop towels or rags • Inch-pound or foot-pound torque
wrench
• Electric or pneumatic drill
•Compressed air source and hoses or
extension cords
Tools Required . . . . . . . . . . . . . . . . 3
Water-Methanol Injection
Introduction and Safety . . . . . . . . . 4
Banks Water-Methanol Injection
System Installation . . . . . . . . . . . . . 4
Windshield Washer Reservoir . . 4
Water-Methanol Tank . . . . . . . . . 5
Injection Pump . . . . . . . . . . . . . . 6
Solenoid . . . . . . . . . . . . . . . . . . . 7
Injection Nozzles . . . . . . . . . . . . 8
Plumbing (Straight-Shot®) . . . . 12
Plumbing (Double-Shot®) . . . . . 13
EGT Thermocouple . . . . . . . . . . 13
Injection Controller . . . . . . . . . 14
Wiring . . . . . . . . . . . . . . . . . . . . 15
MAP/TPS Signal
Intercept Harness . . . . . . . . . . . 18
• 1/4”, 11/32”, and 7/16” drill bits
• 1/8”-27 NPT and 1/4”-18 NPT taps
• Tap handle or equivalent
Injection Controller
Menus Flow Chart . . . . . . . . . . . . 16
• Volt meter or multi-meter
System Setup and Testing . . . . . . 19
• Eye and ear protection
Test Drive . . . . . . . . . . . . . . . . . . . 25
• Permanent marker
System Tuning and
Nozzle Selection . . . . . . . . . . . . . . 26
Highly recommended tools
and supplies:
•Penetrating oil or light lubricant spray
• Center punch and hammer
• Deburr tool
• Compressed air nozzle
Parts list . . . . . . . . . . . . . . . . . . . . 27
Appendix A
Nozzle Flow Rates . . . . . . . . . . . . . . . . 28
Appendix B
Pump Flow Rates . . . . . . . . . . . . . . . . . 28
Appendix C
Error Codes & Trouble Shooting . . . . . 28
Appendix D
Common Key-on Power
Fuse Locations . . . . . . . . . . . . . . . . . . . 29
97651 v.1.0
3
Water-Methanol Injection
Introduction and Safety
Banks Water-Methanol injection systems
are a reliable and cost effective way to
increase power and fuel economy while
decreasing exhaust gas temperatures (EGT).
Banks Straight-Shot provides everything
you will need for safe and effective WaterMethanol injection. Banks Straight-Shot
utilizes your vehicle’s windshield washer
reservoir as the Water-Methanol tank
to save space and reduce cost. Banks
Straight-Shot is a fully programmable, single stage injection system that provides
a direct shot of Water-Methanol through
one or two injection nozzles.
Take care while determining the location
of Water-Methanol injection components
that require power and/or signal as the
wire lengths of the wire harness were
designed for components mounted in the
engine compartment.
Windshield Washer
Reservoir
Figure 1
Banks Double-Shot adds second stage
injection capabilities controlled by a solenoid. Increased injection control results
in increased power and/or fuel economy.
Banks Double-Shot also includes a large
capacity tank to increase time between
fills and accommodates the increased
flow volume of two to three nozzles.
Pure methanol is a flammable and volatile fuel, however when diluted with
water as in Banks PowerBlend, the mixture becomes much safer. Avoid direct
contact with methanol, pure or diluted.
If contact with skin occurs, wash contact
area thoroughly.
Banks Water-Methanol
Injection System
Installation
You have been provided with a limited length of 1/4” diameter nylon tubing
(P/N 45140) to plumb your Banks WaterMethanol injection system, take care
while determining the location of system
components. If needed, extra nylon tubing
can be purchased from Banks Power by
calling (800) 601-8077.
4
97651 v.1.0
Figure 2
: Drilling and tapping
your windshield washer fluid reservoir is only necessary for the
Straight-Shot system. If you have
purchased the Double-Shot system,
proceed to the Water-Methanol
Tank section.
1.
Locate your windshield washer fluid
reservoir and drain all fluid by removing
the supply line at bottom of reservoir.
2.
Use a permanent marker to mark
location where reservoir will be drilled.
Choose a location approximately 1”
above lowest point of reservoir where
there will be no intereference with
the addition of a fitting and tubing.
See Figure 1
3. Remove windshield washer fluid reser-
Figure 3
voir from vehicle for better access when
drilling and tapping.
4. Use a center punch to mark the hole
location and keep the drill bit from wandering. Use 7/16” drill bit to drill a hole
at marked location. Drill perpendicular to
reservoir surface to avoid leaks.
5.
Use 1/4”-18 NPT tap to thread windshield washer fluid reservoir. Ensure tap
is perpendicular to reservoir surface to
avoid leaks. Check the thread depth as
you tap by periodically removing the tap
and screwing the 90º male push-lock (P/N
45121) fitting into the tapped hole. The fitting should thread in 3 to 31⁄2 turns hand
tight. Do not install the fitting in place at
this time.
: Running the tap
too deeply can prevent fitting from
properly sealing.
6. Thoroughly clean inside of reservoir to
remove all debris.
7.
Thread 90-degree male Push-Lock
fitting into reservoir. Tighten 2-3 turns
past hand tight. Do not over tighten.
See Figure 2
1. Determine where tank will be mounted
so that it will not interfere with moving or hot engine components. DO
NOT mount tank inside vehicle where
there are passengers. Test fit tank (P/N
45095-45098) with mounting straps
(P/N 91590-91592) at desired location.
Use a permanent marker to mark where
straps will be mounted. Ensure that the
desired location will not interfere with
vehicle operation and that drilling at
this location for mounting will be safe.
See Figure 3
: Take care while
drilling and know what is behind
the piece you are drilling through.
Note the location of the fuel tank,
fuel lines, wiring, etc.
Figure 4
8.
Add enough water in reservoir to
check for leaks around fitting. Drain water
and reinstall windshield washer fluid reservoir.
Water-Methanol Tank
: A large capacity tank
(P/N 45095-45098) is only provided
in the Double-Shot system. Proceed
to the Injection Pump section if you
purchased the Straight-Shot system.
2. Use a center punch to mark the hole
location and keep the drill bit from wandering. Use 1/4” drill bit to drill necessary
holes where marked to mount the tank
mounting straps. Deburr sharp edges.
See Figure 4
: Use eye and ear
protection while drilling.
97651 v.1.0
5
1. Determine where pump will be mount-
Figure 5
3. Thread 90-degree male Push-Lock fit-
ting (P/N 45121) into threaded bung of
tank. Tighten 2-3 turns past hand tight.
Do not over tighten. Add enough water in
reservoir to check for leaks around fitting.
See Figure 5
ed so that it will not interfere with moving or hot engine components and will
avoid spray and debris from tires. Use
pump bracket as a template to mark
where bracket will be mounted. Ensure
that the desired location will not interfere
with vehicle operation and that drilling at
this location for mounting will be safe.
See Figure 8
Figure 8
4. Drain water and use provided mount-
ing straps, bolts (P/N 91120), nuts (P/N
91110), and washers (P/N 91103) to mount
tank where desired. See Figure 6
Figure 6
: Take care while
drilling and know what is behind
the piece you are drilling through.
Note the location of the fuel tank,
fuel lines, wiring, etc.
2. Use a center punch to mark the hole
Injection Pump
: Injection pump (P/N
45030 or 45031) can be mounted in any
orientation, but is flow directional.
The head unit is labeled with an
arrow to show flow direction. Take
care while determining the mounting location in your vehicle.
See Figure 7
Figure 7
6
97651 v.1.0
locations and keep the drill bit from wandering. Use a 1/4” drill bit to drill the
necessary holes where marked to mount
pump bracket. Deburr sharp edges.
: Use eye and ear
protection while drilling.
Figure 9
3.
Use provided bolts (P/N 91761), nuts
(P/N 91771), and washers (P/N 91102) to
mount pump in your truck. Tighten until
nylon locking feature is fully engaged and
rubber grommet is compressed at least
1/8.” Do not over tighten or damage to
grommets will occur. See Figure 9
where the bracket will be mounted. Ensure
that the desired location will not interfere
with vehicle operation and that drilling at
this location for mounting will be safe.
See Figure 12
Figure 12
Solenoid
: A solenoid (P/N 45035)
is only provided in the Double-Shot
system. Proceed to the Injection
Nozzle(s) section if you purchased
the Straight-Shot system.
: Solenoid must be
mounted upright and is flow directional with the ports labeled “IN”
and “OUT”. Take care while determining the mounting position in
your vehicle. See Figures 10 and 11.
Figure 10
: Take care while
drilling and know what is behind
the piece you are drilling through.
Note the location of the fuel tank,
fuel lines, wiring, etc.
2. Use a center punch to mark the hole
location and keep the drill bit from wandering. Use a 1/4” drill bit to drill necessary holes where marked to mount
solenoid bracket. Deburr sharp edges.
See Figure 13
Figure 11
Figure 13
1.
Determine where the solenoid will
be mounted so that it will not interfere with moving or hot engine components and will avoid spray and
debris from tires. Use solenoid bracket (P/N 45038) as a template to mark
: Use eye and ear
protection while drilling.
97651 v.1.0
7
Figure 14
Injection Nozzle(s)
: If your vehicle is
equipped with a late model Banks
Monster Ram, you do not have to
drill and tap your intake duct as
the Monster Ram has the proper
threaded ports.
1.
Figure 15
Figure 16
Injection nozzle(s) (P/N 45081-45090)
should be mounted in your air intake
duct, post-intercooler (if equipped) and
approximately 6” before throttle body (if
equipped) where possible. When engine
is cool, mark the location on your air
intake duct where injection nozzle(s) will
be installed so that they will not interfere
with moving or hot engine components.
See Figure 19-22
: If installing multiple
injection nozzles, we recommend
separating the injection nozzles by
at least 3” to avoid crossing spray
patterns. See Figure 18
Figure 18
Figure 17
Optional
Primary Stage
Solenoid
Shown
2.
3.
Thread straight Push-Lock fittings
(P/N 45120) into both ports of solenoid. Tighten two turns past hand tight.
See Figure 14
4.
Use provided bolts (P/N 91118), nuts
(P/N 91110), and washers (P/N 91102) to
mount solenoid bracket in your vehicle.
See Figure 15
5.
Use provided screws (P/N 91725)
and washers (P/N 91826) to mount
the solenoid onto solenoid bracket.
See Figure 16 and 17
8
97651 v.1.0
Remove air intake duct and cover
engine and intake tube with clean rags to
avoid getting debris into your engine.
: Intake duct can
be drilled and threaded while on
engine ONLY if you can ensure that
no debris will enter engine or intake
tube. We highly recommend removing intake duct from vehicle.
3. Use a center punch to mark the hole
locations and keep the drill bit from wandering. Use a 11/32” drill bit to drill a hole
at marked location(s). Drill perpendicular to the intake duct surface to ensure
Injection
Nozzle
Throttle
Body
Inlet Engine
Side Side
Figure 19
Reservoir
: Position
Injection Nozzle(s) above
the level of reservoir
and on the Inlet side of
Throttle Body to prevent
gravity and vacuum
siphoning.
Pump
Injection
Nozzle
Throttle
Body
Inlet Engine
Side Side
Figure 20
Reservior
Check Valve
If it is implausible to position
Injection Nozzle(s) above
Pump
reservoir, gravity siphoning can be prevented by
installation of an Anti-Siphon
Check-Valve (P/N 45050),
sold separately.
97651 v.1.0
9
Throttle
Body
Inlet Engine
Side Side
Figure 21
Injection
Nozzle
Reservoir
Solenoid
If it is implausible to position Injection Nozzle(s) on
inlet side of Throttle Body,
Pump
vacuum siphoning can be
prevented by installation of
an Anti-Siphon Solenoid (P/N
45035), sold separately.
Figure 22
Injection
Nozzle
Throttle
Body
Injection
Nozzle
Reservoir
Solenoid
Check
Valve
Pump
“Y” Fitting
10
97651 v.1.0
Double-Shot system
shown: with check valve
for first stage nozzle prethrottle body, high-flow
solenoid for second stage
nozzle(s) post-throttle body.
Pre-throttle body mounting
for all nozzles preferred but
not required with solenoidcontrolled stages.
Figure 23
Drill and tap holes
perpendicular to air
intake duct surface
injection nozzle(s) will spray perpendicular
to intake airflow direction. Deburr sharp
edges. See Figure 23
Figure 25
4.
Use 1/8”-27 NPT tap to thread air
intake duct. Ensure tap is perpendicular
to air intake duct surface to avoid leaks.
Check the thread depth as you tap by
periodically removing the tap and screwing the injection nozzle into the tapped
hole. The injection nozzle should thread
in 3 to 31⁄2 turns hand tight. Do not install
the injection nozzle in place at this time.
Figure 24
be used and thread each injection nozzle
into a 90-degree female Push-Lock fitting
(P/N 45122). Tighten 2-3 turns past handtight. See Figure 25
: Sealant tape must
be applied properly to avoid leaks.
Clean threads with rag. Start at second
thread in from end. Wrap tightly following direction of threads to avoid tape
pealing away from Injection Nozzle when
threaded into fitting. Overlap tape, moving
towards base of threads creating two layers of sealant tape. See Figure 26
See Figure 24
Figure 26
: Running the tap
too deeply can prevent injection
nozzle(s) from properly sealing.
5.
Apply provided sealant tape (P/N
91099) to threads of injection nozzle(s) to
97651 v.1.0
11
6. Thread Injection Nozzle assembly into
Figure 28
the air intake duct. Cover open end of the
90-degree Push-Lock fitting to avoid debris
entering intake duct. See Figure 27
Figure 27
Plumbing (Straight-Shot)
: If you purchased the
Double-Shot system proceed to the
Plumbing (Double-Shot) section.
: Route and secure
tubing where it will not interfere
with moving or hot engine components. Avoid sharp turns that may
kink tubing and sharp edges that
may damage tubing.
: Cut tubing using
a Pocket or X-Acto knife to avoid
pinching the tubing. Pinching the
tubing will cause it to not seat
properly.
: Make all cuts as
square as possible to avoid leaks.
3.
For a single injection nozzle, secure
and route tubing from pump outlet to
injection nozzle assembly in intake duct.
Properly cut tubing and secure into injection nozzle assembly.
4.
For two injection nozzles, secure and
route tubing from pump outlet to port
#1 of “Y” fitting (P/N 45123). Properly
cut tubing and secure into “Y” fitting.
See Figure 29
1.
: Determine where you
want Push-Lock “Y” fitting located and
route tubing appropriately. Choose a
location that is easily accessible and
can be checked for leaks.
Carefully pull on tubing to ensure tubing is
secured properly.
4a. Secure tubing in port #2 of “Y” fitting
and route tubing to first injection nozzle
assembly. Properly cut tubing and secure
into injection nozzle assembly.
Secure one end of 1/4” Nylon tubing (P/N 45140) into Push-Lock fitting on
windshield washer fluid reservoir by firmly
pushing tubing into Push-Lock fitting.
2.
Route tubing to injection pump inlet.
Cut tubing, allowing approximately 1/2”
for securing into injection pump. Properly
secure tubing into injection pump inlet.
See Figure 28
4b.
Repeat step 4a for second injection
nozzle assembly using port #3 on the
“Y” fitting.
5. Use tie wraps to secure all tubing.
12
97651 v.1.0
Plumbing (Double-Shot)
4. Secure tubing in port #2 of “Y” fitting
: Route and secure tubing where it will not interfere with
moving or hot engine components.
Avoid sharp turns that may kink
tubing and sharp edges that may
damage tubing.
5. Secure tubing in port #3 of “Y” fitting
: Cut tubing using
a Pocket or X-Acto knife to avoid
pinching the tubing. Pinching the
tubing will cause it to not seat
properly.
and route tubing to inlet of check valve.
Properly cut and secure tubing in PushLock check valve.
and route tubing to “IN” port of solenoid.
Properly cut and secure tubing in PushLock on solenoid. See Figure 30
Outlet
Figure 30
1. Secure one end of 1/4” Nylon tubing
(P/N 45140) into Push-Lock fitting on high
capacity tank by firmly pushing tubing into
Push-Lock fitting. Carefully pull on tubing
to ensure tubing is secured properly.
2.
Route tubing to injection pump
inlet. Cut tubing, allowing approximately
1/2” for securing into injection pump.
Properly secure tubing into injection pump
inlet.
: Make all cuts as
square as possible to avoid leaks.
Figure 29
Inlet
6. Secure tubing in outlet of check valve
and route to the first injection nozzle
assembly. Properly cut tubing and secure
into injection nozzle assembly.
7. For two injection nozzles, secure tub-
ing in Push-Lock fitting of solenoid labeled
“OUT” and route to the second injection
nozzle assembly. Properly cut tubing and
secure into injection nozzle assembly.
8.
For three injection nozzles, secure
tubing in Push-Lock fitting of solenoid
labeled “OUT” and route to port #1 of “Y”
fitting (P/N 45123). Properly cut tubing
and secure in “Y” fitting. Secure tubing
in port #2 of “Y” fitting and route tubing
to the second injection nozzle assembly.
Properly cut tubing and secure into injection nozzle assembly. Repeat for the third
injection nozzle assembly using the #3
port of the “Y” fitting.
EGT Thermocouple
3. Route tubing from injection pump out-
let to port #1 of “Y” fitting (P/N 45123).
Properly cut tubing and secure into “Y”
fitting. See Figure 29
: An EGT thermocouple (P/N
63042) is only provided in the Double-Shot
system. If you purchased the StraightShot system, proceed to the Wiring
and Controller section. See Figure 31
1. The thermocouple monitors the tem-
perature of the exhaust gases entering
97651 v.1.0
13
the turbocharger at the turbine housing.
Installation requires that the exhaust manifold be drilled near the manifold outlet.
It is recommended that the manifold be
removed from the engine to thoroughly
clean out all metal chips from drilling. All
metal shavings must be cleaned from the
manifold to avoid turbine wheel damage.
Figure 31
6. Thoroughly clean exhaust manifold
with solvent to remove any debris and
reinstall exhaust manifold on engine.
: Failure to remove
all metal chips could result in catastrophic damage to the turbocharger’s turbine wheel.
7. Remove the NPT fitting from the ther-
mocouple and install it on the exhaust
manifold. Use supplied anti-seize lubricant
on the threads and torque to 14–16 lb-ft.
8. Reinstall the exhaust manifold. Apply
anti-seize lubricant to the manifold bolt
threads and torque as specified in service
manual.
9. Install thermocouple in fitting on
exhaust manifold. See Figure 32
Figure 32
2.
Mark location on exhaust manifold
(pre-turbo) where EGT thermocouple will
be mounted so that it will not interfere
with any engine components.
3.
Remove exhaust manifold and cover
the exhaust ports and up-pipe to avoid
debris entering engine or exhaust system.
4. Drill a 7⁄16” hole in exhaust manifold at
marked location perpendicular to manifold
surface. Deburr sharp edges.
5. Tap the hole for a 1⁄4” NPT thread. Check
the thread depth as you tap by periodically
removing the tap and screwing the pipe
coupling into the tapped hole. The coupling
should thread in 3 to 31⁄2 turns hand tight.
Do not install the probe in place at
this time.
: Running the tap too
deeply can prevent the pipe fitting
from properly sealing.
14
97651 v.1.0
Injection Controller
: A basic mounting panel
is provided to mount injection controller. Other mounting options,
including A-pillar pod mounts, are
available through Banks Power
for vehicle specific mounting. See
Figure 33
1. Determine where the injection control-
ler (P/N 45020 or 45021) will be mounted
using mounting panel (P/N 63001) and
controller bracket (P/N 63006) where it
will not interfere with driving operations.
Figure 33
Figure 35
2.
: Take care when
installing the mounting panel as to
not damage anything critical with
fasteners.
Connect both 8-pin connectors to
controller where appropriate. Connect
2-pin connector for EGT thermocouple,
if equipped. See Figure 35
Figure 36
2. Install the mounting panel using supplied fasteners.
3. Install injection controller in mounting
panel and secure using controller bracket.
Wiring
3.
: Route and secure wiring where it will not interfere with
moving or hot engine components
(along OEM wiring where possible).
Avoid sharp edges that may damage
wiring.
4.
Figure 34
Secure boost reference hose to reference port barb on back of injection controller using the 3/32” hose (P/N 94118) as
an adapter between the boost reference
hose and the reference port barb. See
Figure 36
Route appropriate connectors of signal harness to respective Water-Methanol
injection components and fasten connectors. Secure wiring with tie wraps.
5. Route appropriate connectors of pump
harness to respective Water-Methanol
injection components and fasten connectors. Secure wiring with tie wraps.
1.
Figure 37
Using provided system schematics,
find connectors for injection controller on
the pump harness (P/N 62831) and signal
harness (P/N 62832). Carefully feed these
connectors and boost reference hose (P/N
94445) through firewall grommet (usually
located underneath dash) to injection controller. See Figure 34
97651 v.1.0
15
97651 v.1.0
PR ES S
MENU
ction
16
MAP
INPT
LED
DISP
OCTL
B1
T1
Pressing the select button, any time the injection system is enabled
and the controller is in display mode, will provide a quick shot of
water-methanol to cool your intake air charge. This one second
burst at 50% pump duty cycle is perfect for pre-cooling your induction system while staging. A built-in five second delay is used as a
safety precaution to avoid overuse.
Quick-Cool
Injection Controller Menus Flow Chart
97651 v.1.0
17
PRES S
MENU
Input Dependent Main Menu S
TDC4
BDC4
PRESS
SELE cT
T4
B4
PR ES S
SE LE cT
Map - Manifold Absolute Pressure
Octl - Output Control
Pdc - Pump Duty Cycle
D6.7 - Dodge 6.7L
Disp – Display
E+B - Egt And BOOst
Thrt – Throttle
Ver - Version
F6.0 - Ford 6.0L
Tdcx – Throttle Duty Cycle X
Egtx - Egt Reference Value X
Egt - Exhaust Gas Temperature
Tx – Throttle Reference Value X
Int – Internal
D5.9 - Dodge 5.9L
S2st - Solenoid #2 Status
Inpt – Input
Bst – Boost
Edcx - Egt Duty Cycle X
F7.3 - Ford7.3l
Bdcx - Boost Duty Cycle X
E+T - Egt And ThrOTtLE
F6.4 - Ford 6.4L
Bx - Boost Reference Value X
Set desired value using
menu button to scroll
and select button to
make selection.
Options ___3 and ___4 will only display if equipped with secondary solenoid.
Options e___ will only display if equipped with egt thermocouple.
Input dependent main menu selection displays “b” if map is selected for input
(default) and “t” if thrt is selected for input.
Main menu options are bold.
Set desired value using
menu button to scroll
and select button to
make selection.
TDC3
T3
BDC3
PR ES S
MENU
TDC2
BDC2
B3
T2
B2
VER
VER(VERSION)
EDC4
EG T4
EDC3
EG T3
EDC2
EG T2
EDC1
EG T1
PR ES S
MENU
TDC1
BDC1
6. Install the pump pressure switch sub-
harness, using the system schematics for
reference. See Figure 37
Figure 38
on the desired injection controller
input (boost or throttle), the MAP
or TPS signal must be intercepted
and sent to injection controller. For
boost based systems, the MAP signal must be intercepted. For throttle
based systems, the TPS signal must
be intercepted.
Certain supported vehicles use the OEM
MAP or TPS sensor with a pigtail harness
to intercept the desired signal.
For supported vehicles:
7. Use the provided list of fuse locations
(Appendix D, pg. 29) or a multimeter to
find a fuse with key-on power for the
injection controller. Connect the fuse tap
for the injection controller. See Figures
38 & 39
Figure 39
8. Fasten all other connectors and termi-
nals (power supplies, ground leads, etc.) of
pump and signal harnesses to appropriate
locations, using system schematics for
reference. Secure wiring with tie wraps.
MAP/TPS Signal
Intercept Harness
: A vehicle specific MAP/
TPS signal intercept harness (pigtail
harness) is only included in vehicle specific methanol-water injection systems. If you purchased a
universal methanol-water injection
system, proceed to the System
Testing and Setup section. Based
18
97651 v.1.0
1. Locate the MAP or TPS sensor on your
vehicle, depending on the desired input
mode. Disconnect the OEM wire harness by releasing locking mechanism. A
small standard screwdriver can be used to
release locking mechanism, if necessary.
See Figure 40
Figure 40
2. Connect pigtail harness (See Parts List
for P/Ns) to MAP or TPS sensor and check
for full engagement of locking mechanism.
See Figure 41
Figure 41
3.
Connect OEM wire harness to pigtail
harness and check for full engagement of
locking mechanism. See Figure 42
Figure 42
be followed in order, and that any
leaks are corrected before vehicle
operation.
1. Fill windshield washer fluid reservoir or
high capacity tank with distilled water.
2. Turn vehicle ignition to on without start-
ing the vehicle. The injection controller
screen should light up and scroll “BANKS
POWER” along with the controller software
version number.
3.
4. Connect 1-pin male connector to the
blue lead of signal harness and check
for full engagement of locking mechanism. See system schematic for reference.
See Figure 43
Figure 43
Remove tubing from each injection
nozzle assembly by pressing in the collar
of the push-lock fitting and gently pulling
on tubing. Place end(s) of tubing into a
clear container of suitable size (the high
volume pump can move more than a
gallon of water a minute) and secure container in a stable position.
: Tubing must be
disconnected from injection nozzle
assembly while priming pump, otherwise water could flood and damage engine.
4. Temporarily disconnect the pump pres: Route and secure wiring
where it will not interfere with moving or hot engine components (along
OEM wiring where possible). Avoid
sharp edges that may damage wiring.
System Testing and Setup
: Use “MENU” button on
injection controller to scroll through a
menu and “SELECT” button to choose
a menu option. See injection controller menu flow chart (pages 16-17) for
an overview of controller menus.
: This section of the
manual will walk you through the
initial purging and pressure test process to ensure that your installation
is clean and leak-free. It is critical to
safe system operation that each step
sure switch connector from the signal
harness, or remove one pump pressure
switch lead from the pump. Now, the system may be primed and purged by using
the injection controller’s “TEST” mode. To
activate “TEST” mode:
4a. Scroll through the main menu by
pressing the “MENU” button. Press the
“SELECT” button to select the “OCTL”
(output control) sub-menu.
4b. Scroll through the “OCTL” sub-menu
by pressing the “MENU” button. Press the
“SELECT” button to select and activate
“TEST” mode. Any connected solenoids
will open, the pump will turn on and run
at 50% duty cycle for 60 seconds, and
then turn off automatically. Let the test
mode run until water flows out of tubing
into clear container, and then turn it off
by selecting “OFF” from the “OCTL” menu.
97651 v.1.0
19
Figure 44
4c. If there is debris present in the con-
tainer after running the initial test, re-fill
the system tank with clean distilled water
and repeat “TEST” mode until all debris
remaining from installation has been
purged from the system. Check all tubing
connections for leaks.
: If the controller displays an error code, or the pump
does not turn on when activating
“TEST” mode, refer to the error code
index (page 27) and use system
schematic (P/N 97650-A or 97651A) to ensure all components were
connected to appropriate connectors. Check all connectors for full
engagement. If pump turns on, but
water does not flow out of tubing,
use system schematic (P/N 97650-A
or 97651-A) to ensure system was
plumbed correctly.
4d.
Remove all injector nozzle(s) from
their mounting ports on the engine and reconnect them to their supply tubes. Empty
water from the clear container used in
the previous step, insert the assembled
injector nozzles and supply lines back into
the container and re-secure in a stable
position.
4e. Initiate another “TEST” mode from
the injection controller and examine the
spray pattern from each nozzle. A clean,
evenly-distributed spray cone should be
20
97651 v.1.0
visible from every nozzle (some moderate
pulsation is normal and will vary based on
nozzle selection). Examine the threaded
joint between each nozzle and nozzle
holder carefully for any leaks during this
high pressure test - tighten the assembly
in quarter turn steps until corrected.
4e. Dribbling or spitting from one or
more nozzles while other nozzles atomize
properly indicates a partially plugged nozzle
or filter - exit “TEST” mode, remove the
nozzle from the holder fitting. Use pliers to
unscrew screen holder and examine the
screen for debris. 4g. If no leaks are noted
and each nozzle is atomizing correctly,
exit “TEST” mode and turn off the vehicle’s
ignition switch to power down the injection controller.
5.
Double-check tubing and all connections for leaks. Permanently install injection nozzles and tubing into appropriate
locations, and reconnect pump pressure
switch.
: To setup the StraightShot injection controller for firsttime use, several selections needs
to be made for the controller to configure it for your specific application.
6. Turn vehicle ignition to on without
starting the vehicle. Select the “INPT”
(input) sub-menu using “MENU” button to
scroll through main menu and “SELECT”
button to select “INPT”. Scroll through the
“INPT” menu and select “MAP” (Manifold
Absolute Pressure) for boosted applications or “THRT” (throttle) for non-boosted
applications. “MAP” is the default input
method, and requires that a specific MAP
sensor type be selected (in the following
step). If “THRT” mode is selected, no further input configuration is required - the
controller will display throttle value from
0-100% based on a 0.5V-4.5V range.
: Main menu, “OCTL”
submenu, and “DISP” sub-menu
will display different options based
on the selected “INPT” mode. If
“MAP” is selected, the main menu
will display boost reference values
and boost duty cycle values (B1
and BDC1, for example). If “THRT” is
selected, the main menu will display
throttle reference values and throttle duty cycle values (T1 and TDC1,
for example).
7. If “INPT” is set to “MAP”, you must select
the appropriate manifold absolute pressure
sensor range. Scroll through main menu and
select “MAP” and then select appropriate
MAP sensor from “MAP” menu.
For Universal systems with the 45021
controller using the internal 100PSIA
MAP sensor:
8. Turn on your water-methanol system by
scrolling through main menu and selecting
“OCTL”. Select desired control method from
“OCTL” menu. See injection controller menu
flow chart for menu structure.
“OFF” – Turns water-methanol injection system off (gauge features will still function)
“BST” – Controls system using boost pressure (Boosted applications only)
“THRT” – Controls system using percent
throttle opening (Non-boosted applications
only)
“EGT” – Controls system using exhaust
gas temperature (Must be equipped with
EGT thermocouple)
“INT” – Select this for use with the internal
100PSIA sensor and boost reference line
“E+B” – Controls system using exhaust gas
temperature and boost pressure (Boosted
applications only)
For vehicle specific systems with the
45020 controller using a factory MAP
sensor:
“E+T” – Controls system using exhaust gas
temperature and percent throttle opening.
(Non-boosted applications only)
“LBZ” –Chevy/GMC vehicles equipped with
Duramax LBZ engine
“TEST” – Opens any connected solenoids
and tests for system pressure,automatically
turns pump off and closes solenoids when
system reaches 40 PSI. If pump pressure
switch is disconnected or 40 PSI output
pressure switch point is not exceeded,
pump will run at 50% duty cycle for 60
seconds with all solenoids open.
“LB7” –Chevy/GMC vehicles equipped with
Duramax LB7 engine
“LLY” –Chevy/GMC vehicles equipped with
Duramax LLY engine
“LMM” –Chevy/GMC vehicles equipped with
Duramax LMM engine
“LML” –Chevy/GMC vehicles equipped with
Duramax LML engine
“D5.9” –Dodge vehicles equipped with
Cummins 5.9L engine
“D6.7” –Dodge vehicles equipped with
Cummins 6.7L engine
“F7.3” –Ford vehicles equipped with
Powerstroke 7.3L engine
“F6.0” –Ford vehicles equipped with
Powerstroke 6.0L engine
“F6.4” –Ford vehicles equipped with
Powerstroke 6.4L engine
: When using any control
method based on controlling EGT,
injecting distilled water only is recommended as a mixture with even a
moderate methanol percentage can
increase EGT at high injection rates.
9. Set desired display parameter by
selecting “DISP” from main menu and
then selecting desired display option.
“BST” – Displays manifold pressure in PSI
(Boosted applications only)
“THRT” – Displays percent open throttle
(Non-boosted applications only)
“EGT” – Displays exhaust gas temperature
97651 v.1.0
21
in degrees Fahrenheit (If equipped with
EGT thermocouple)
“PDC” – Displays pump duty cycle in percent.
“S2ST” – Displays solenoid #2 status as
on or off (If equipped with secondary
solenoid)
10. Turn the injection activity LED on or
off by selecting “LED” from main menu
and then selecting “ON” or “OFF”. When
“ON”, the Alert LED will flash with a frequency that corresponds to pump duty
cycle when pump is running. When “OFF”,
the LED will not flash to indicate injection
activity, but will still function normally to
indicate any system errors.
11. To turn water-methanol system off,
select “OCTL” from main menu and then
select “OFF” from the “OCTL” menu.
Your injection system will now operate
with the default setpoint values. To tailor the system’s activation points and
injection quantity to your specific engine,
please refer to the advanced tuning section (below).
Advanced Tuning
The Banks Straight-Shot and Double-Shot
injection systems offer a wide working
injection flow range, as well as a wide
range of user-selectable setpoints to control injection by. The goal of these wide
flow- and adjustment ranges are to match
a progressively increasing amount of injection to your engine’s air-, load-, or EGTcurve. To vary injection quantity across a
fixed size injection nozzle, supply pressure
to the nozzle must be varied (as opposed
to a typical automotive fuel injector, which
uses a fixed supply pressure, and varies
injection rate by switching the injector on
and off rapidly).
The Straight-Shot and Double-Shot systems vary supply pressure by increasing
the duty cycle supplied to the injection
pump. A low duty cycle supplies mini-
22
97651 v.1.0
mal power to the pump, and creates a
low output pressure. Increasing the duty
cycle increases the power supplied to the
pump, generating an increased output
pressure (and increased flow across the
injection nozzle). Flow across the nozzle
does not increase linearly with pressure,
however - the injection controller and
the injection pump compensate for this
to a degree. To learn more, and view full
nozzle flow and pump capacity curves,
please visit our webpage at http://www.
bankspower.com/straightshot
12. Set the first reference value (B1 or T1)
to control when pump will turn on and first
duty cycle value (BDC1 or TDC1) to control
pump duty cycle at the first reference value.
For boosted vehicles, reference values are
boost pressure in PSI. For non-boosted
vehicles, reference values are percent open
throttle where 0 is closed throttle and 100 is
wide open throttle.
12a. Scroll through main menu and select
“B1” or “T1”, depending on your application.
Scroll through the values and select the
reference value that you want the pump to
turn on. If configuring a StraightShot system
with only one injection stage, this setpoint
should be above your tyical light-load boost
/ throttle value. For DoubleShot systems
where a small injection quantity is desired
at light load, this should be set several PSI
(or %) below your typical light-load boost
/ throttle value. The default setting is 10
PSI, which should be changed to a much
higher setting (50% or more) if configuring a
throttle-based system.
12b. Scroll through main menu and select
“BDC1” or “TDC1”, depending on your application. Scroll through the values and select
the percentage of pump duty cycle at which
the pump will run once triggered by the
first reference value. The default setting is
30% duty cycle - if this value is set too low,
with too large of a nozzle, it can cause a
low initial pump output pressure which can
result in improper atomization at the nozzle.
This may also trigger a Pump Output Error
97651 v.1.0
23
24
97651 v.1.0
code if the 40 PSI pump output pressure
switch is not triggered. However, if this
value is set too high, the initial output
pressure spike and injection ‘hit’ can be
too severe and cause the engine to bog
or misfire.
13.
Repeat step 12 to set remaining reference values and accompanying
duty cycle percentage values.
: Straight-Shot systems
have two reference values with
accompanying duty cycle values.
Double-Shot systems have four reference values with accompanying
duty cycle values.
EXAMPLE: For boosted applications,
your water-methanol injection system
will be inactive until boost pressure
reaches the first boost reference value
(B1), at which value first injection nozzle (or nozzle set) will begin to spray
with a volumetric flow rate based on
the first duty cycle value (BDC1). This
injection nozzle (or injection nozzle set)
will continue to spray while flow rate
increases (with increasing pump duty
cycle) until boost pressure reaches the
second boost reference value (B2). At
this value, the pump duty cycle will
equal that of the second duty cycle
(BDC2) percentage, and will remain at
this duty cycle if boost continues to
rise. Similarly, for Double-Shot systems
the second injection nozzle (or second
injection nozzle set) will begin spraying
once boost pressure reaches B3 with a
pump duty cycle equal to BDC3. Flow
rate will increase until boost pressure
reaches B4, at which value the pump
duty cycle will equal that of BDC4.
For non-boosted applications, your
water-methanol injection system will be
inactive until percent throttle opening
reaches the first throttle reference value
(T1), at which value first injection nozzle
(or injection nozzle set) will begin to
spray with a volumetric flow rate based
on the first duty cycle value (TDC1) . This
injection nozzle (or injection nozzle set)
will continue to spray while flow rate
increases (with increasing pump duty
cycle) until throttle opening reaches the
second throttle reference value (T2). At
this value, the pump duty cycle will equal
that of the second duty cycle (TDC2)
percentage, and will remain at this duty
cycle if throttle percentage continues to
rise. Similarly, for Double-Shot systems
the second injection nozzle (or second
injection nozzle set) will begin spraying
once throttle opening reaches T3 with
a pump duty cycle equal to TDC3. Flow
rate will increase until throttle opening
reaches T4, at which value the pump
duty cycle will equal that of TDC4. Note
that DC stays constant past T4 setpoint.
Test Drive
1. Drain water from windshield washer
fluid reservoir or high capacity tank. Fill
with Banks PowerBlend injection fluid.
2. Start vehicle and allow it to reach
operating temperature before driving.
3. Ensure the Water-Methanol injection
system is turned on (see System Setup
and Testing, step 8).
4. Set injection controller to display
pump duty cycle (see System Setup and
Testing, step 9) to check if pump is running during driving conditions.
5. Drive normally in a minimal traffic
area where you can safely monitor the
injection controller. Once boost pressure reaches the first boost reference
point, the injection controller should
display the first pump duty cycle (BDC1).
Pump duty cycle should increase as
boost pressure increases, until boost
pressure reaches the second boost reference point (B2).
If injection controller only displays zero for
pump duty cycle, the pump is not turning
on. Ensure system is turned on. There
may be an issue with the wiring or setup.
97651 v.1.0
25
Check all connections and check system
setup on injection controller.
6. Park vehicle in a safe location and
check for any leaks in Water-Methanol
injection system.
System Tuning and
Nozzle Selection
The Straight-Shot and Double-Shot systems come pre-packaged with several
different nozzle options that cover a
wide range of applications, but some
controller setting optimization may help
dial in your system for your intended
usage.
When configuring for maximum performance, the largest kitted nozzles should
be installed. If engine hesitation, misfiring, or early ignition (excessive combustion noise or rattling) is experienced,
reduction of the commanded pump duty
cycle, along with raising the boost reference points will reduce the injection
quantity to help reduce this. If required,
reduce the nozzle size to make large
changes in injection quantity.
If typical fluid consumption is higher
than desired, increase the initial boost
reference point to decrease the frequency with which the controller activates (turning on only at higher load).
If more frequent injection is desired (for
instance, when combating a constant
high-EGT condition with distilled water,
or offsetting diesel fuel usage with a
water-methanol mixture), a proportionally small jet should be used, with a
reduced initial boost reference point
and low starting and final pump duty
cycle values (a ‘flat’ response curve).
26
97651 v.1.0
Parts List
45150
45150-1
45062
45085
45087
45090
45122
45123
91099
45020
45030
45140
62001
62831
62832
62837
63001
63006
91102
91761
91771
91846
91868
97651
97651-A
62832-10
45151
45150-1
62832-11
45155
45150-1
62832-20
45156
45150-1
62832-21
45160
45150-1
62832-30
45161
45150-1
62832-31
Straight-Shot - Methanol-Water Injection System - 2001-10 Chevy 6.6L, LB7-LMM
Base System, Straight-Shot MWI - Controller w/o Onboard MAP Sensor
Injection Nozzle Kit-2, Methanol-Water Injection Systems
Injection Nozzle, Methanol-Water, #4, 30lb/hr @ 100PSI, 100 Degree Full Cone
Injection Nozzle, Methanol-Water, #7, 52lb/hr @ 100PSI, 100 Degree Full Cone
Injection Nozzle, Methanol-Water, #14, 103lb/hr @ 100PSI, 100 Degree Full Cone
Fitting, Nozzle, 90 Deg Swivel, 1/4" NPTF- 1/4" Push Lock - MWI
Fitting,"Y", Female 1/4" Push-Lock, Black Nylon - MWI
Teflon Tape, 1/2" X 100" Module, Injection Controller - Methanol-Water Injection
Pump Assy, High Volume, Methanol-Water Injection
Tubing, 0.040" Wall, Nylon 11, Black-Methanol-Water Inj
Cable Tie, Black, 6" Pump Harness, Water-Methanol Injection Controller
Signal Harness, Contoller - Methanol-Water Injection
Sub-Harness, Switch, Pump Pressure - Methanol-Water Injection
Mounting Panel, One Gauge - Black, W/Fasteners
Bracket, Module, Six-Gun/Bullet/WMI - Various Applications
Washer, Sae Flat, Zinc - 1/4"
Hex Bolt, Flange Head - 6Mm-1.00 X 45MM
Nut, Nylock - M6 X 1.0, Zinc
Washer, Internal Tooth Lock - #8
Hex Nut, Zinc - 8-32
Owner's Manual - Methanol-Water Injection System - Application Based
Addendum, Owner's Manual-Schematic, MWI - Application Based
Pigtail Harness, MAP, Water-Methanol Injection Controller, Duramax -LB7-LMM
Systems below have identical content as the system above with the exception of the Pigtail Harness
Straight-Shot - Methanol-Water Injection System - 2011-13 Chevy 6.6L, LML
Base System, Straight-Shot MWI - Controller w/o Onboard MAP Sensor
Pigtail Harness, MAP, Water-Methanol Injection Controller, Duramax-LML
Straight-Shot - Methanol-Water Injection System - 2003-07 Dodge 5.9L
Base System, Straight-Shot MWI - Controller w/o Onboard MAP Sensor
Pigtail Harness, MAP, Water-Methanol Injection Controller, 2003-07 Dodge 5.9L
Straight-Shot - Methanol-Water Injection System - 2007-13 Dodge 6.7L
Base System, Straight-Shot MWI - Controller w/o Onboard MAP Sensor
Pigtail Harness, MAP, Water-Methanol Injection Controller, Dodge 6.7L
Straight-Shot - Methanol-Water Injection System - 1994-07 Ford 7.3-6.0L
Base System, Straight-Shot MWI - Controller w/o Onboard MAP Sensor
Pigtail Harness, MAP, Water-Methanol Injection Controller, Ford 7.3-6.0L
Straight-Shot - Methanol-Water Injection System - 2008-10 Ford 6.4L
Base System, Straight-Shot MWI - Controller w/o Onboard MAP Sensor
Pigtail Harness, MAP, Water-Methanol Injection Controller, Ford 6.4L
45170
45170-1
45040
45035
45038
45120
91102
91110
91118
91725
91826
45071
45084
45087
45088
45090
45122
45123
91099
45108
62001
63042
63060
92273
45020
45030
45050
45140
62001
62831
62832
62837
63001
63006
91102
91761
91771
91846
91868
97651
97651-A
62832-10
45147
45098
91103
91110
91120
91592
Double-Shot - Methanol-Water Injection System - 2001-10 Chevy 6.6L, LB7-LMM
Base System, Double-Shot MWI - Controller w/o Onboard MAP Sensor
Solenoid Kit, Methanol-Water Injection
Solenoid, Methanol-Water Injection
Bracket, Solenoid Mount, Single - Methanol-Water Injection
Fitting, Straight, 1/4" NPTM - 1/4" Push Lock - MWI
Washer, Sae Flat, Zinc - 1/4"
Nut, Nylock - 1/4"-20
Hex Bolt, Grade 5, Zinc - 1/4"-20 X 1"
Screw - Button Head, Socket Cap - 10-32 X 3/8" - 18.8-S/S
Washer, Int Tooth Lock, Zinc - #10
Injection Nozzle Kit-11, Methanol-Water Injection Systems
Injection Nozzle, Methanol-Water, #3, 22lb/hr @ 100PSI, 100 Degree Full Cone
Injection Nozzle, Methanol-Water, #7, 52lb/hr @ 100PSI, 100 Degree Full Cone
Injection Nozzle, Methanol-Water, #10, 74lb/hr @ 100PSI, 100 Degree Full Cone
Injection Nozzle, Methanol-Water, #14, 103lb/hr @ 100PSI, 100 Degree Full Cone
Fitting, Nozzle, 90 Deg Swivel, 1/4" NPTF- 1/4" Push Lock - MWI
Fitting,"Y", Female 1/4" Push-Lock, Black Nylon - MWI
Teflon Tape, 1/2" X 100" Thermocouple Kit - Methanol-Water Injection Systems
Cable Tie, Black, 6" Thermocouple, Pyrometer - Chevy, Dodge, Ford Pwr Sys
Leadwire, Pyrometer, Electric - Various Applications
Weld Bung, 1/4" NPT
Module, Injection Controller - Methanol-Water Injection
Pump Assy, High Volume, Methanol-Water Injection
Check Valve, In-line - Methanol-Water Injection
Tubing, 0.040" Wall, Nylon 11, Black-Methanol-Water Inj
Cable Tie, Black, 6" Pump Harness, Water-Methanol Injection Controller
Signal Harness, Contoller - Methanol-Water Injection
Sub-Harness, Switch, Pump Pressure - Methanol-Water Injection
Mounting Panel, One Gauge - Black, W/Fasteners
Bracket, Module, Six-Gun/Bullet/WMI - Various Applications
Washer, Sae Flat, Zinc - 1/4"
Hex Bolt, Flange Head - 6Mm-1.00 X 45MM
Nut, Nylock - M6 X 1.0, Zinc
Washer, Internal Tooth Lock - #8
Hex Nut, Zinc - 8-32
Owner's Manual - Methanol-Water Injection System - Application Based
Addendum, Owner's Manual-Schematic, MWI - Application Based
Pigtail Harness, MAP, Water-Methanol Injection Controller, Duramax -LB7-LMM
Tank Kit, 7 Gallon - Methanol-Water Injection
Tank, 7 Gal, PE, Natural, with 1/4" FPT Fitting weld-on; 3.5" Top Vented Cap, Black, w/8" Tether
Washer, Uss, Zinc - 1/4"
Nut, Nylock - 1/4"-20
Hex Bolt, Grade 5, Zinc - 1/4"-20 X 1 1/8"
Strap, Mounting - MWI Tank, Large
97651 v.1.0
1
1
1
1
1
2
1
1
1
1
10
12
1
1
1
1
1
8
4
4
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
27
1
1
1
1
2
4
2
2
2
2
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
25
12
1
1
1
1
1
8
4
2
2
2
1
1
1
1
1
8
4
4
2
91102
Washer, Sae Flat, Zinc - 1/4"
91761
Hex Bolt, Flange Head - 6Mm-1.00 X 45MM
91771
Nut, Nylock - M6 X 1.0, Zinc
91846
Washer, Internal Tooth Lock - #8
91868
Hex Nut, Zinc - 8-32
97651
Owner's Manual - Methanol-Water Injection System - Application Based
97651-A
Addendum, Owner's Manual-Schematic, MWI - Application Based
Parts
List (Continued)
62832-10
Pigtail Harness, MAP, Water-Methanol Injection Controller, Duramax -LB7-LMM
45147
Tank Kit, 7 Gallon - Methanol-Water Injection
45098
Tank, 7 Gal, PE, Natural, with 1/4" FPT Fitting weld-on; 3.5" Top Vented Cap, Black, w/8" Tether
91103
Washer, Uss, Zinc - 1/4"
91110
Nut, Nylock - 1/4"-20
91120
Hex Bolt, Grade 5, Zinc - 1/4"-20 X 1 1/8"
91592
Strap, Mounting - MWI Tank, Large
Systems below have identical content as the system above with the exception of the Pigtail Harness
45171
Straight-Shot - Methanol-Water Injection System - 2011-13 Chevy 6.6L, LML
45170-1
Base System, Double-Shot MWI - Controller w/o Onboard MAP Sensor
62832-11
Pigtail Harness, MAP, Water-Methanol Injection Controller, Duramax-LML
45175
Straight-Shot - Methanol-Water Injection System - 2003-07 Dodge 5.9L
45170-1
Base System, Double-Shot MWI - Controller w/o Onboard MAP Sensor
62832-20
Pigtail Harness, MAP, Water-Methanol Injection Controller, 2003-07 Dodge 5.9L
45176
Straight-Shot - Methanol-Water Injection System - 2007-13 Dodge 6.7L
45170-1
Base System, Double-Shot MWI - Controller w/o Onboard MAP Sensor
62832-21
Pigtail Harness, MAP, Water-Methanol Injection Controller, Dodge 6.7L
45180
Straight-Shot - Methanol-Water Injection System - 1994-07 Ford 7.3-6.0L
45170-1
Base System, Double-Shot MWI - Controller w/o Onboard MAP Sensor
62832-30
Pigtail Harness, MAP, Water-Methanol Injection Controller, Ford 7.3-6.0L
45181
Straight-Shot - Methanol-Water Injection System - 2008-10 Ford 6.4L
45170-1
Base System, Double-Shot MWI - Controller w/o Onboard MAP Sensor
62832-31
Pigtail Harness, MAP, Water-Methanol Injection Controller, Ford 6.4L
Appendix A: Nozzle Flow Rates
BANKS PN
45081
45082
45083
45084
45085
45086
45087
45088
45089
45090
BANKS DESCRIPTION
Nozzle, Water-Methanol Injection, #01
Nozzle, Water-Methanol Injection, #02
Nozzle, Water-Methanol Injection, #03
Nozzle, Water-Methanol Injection, #04
Nozzle, Water-Methanol Injection, #05
Nozzle, Water-Methanol Injection, #06
Nozzle, Water-Methanol Injection, #07
Nozzle, Water-Methanol Injection, #08
Nozzle, Water-Methanol Injection, #09
Nozzle, Water-Methanol Injection, #10
STAMPED #
1
2
3
4
5
6
7
8
9
10
Appendix B: Pump Flow Rates
BANKS PN
45030
45031
BANKS DESCRIPTION
Pmp Assy, Low Volume, Water-­‐Methanol Inj.
Pmp Assy, Low Volume, Water-­‐Methanol Inj.
8
4
2
2
2
1
1
1
1
1
8
4
4
2
1
1
1
1
1
1
1
1
1
1
FLOW RATE @ 100 PSI ΔP
HORSEPOWER POTENTIAL
GAL / HR LB / HR* CC / MIN GAS (SUPPORTED) DIESEL (ADDED)*
0.75
6
47
23
3
1
7
63
31
4
2
15
126
63
8
3
22
189
94
12
4
30
252
125
16
5
37
315
156
20
7
52
442
219
28
10
75
631
313
40
12
90
757
375
48
14
105
883
438
56
*BASED ON A 50/50 MIX OF METHANOL AND WATER
FLOW RATE @ 100 PSI ΔP
HORSEPOWER POTENTIAL
GAL / HR LB / HR* CC / MIN GAS (SUPPORTED) DIESEL (ADDED)*
43.7
327
2757
1250
175
23.3
175
1470
750
90
*BASED ON A 50/50 MIX OF METHANOL AND WATER
Appendix C: Error Codes & Trouble Shoo6ng
ERROR CODE
DESCRIPTION
MAP ERR1
MAP sensor signal voltage too low or high
SOL ERR2
Solenoid (either primary or 2nd stage) control current too high
FLD ERR3
Pump output pressure switch error
EGT ERR4
EGT sensor connecBon problem
STAT ERR5
System Status output line connecBon problem
PUMP ERR6
Pump overcurrent problem
28
97651 v.1.0
TROUBLESHOOT
Check sensor connecBon and harness leads for shorts or broken connecBons. Refer to system schemaBc (P/N 97650-­‐A or 97651-­‐A).
Check solenoid harness connecBons and leads for shorts to ground. Refer to system schemaBc (P/N 97650-­‐A or 97651-­‐A).
Typical indicaBon of low / out of fluid state, check and fill reservoir. If condiBon does not correct, check connecBon and harness leads for shorts or broken connecBons. Refer to system schemaBc (P/N 97650-­‐A or 97651-­‐A). If no connecBon errors found, inspect downstream fluid plumbing from pump for leaks. If no leaks found, increase starBng pump duty cycle to a higher value, as inadequate line pressure (<40 PSI) to trigger the pump output pressure switch may be present -­‐ common with larger nozzle(s).
Check sensor connecBon and harness leads for shorts or broken connecBons. Refer to system schemaBc (P/N 97650-­‐A or 97651-­‐A).
Check harness connecBon and leads for shorts to ground. Refer to system schemaBc (P/N 97650-­‐A or 97651-­‐A).
Check pump harness connecBon and leads for shorts to ground. Refer to system schemaBc (P/N 97650-­‐A or 97651-­‐A).
Appendix D: Common Key-­‐on Power Fuse LocaFons
MAKE
FORD
FORD
FORD
FORD
FORD
GM
GM
GM
GM
DODGE
DODGE
DODGE
DODGE
YEAR
1994-­‐1997
2000-­‐2001
2002-­‐2007
2008-­‐2010
2011
2001-­‐2002
2003-­‐2006
2007
2008-­‐2013
2003-­‐2005
2006-­‐2009
2010-­‐2011
2012
ENGINE
7.3L
7.3L
7.3L/6.0L
6.4L
6.7L
LB7
LB7/LLY/LBZ
LBZ/LMM
LMM/LML
5.9L
5.9L/6.7L
6.7L
6.7L
FUSE #
I
19
F2.22
F36
F52
15
PCM1
42
40
15
28
M33
M28
AMPERAGE
20
10
20
10
10
10
15
10
10
10
10
15
15
LOCATION
UNDER HOOD
STEERING COLUMN
STEERING COLUMN
UNDER HOOD
UNDER HOOD
UNDER HOOD
UNDER HOOD
UNDER HOOD
UNDER HOOD
UNDER HOOD
UNDER HOOD
UNDER HOOD
UNDER HOOD
Installation Notes
97651 v.1.0
29
Installation Notes
30
97651 v.1.0
Installation Notes
97651 v.1.0
31
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334 -1743
Product Information & Sales: (800) 438-7693
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
32
97651 v.1.0
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