Holley 02121NOS User's Manual
Contents
1. A Holley Performance Brand P N 199R10382 2005 Mustang Wet Single Fogger Kit Kit Number 02121NOS OWNER S MANUAL CONGRATULATIONS on purchasing your NOS Nitrous Oxide Injection System Your system is composed of the highest quality components available It should provide many miles of trouble free performance when used correctly If you have any questions regarding the performance of your system call NOS Technical Service at 1 866 GOHOLLEY NOTICE Installation of Nitrous Oxide Systems Inc products signifies that you have read this document and have agreed to the terms stated within It is the purchaser s responsibility to follow all installation instruction guidelines and safety procedures supplied with the product as it is received by the purchaser to determine the compatibility of the product with the vehicle or the device the purchaser intends to install the product on Nitrous Oxide Systems Inc assumes no responsibility for damages occurring from accident misuse abuse improper installation improper operation lack of reasonable care or all previously stated reasons resulting from incompatibility with other manufacturers products Nitrous Oxide Systems Inc assumes no responsibility or liability for damages incurred by the use of products manufactured or sold by Nitrous Oxide Systems Inc on vehicles used for competition or racing Nitrous Oxide Systems Inc neither recommends nor condones the use of products manufact2. E 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 2 1 1 1 1 1 2 1 2 1 1 1 PARTS SHOWN HERE ARE NOT TO SCALE Fao a pi ot used POD T F BET Figure 1 Kit 02121NOS Wet Kit Components Chapter 2 Kit Installation 2 1 Bottle Mounting Instructions NOTE Disconnect the battery ground before beginning installation 2 1 1 Street Vehicles Accurate calibration of your NOS nitrous system depends on the bottle remaining at a stable temperature Mount the bottle away from heat sources such as the engine compartment or exhaust system and away from windows where the bottle is exposed to direct sunlight 2 1 2 Racing Vehicles Before mounting a nitrous bottle in a racing vehicle intended for use in sanctioned events check with the sanctioning association for any rules regarding this subject Most associations require that the bottle be mounted within the confines of the safety roll cage with the safety pressure relief cap vented away from the driver s compartment Front of Vehicle 4 Short Bracket U Figure 2 Nitrous Bottle Siphon Tube Orientation Figure 3 Nitrous Bottle Mounting Orientations 2 2 Bottle Orientation Bottle placement is critical to the performance of your NOS nitrous system It is important to understand how the bottle valve and siphon tube are assembled to properly orient the bottle in your vehicle and ensure that it picks up liquid nitrous while undergoing accele
3. O System is armed O Engine is at wide open throttle a RPM conditions are met Horsepower and torque increases due to these kits will vary with engine displacement and modifications Approximate power increase estimates can be made based upon the massflow of nitrous oxide into the engine The following table is provided to allow you to estimate the power increase you can expect for your application NOS strongly suggests that an upper limit of about 40 to 50 increase in power output from your stock engine Exceeding this can result in premature engine failure Table 1 Jetting Combinations 43 PSI Fuel Pressure Kit Nitrous Fuel Approximate Power Jetting Increase BHP 02121NOS 20 16 90 HP 36 30 75 HP Driveability fuel economy and exhaust emissions should not be affected under normal part throttle conditions 1 2 System Requirements When used correctly these kits will work with stock internal engine components To ensure proper performance and engine life the following is an absolute must A Manual Transmissions If the vehicle is to be exposed to severe operating conditions such as drag strip usage the standard clutch should be replaced with a high performance unit Automatic Transmissions If the vehicle is to be exposed to severe operating conditions such as drag strip usage a reputable high performance transmission shop should service the automatic transmission 1 3 Kit Components Before beginning the installatio
4. WARNING Death or injury may occur from working on a charged electrical system 1 Disconnect the car battery at the ground cable if not already done 2 Install the WOT Window Switch 27 as follows A Find a suitable mounting location away from heat and vibration ex firewall B Loosely route the WOT Window Switch wires to the locations found on the drawing C Route the Red White wire from the WOT Window Switch through the firewall Route the wire as close to the center console as possible 3 Install the NOS arming switch panel leftmost switch in the vehicle interior next to the power outlet within easy reach of the driver See Figures 13 17 The NOS arming switch panel included in this kit has switches included for a bottle heater NOS P N 14164NOS and 14169NOS and an NOS purge NOS P N 16030NOS which can be purchased separately Either the left most or right most rocker switch can be used for a master arming switch The middle pushbutton switch is designed for a purge only The arming switch is to be used to activate the nitrous system once safe engine RPM levels are reached NOTE Refer to the factory service manual for center console removal 13 10 14 Snap in rocker switches amp use backing plate with purge switch Figure 14 Hand tighten the purge switch Installation complete Figure 16 i Figure 17 Install the wiring relay and relay harness in the engine compartment near the battery The re
5. 05 20
6. Solenoid AA 17 3 2 Nitrous oolenoid FIUNger o ser AA OaE 17 321 General Mor malo eseti a ide 17 3 2 2 Nitrous Solenoid Plunger Disassembly and Inspection ccoooocccccoccnnonoccnccnncnnnnnnnnnononononnnnononncnnnnnnrnnnnnnnnnnnnnrnnnnnnnnns 17 Appendix A Troubleshooting Guide 2 nnmnnn 18 Nitrous Oxide ACCESSONICS AA aoip epsilon theesieetieets 20 WHAT IS NITROUS OXIDE NITROUS OXIDE IS a cryogenic gas composed of nitrogen and oxygen molecules 1s 36 oxygen by weight 1s non flammable by itself 1s stored as a compressed liquid Exists in two grades U S P and Nitrous Plus a U S P is medical grade nitrous oxide its common use is dental and veterinary anesthesia It is also commonly used as a propellant in canned whipped cream U S P is not available to the public A Nitrous Plus differs from U S P in that it contains trace amounts of sulphur dioxide added to prevent substance abuse Nitrous Plus is intended for automotive applications and is available for sale to the public In automotive applications Nitrous Plus and fuel are injected into the engine s intake manifold which produces the following results AU Lowers engine intake air temperature producing a dense inlet charge O Increases the oxygen content of the inlet charge air is only 22 percent oxygen by weight O Increases the rate at which combustion occurs in the engine s cylinders Do s and Don ts of Nitrous Ox
7. OS WOT window switch is preset to activate the TPS at 4 3 volts The rpm portion of the WOT Window switch activates the solenoids at 3000 rpm and turns them off at 6000 rpm This is the recommended factory preset for the WOT Window switch To verify the WOT Window switch operation or to troubleshoot this switch refer to the WOT Window switch troubleshooting section See Figure 21 Figure 21 Default Settings 15 2 10 WOT Window Switch Troubleshooting Verifying the operation of the NOS WOT Window Switch NOTE NOS highly recommends that the user NOT change the factory WOT Window Switch settings The WOT Window Switch should be set at the 3000 rpm low and 6000 rpm high default settings With the NOS WOT Window Switch these values are adjustable but altering them is not recommended The NOS WOT Window Switch also has a TPS Microswitch built into the unit The default and recommended setting is 4 3 volts This setting ensures that the NOS nitrous system will only activate at FULL THROTTLE above 3000 rpm and that it SHUTS OFF at 6000 rpm NOTE The NOS WOT Window Switch needs to be connected to cylinders that fire one after another In other words the first coil 1 wire needs to be connected to a cylinder which fires before another In this case cylinder 1 coil 1 wire on WOT Window switch fires before cylinder 3 coil 3 wire on WOT Window switch If these wires are installed opposite of this the WOT Window switch will not ac
8. YSTEM SAFETY TIPS WARNINGS gt Do not attempt to start the engine if the nitrous has been injected while the engine was not running Disconnect the coil wire and turn the engine over with the throttle wide open for several revolutions before attempting to start Failure to do so can result in extreme engine damage gt Never permit oil grease or any other readily combustible substances to come in contact with cylinders valves solenoids hoses and fittings Oil and certain gases such as oxygen and nitrous oxide may combine to produce a highly flammable condition gt Never interchange nitrous and fuel solenoids Failure to follow these simple instructions can result in extreme engine damage and or personal injury gt Never drop or violently strike the bottle Doing so may result in an explosive bottle failure gt Never change pressure settings of safety relief valve on the nitrous bottle valve Increasing the safety relief valve pressure settings may create an explosive bottle hazard gt Identify the gas content by the NOS label on the bottle before using If the bottle is not identified to show the gas contained return the bottle to the supplier Do not deface or remove any markings which are on the nitrous bottle Nitrous bottle valves should always be closed when the system is not being used Notify the supplier of any condition which might have permitted any foreign matter to enter the valve or bottle Keep the valves cl
9. a wrench to ensure the nozzle doesn t rotate out of position when the line is tightened 2 7 Nitrous Feed Line Mounting HINT Most late model vehicles have access plugs in the trunk floor which are convenient for nitrous line routing Following the fuel lines along the underbody and entering the engine bay through the front fender well between the plastic inner fender panel and the body usually works well 1 Determine the route for your nitrous feed line to follow Ensure the path is clear of exhaust system suspension steering wheels electrical lines and components and tires 2 Feed the nitrous supply line 19 along the proposed route 3 If itis necessary to support the nitrous supply line under the vehicle use 1 2 Tinnerman clamps or nylon tie wraps to support the line securely 4 Attach the nitrous supply line to the 4AN bottle nut adapter 1 on the nitrous bottle WARNING Nitrous oxide can cause death if inhaled Severe frostbite can occur if allowed to contact the skin Always point the nitrous line opening away from people when purging the line 5 Attach the nitrous supply line to the filter installed in the nitrous solenoid inlet port 2 8 Fuel Supply Connection 1 Remove the fuel pressure sensor from the fuel rail This sensor is located on the driver s side of the engine and is attached to the fuel rail with two 8mm headed bolts See Figure 7 WARNING Do not use Teflon Tape on any pipe threads Pieces of Teflon
10. amp the fuel solenoid 7 in a bench vise 5 Thread the 1 8 NPT x 4AN Fuel Filter Fitting 11 into the inlet port of the fuel solenoid Remove from the vise 6 Thread the 1 8 NPT male end of the red 2 ft 3AN hose 18 into the outlet port of the fuel solenoid Use Teflon paste to avoid leaks 7 Attach the nitrous solenoid to the solenoid mounting bracket 24 Attach the fuel solenoid to the solenoid mounting bracket 24 See Figure 6 10 N LO WSs yyy Figure 6 8 Mount the solenoid assembly to the driver s side foremost valve cover bolt See Figure 6 Ensure that the assembly and lines do not interfere with engine accessories or body parts and that hoses reach the Soft Plume nozzle inlet ports without being stretched or kinked 9 Securely mount the solenoid assembly 2 6 Solenoid Soft Plume Nozzle Hose Connection 1 Select the proper nitrous and fuel jets 13 16 Place the desired jets in the Soft Plume nozzle making sure that the jets are inserted into the correct locations as marked on the nozzle 2 Connect and tighten the open end of the blue 2 ft 3AN hose 17 to the Soft Plume nozzle inlet port marked nitrous Hold the Soft Plume nozzle in position with a wrench to ensure the nozzle doesn t rotate out of position when the line is tightened 3 Connect and tighten the open end of the red 2 ft 3AN hose 18 to the Soft Plume nozzle inlet port marked fuel Hold the Soft Plume nozzle in position with
11. ctions crimped Preparing for Operation or plugged Chapter 4 Malfunctioning fuel Turn arming switch ON Cycle the Repair replace solenoid solenoid microswitch Solenoid should make clicking noise Change in engine speed Malfunctioning nitrous Remove and inspect solenoid Repair replace solenoid when nitrous bottle valve solenoid is opened Preparing for Operation Chapter 4 system is activated opened improperly Plugged nitrous filter Inspect filter Clean replace filter 75 to 85 F supply 1 800 99 REFILL 18 Mismatched N2O fuel Compare jetting to recommended values Install correct jets jetting Excessive fuel Install fuel pressure gauge such as NOS pressure P N 15906NOS in the fuel line Measure Regulate pressure down or install smaller fuel the pressure during acceleration with the system activated Loose nitrous solenoid Inspect the solenoid wiring wiring Malfunctioning nitrous WARNING Solenoid discharges nitrous Rebuild solenoid solenoid at a high rate Dont inhale nitrous death may occur Skin contact may cause frostbite Close bottle valve Disconnect the nitrous solenoid outlet port Disconnect the solenoid lead Open the nitrous bottle valve Connect the 12V to the solenoid Solenoid should discharge N2O at a high rate when system is activated incorrectly Figure 12 instructions Loose ground wire s Connect 12V test light to battery Tighte
12. d tighten the bracket clamps 2 4 Soft Plume Nozzle installation NOTE The recommended mounting location for the Soft Plume nozzle is in the air inlet duct between the throttle body and the mass airflow sensor in applications where a mass airflow sensor is used Install the nozzle as shown in Figure 5 before the throttle body or any major turn in the air inlet duct See Figure 5 1 Before making any permanent modifications to the vehicle layout the location of all the major components solenoid nozzle fuel nitrous supply lines etc 2 Install the Soft Plume Nozzle 22 taking into account the length of the nitrous and fuel supply hoses and the intended location of the solenoids Take into account that the nozzle mounting bung 21 needs to be restrained during final installation and accessibility of a tool is important Make sure the nozzle and feed lines will not interfere with engine components or accessories and will not interfere with the hood when closed The nozzle should not move from the perpendicular position in the air inlet duct due to strain induced by the nitrous and or fuel supply hose 3 Remove the air inlet duct CAUTION All debris must be removed from the air inlet duct Use compressed air if available Failure to do so can result in severe engine damage 3A Mounting Surface Drill a 7 16 hole perpendicular to the inlet duct centerline through the inlet duct Insert the Soft Plume nozzle mounting bung 21 in
13. ers Debris lodged in a nitrous or fuel solenoid can cause catastrophic engine failure NO SEALER AN gt REQUIRES TEFLON NPT PIPE paste TO SEAL FITTING OU Use sealant of any kind on AN type fittings A Allow nitrous pressure to exceed 1100 psi Excessive pressure can cause swelling or in extreme cases failure of the nitrous solenoid plunger Solenoid plungers are designed so that pressure induced failures will prevent the valve from operating No leakage should occur with this type of failure Inhale nitrous oxide Death due to suffocation can occur Allow nitrous oxide to come in contact with skin Severe frostbite can occur Use octane boosters that contain methanol Fuel solenoid failure may occur producing severe engine damage ODO Chapter 1 Introduction to your NOS Nitrous Oxide Kit 1 1 General Information Kit Number 02121NOS is intended for 2005 Mustang 4 6L 3 valve engines NOTE This nitrous oxide injection system injects a mixture of nitrous oxide and fuel into the air intake duct If the instructions are not carefully followed poor mixture distribution can occur resulting in variations of air to fuel ratio from cylinder to cylinder In extreme cases intake manifold backfires can occur if the instructions are not followed exactly These kits have been designed for safety and smoothness of operation Nitrous oxide is injected into the engine only when the following conditions are met a Bottle valve is opened
14. ide Do s O Read all instructions before attempting to install your NOS nitrous system O Make sure your fuel delivery system is adequate for the nitrous jetting you have chosen Inadequate fuel pressure or flow will result in engine damage O Use 14 gauge minimum wire when installing electrical system components a Use high quality connections at all electrical joints Uu Use Teflon based paste on pipe style fittings OU Make sure your engine and related components ignition carburetor and driveline are in proper working condition A If nitrous is accidentally injected into the engine when it is not running remove the engine coil wire open the throttle and crank the engine 10 to 15 seconds before starting Failure to do so can result in an explosive engine failure O Use your NOS nitrous system only at wide open throttle and at engine speeds above 3000 RPM Install a proper engine to chassis ground Failure to do so may result in an explosive failure of the main nitrous supply line O Use a high quality fuel as suggested in Chapter 3 Baseline Tuning Suggestions Don ts O Engage your nitrous system with the engine off Severe engine damage can occur A Modify NOS nitrous systems if you need a non stock item call NOS Technical Service for assistance A Overtighten AN type fittings O Use Teflon Tape on any pipe threads Pieces of Teflon tape can break loose and become lodged in nitrous or fuel solenoids or solenoid filt
15. lay s orange wire should reach the battery terminal Connect the orange relay wire to the battery terminal Install a 15 AMP fuse into the fuse socket Connect one wire from each solenoid together Join the solenoid wires to the blue relay wire Join the remaining solenoid wires together Connect to a good chassis ground Connect the WOT Window Switch wire to the green relay wire and then to a good chassis ground Connect red relay wire solid red wire on the WOT Window Switch Connect the tan wire of the WOT Window Switch to coil 1 cylinder 1 on the Mustang white pink stripe wire on car See Figure 18 2 VF Va o e dd Coil 3 is closest U to the firewall EFI MT LLL Coil 1 is closest h to the radiator WS Figure 18 HUG Figure 19 bl 11 Connect the brown yellow striped wire on the WOT Window Switch to the green white striped wire of coil 3 cylinder 3 on the car See Figure 19 12 Connect the black wire of the WOT Window Switch to a ground 13 Connect the yellow white striped wire on the WOT Window Switch to the yellow white striped on the car TPS sensor See Figure 20 4 Figure 20 14 Connect the red white striped wire on the WOT Window Switch to the upper pin of the arming switch in the dash 15 Connect the lower pin of the NOS arming switch to a 12 volt switched power source in the car 16 If these steps are verified proceed to the next section NOTE The N
16. mately half way Once all the LED lights illuminate the NOS system is active After 2500 RPM is reached the middle LED System Activation left LED RPM should turn off 7 If these steps are verified the NOS WOT Window Switch is operating normally 8 Reset the dials to the default settings 3 000 rpm low and 6 000 rpm high for on and off Also reset the TPS to 4 3 volts TPS left dial to 4 and TPS right dial to 3 If there are further issues with the WOT Window Switch please contact NOS tech service with any questions 16 Chapter 3 Routine Maintenance 3 1 Nitrous Solenoid Filter When nitrous bottles are refilled they can become contaminated with debris if the refiller does not have an adequate filter in their transfer pump mechanism Contaminants in the bottle will eventually become lodged in the nitrous solenoid filter fitting You should periodically after every 20 30 pounds of nitrous usage examine the mesh in the nitrous filter for debris To clean the filter follow the following steps 1 Close the valve on the nitrous bottle Empty the main nitrous feed line Disconnect the main nitrous feed line from the nitrous solenoid Remove the nitrous filter fitting from the nitrous solenoid Remove all Teflon paste debris from the solenoid inlet port threads and from the nitrous solenoid filter pipe threads Examine the mesh in the nitrous filter fitting for contaminants Blow out debris with compressed air if necessary Appl
17. n of your NOS kit compare the components in your kit with those shown in Figure 1 and listed in Table 2 If any components are missing please contact NOS Technical Support at 1 866 GOHOLLEY Table 2 NOS 2005 Mustang 02121NOS Parts List NOS P N 16220NOS 16210NOS 14745NOS 14126 SNOS 14127 SNOS 1 2 3 N O Powershot Solenoid 16020NOS Powershot Fuel Solenoid 16080NOS 15604 SNOS 15618NOS 15570NOS 15571NOS 17961 SNOS 13760 16NOS 13760 20NOS 13760 30NOS A Vicar MA EN i Oooo VEA EE EEES EA ESE Oooo o 1 RelayWiringHarnmess 41 Oo 30AmpRelay o Z o Z o 4an 1 8NPT Nitrous Filter Blue 1 FuelFilter Red Tt 4AN 1 8NPTFitting Red 414 Pp 0 016 Flare Jet 4 P0020 Flare Jet P0080 Flare Jet P0086 Faredet o o 1 13760 368NOS BAN x2ft Hose Blue 1 15060 1N0S BAN x2ft Hose Red 1 15060 2NOS 4AN 16 ft Hose Blue Cc 7 15300N0S Nozzle Mounting Bung Nut 1 13713 SNOS Nozzle Mounting Bung 1 3715 SNOS po FoggerNozzle 1 13716NOS 8 32x5 16Phillips Head Screws 4 16506 SNOS Solenoid Bracket 414 49R3002 ne Oooo Ka a ERE A a TRA Ki er MO EN ti Cd O O AN ay KHAN Sl Washers 46R1421 15610N0S 200R539A 40R827A 49R3003 89R693 5R2218 52 R424 89R694 4AN 7 1 4 in 90 Hose 15751 VSNOS A1001 SNOS Basic Wire Pack 5m 1 15612 VSNOS po Microswitch tt 15640NOS_ O en TSC PANTO M Screw 2
18. n repair loose terminal Check for continuity at grounds grounds noted in Fig 12 Malfunctioning arming Turn arming switch on Connect 12V test Replace pushbutton switch light to battery terminal Check for power at pole 2 No power to arming Connect 12V test light to battery Repair wiring switch terminal Check for power at pole 1 on arming switch Malfunctioning throttle Temporarily disconnect power relay red Replace throttle microswitch wire from microswitch Connect 12V test microswitch jetting light to battery terminal Manually set microswitch ON Check for continuity at microswitch positive terminal Fig 12 condition through exhaust with system activated decrease fuel pressure when system is activated timing increments Inadequate octane fuel Use higher octane fuel too high range maximum 2 steps Too much nitrous flow Reducer nitrous jetting Engine detonates heavily Inadequate fuel delivery when system is activated due to Plugged fuel filter Inspect fuel filter Clean or replace filter Crimped fuel line Inspect fuel line Replace crimped line Repair replace fuel pump Weak fuel pump Install fuel pressure gauge such as NOS P N 15906N0S in the fuel line Run engine under load at wide open throttle with system activated Fuel pressure should be within 5 PSI of fuel pressure at idle system is activated gap 0 030 to 0 035 component failure dist
19. o the engine if the fuel pressure is below what is required to supply the required extra fuel This fuel pressure safety switch can be adjusted to any desired setting but is preset to 35 PSI at the factory The primary purpose of a Purge Valve P N 16030NOS is to release trapped air or gaseous nitrous from the feed line s This helps to ensure consistent performances And purging looks cool too Nitrous Pressure Gauges P N 15910NOS measure from 0 1500 psi although recommended level is 900 950 psi and are essential in monitoring the bottle The Quick Release Hinged Aluminum Bracket P N 14140NOS is available for 10 Ib and 15 lb bottles P N 14147NOS is available for the carbon fiber bottle P N 15686NOS P N 16030NOS P N 15910NOS P N 14140NOS For those who want the ultimate in appearance NOS offers many popular bottles that are fully polished P N 14745 PNOS is our 10 Ib fully polished bottle For optimum weight reduction and distinctive high tech looks these DOT approved NOS carbon fiber wrapped bottles are it It weighs about half of the standard bottle empty P N 14747NOS has 12 5 Ib capacity P P N 14745 PNOS P N 14747NOS To order contact your local NOS dealer NOS Technical Support Toll Free Phone 1 866 GOHOLLEY Phone 1 270 781 9741 Fax 1 270 781 9772 For online help please refer to the Tech Service section of our website www holley com For bottle refill information 1 800 99 REFILL 199R10382 Date 11 10
20. osed on all empty bottles to prevent accidental contamination After storage open the nitrous bottle valve for an instant to clear the opening of any possible dust or dirt Vv Vv Y VW V Y It is important that all threads on the valves and solenoids are properly mated Never force connections that do not fit properly TABLE OF CONTENTS WHAT IS NITROUS OXIDE Sudan nia 4 Do s and Don ts Of Nitrous ON O rosoning NAA NAAN Gp G DANG NANANA NAA NALNG Na 4 Chapter 1 Introduction to your NOS Nitrous Oxide Kit oocooncconccocccocccoococoncococaronaroncnnonaronanons 4 dl 3GEReralINTONMALON ana NAA AA AA ai ia 4 T2 System IREQUINCIMONES ranna A E ee 5 MS AECE ONO PONS rada 6 Chapter 2 Kit Installation ainia acacia 7 215 DOMES MOUNTING IASTUCION Sivad ad 7 Pa Bag SA A ee 7 ENG IACI o AA A O re O AA RA AA 7 2 2 BONS Onena cl ana Aa a naa aa nA AA NAN 8 Zone eA ALLO aaa aaa haa AA AA AA 8 2 4 SO PIUMe Nozio do aaa asa 9 2 5 solenoid MONIN ahaha aala maala alalang Unan aaa alaala 10 2 6 Solenoid Soft Plume Nozzle Hose Connection 1 tee aaeei a aa aaan aa aai ai aiai ia 11 2 1 INIMOUS Feed Line MOLA A eh AA KANA LAKAD at Seal 11 2 90 Fuel SUDDIY Conneccion cta tia di cas 11 2 9 Electrical System Installation WOT Window Switeh 1 11 13 2 10 WOT Window Switch Troubleshooting Verifying the operation of the NOS WOT Window Switch occccooccccccoccncoco 16 Chapter 3 Routine Maintenant e misil 17 S1 Nitrous
21. ous solenoid base Do this by double nutting the stem or by using a solenoid stem removal tool NOS P N 16665 SNOS Do not use pliers on the solenoid stem Damage to the stem will result 6 Remove the stem spring and plunger from the solenoid base 7 Examine the plunger seal for swelling The seal surface should be flat except for a small circular indentation in the center of the seal A fuel contaminated seal will protrude from the plunger and be dome shaped A fuel contaminated seal may return to its original shape if left out in the fresh air for several days It may then be returned to service A seal which has been overpressurized may be dome shaped or the sealing surface may be flat with the seal protruding out of the plunger A dome shaped seal may return to its original shape if left out in the fresh air for several days It may then be returned to service A seal which is flat but protrudes from the plunger body has probably failed internally and should be replaced 17 RETAINING NUT COIL INSIDE STEM BASE Figure 23 Exploded View of a Typical Solenoid Appendix A Troubleshooting Guide The troubleshooting chart on the following pages should help determine and rectify most problems with your installed NOS system If you still need assistance determining or fixing problems call the NOS Technical Support at 1 866 GOHOLLEY speed when the fuel incorrectly solenoid is activated Inspect fuel line for restri
22. ration All NOS nitrous bottles are assembled so that the bottom of the siphon tube is at the bottom of the bottle and opposite the bottle label Figure 2 Whenever the bottle is mounted in a lay down position the valve handle must be towards the front of the vehicle with the label facing up Figure 3A If the bottle is mounted vertically the valve handle and label must face toward the front of the vehicle Figure 3B This orientation will position the siphon tube at the back of the bottle where the liquid N20 will be during acceleration WARNING DO NOT attempt to remove the siphon tube without completely emptying the bottle of all nitrous and pressure Failure to completely empty the bottle will result in an explosive condition causing injury or death A bottle mounted upside down must have the siphon tube removed before use Figure 3C Non siphon bottles can be specially ordered from NOS If the bottle must be mounted parallel to the axles of the vehicle sideways the valve handle and label must be angled at approximately 45 toward the front of the vehicle Figure 3D This orientation will position the siphon tube toward the rear of the bottle NOTE When using a bottle with a siphon tube the tall bracket should be at the valve end of the bottle and the short bracket at the bottom Figure 3E The most efficient mounting is the lay down position Figure 3A with the valve handle toward the front of the vehicle This position allow
23. ributor cap etc components Surges under acceleration Check bottle weight when system is activated nitrous Compare bottle position and orientation to Mount or orient bottle incorrectly instructions Figures 2 4 3 correctly 19 Nitrous Oxide Accessories NOS systems are calibrated for optimum performance with a bottle pressure of 900 950 psi The pressure will change with temperature Heater kits are thermostatically controlled to keep the bottle near 85 F to provide correct pressure Bottle Heater P N 14164NOS is available for 10 amp 15 Ib bottles Insulating the bottle helps maintain pressure by keeping heat in the bottle when it s cold or heat out when it s hot outside The blankets are made of a rugged easily cleaned Nylon outer shell with insulation It s also an excellent dress up accessory and perfect for covering battle scarred bottles Bottle Blanket P N 14165NOS is a 7 diameter blanket for the 10 Ib bottle The Remote Bottle Valve P N 16058NOS is the perfect convenience accessory it electronically turns the nitrous bottle on and off with the flick of a switch no more trips to the trunk It is also great as a safety shut off valve It operates on 12V DC The complete kit includes hardware and installation instructions CA p i a 4 a MN a F P N 14165NOS P N 16058NOS P N 14164NOS With the 35 PSI Adjustable Pressure Switch P N 15686NOS you won t be blasting nitrous int
24. s the greatest amount of liquid to be used before the siphon tube begins to pick up gaseous nitrous oxide 2 3 Bottle Installation After you have determined the location and orientation of the nitrous bottle use the following procedure to install the bottle NOTE Numbers in parentheses refer to the parts list assembly drawing number for the component Figure 4 shows the installation assembly for the Universal Wet NOS system 17 Install k solenoids NA on bracket as shown here S Figure 4 Exploded View of Kit 02121NOS Wet NOS System 1 Install the bottle nut adapter 1 and Teflon washer 2 on the nitrous bottle 3 Tighten securely 2 Loosely install the bottle mounting brackets 4 amp 5 on the nitrous bottle as shown in Figure 3E 3 Locate the bottle bracket assembly in the desired mounting location ensuring that the location will provide easy access to the bottle valve hose connection and bracket clamp bolts to facilitate bottle changing 4 Use the assembled bottle bracket unit as a pattern to mark and drill four 5 16 holes in the mounting surface CAUTION When drilling or punching holes for these brackets be aware what component wires or hoses are located or routed behind the general area to avoid vehicle or equipment malfunction 5 Mount the brackets securely to the surface recommended minimum of 5 16 bolts or No 12 sheet metal screws 6 Secure the nitrous bottle in the mounting brackets an
25. tape can break loose and become lodged in nitrous or fuel solenoids or solenoid filters Debris lodged in a nitrous or fuel solenoid can cause catastrophic engine failure 11 2 Install the 4AN fitting 12 into the injector block with Teflon paste while secured in a soft jaw vise Tighten securely See Figure 9 WARNING Do not tighten fittings while installed on the fuel rail Install these while secured in a soft jaw vise 3 Thread the 90 end of the 6 4AN hose into the fitting in the injector block hand tighten and add a 1 2 turn See Figure 10 4 Insert the injector block with O ring pressed into the rail Lube the o ring with o ring lube or Vaseline See Figure 11 Figure 8 Figure 11 5 Using the supplied bolts and washers tighten the injector block down after installing the fuel pressure sensor on top CAUTION All debris must be removed from the fuel rail Failure to do so will result in an engine failure 12 IN LINE POWER ain RELAY GROUND FUS ee ARMING SWITCH ORANGE 1 HARNESS PLUG NEG POS GREEN pi BATTERY BLUE IGNITION nG SWITCHED 12 VOLTS Red White O Ofra WOT Gro WINDOW Lz to Coil 1 SWITCH Brown Yellow to Coil 3 Yellow White to TPS O Eat GROUND GROUND Figure 12 Electric Wiring Schematic 2 9 Electrical System Installation WOT Window Switch Refer to Figure 12 and the procedures in this section for electrical system installation
26. tivate properly 1 To verify the operation of the NOS WOT Window Switch first remove the 4 screws that hold the cover onto the WOT Window Switch box IMPORTANT Disconnect the solenoid control wires Make sure the nitrous bottle valve is closed 2 The lower left and top left dials set the maximum and minimum RPM at which the nitrous turns on or off LB Figure 22 3 Set the lower left dial to 1 and lower right dial to 5 Set the upper left dial to 2 and the upper right dial to 5 This sets the RPM Window to turn nitrous on at 1500 RPM and off at 2500 RPM Set the TPS left dial to 2 and the TPS right dial to O This sets the TPS to turn on at 2 0 volts or about 1 4 to 1 2 throttle See Figure 22 IMPORTANT Make sure that the nitrous and fuel solenoids are disconnected before proceeding 4 Verify the RPM operation by starting the vehicle CAUTION EXERCISE EXTREME CAUTION WHILE TROUBLESHOOTING THE WOT WINDOW SWITCH AS WORKING AROUND A RUNNING ENGINE IS EXTREMELY DANGEROUS SECURE ALL LOOSE CLOTHING AND ITEMS TO SAFEGUARD AGAINST CONTACT WITH THE ENGINE ACTIVE NITROUS AND FUEL SYSTEMS ARE EXTREMELY DANGEROUS 5 Have an assistant watch the top row of LED lights in the WOT Window Switch box while slowly bringing the engine speed to 1500 RPM The top left LED RPM window should illuminate at or above 1500 RPM 6 Next bring the engine speed to 2500 RPM The top left LED should still be lit while the throttle is depressed approxi
27. to the 7 16 hole with the head inside the duct Use Loctite or a similar compound on the nozzle adapter threads and securely tighten the nozzle mounting bung nut 20 to the nozzle mounting bung 21 This hole should be drilled onto the bottom towards the underside of the car of the air intake tube CAUTION Severe engine damage can occur if the nozzle adapter nozzle assembly works loose from the air inlet duct Ensure that the Soft Plume nozzle is securely tightened in the air duct 4 Note the discharge side of the Soft Plume nozzle Install the Soft Plume nozzle in the inlet duct with the discharge side pointed toward the engine downstream or in the direction of the induced air stream Use Teflon paste to ensure adequate sealing 5 Install the air inlet duct Install nozzle here SOFT PLUME NOZZLE FLARE JET ES i SPRAY FUEL LINE EY Pa INTO 3 sf MANIFOLD PLENUM NITROUS UY LINE 4 foot Figure 5 Soft Plume Nozzle Installation Cut Away amp Installation Photo 2 5 Solenoid Mounting CAUTION Do not overtighten the vise in the following procedure or the solenoid will be damaged 1 Clamp the nitrous solenoid 6 in a bench vise 2 Thread the 1 8 NPT x 4AN nitrous filter fitting 10 into the inlet port of the nitrous solenoid Use Teflon paste to avoid leaks 3 Thread the 1 8 NPT male end of the blue 2 ft 3AN hose 17 into the outlet port of the nitrous solenoid Remove from the vise 4 Cl
28. ured or sold by Nitrous Oxide Systems Inc on vehicles which may be driven on public roads or highways and assumes no responsibility for damages incurred by such use NOS nitrous oxide is legal for use in most states when used in accordance with state and local traffic laws NOS does not recommend or condone the use of its products in illegal racing activities NOS has not pursued California Air Research Board CARB exemptions for these kits hence they are not legal for use on pollution controlled vehicles in California A correctly installed NOS nitrous system should not alter the emission control performance of your vehicle under standard EPA test cycle conditions HAZARDS DEFINED This manual presents step by step instructions that describe the process of installing your NOS Nitrous Oxide Injection System These procedures provide a framework for installation and operation of this kit Parts are referenced by name and number to avoid confusion Within the instructions you are advised of potential hazards pitfalls and problems to avoid The following examples explain the various hazard levels WARNING Failure to comply with instructions may result in injury or death CAUTION Failure to comply with instructions may result in damage to equipment NOTE This information is important needs to be emphasized and is set apart from the rest of the text HINT These special instructions provide a handy work tip NITROUS OXIDE INJECTION S
29. y fresh Teflon paste to the nitrous filter pipe threads Reinstall the filter in the nitrous solenoid mr OL E SO N Reconnect the main nitrous supply line to the nitrous solenoid 3 2 Nitrous Solenoid Plunger 3 2 1 General Information The seals used in NOS nitrous solenoid plungers are constructed from materials that are designed to be used with nitrous oxide When kept free from fuel contaminants or from overpressurization they should provide trouble free performance You should periodically after every 20 30 pounds of nitrous usage examine the seal in the nitrous solenoid plunger The seals used in NOS nitrous solenoid plungers are designed to work at pressures up to 1100 psi Exposing the plunger to excessive pressure whether the vehicle is sitting or in use can result in the seal in the plunger seal swelling or in extreme cases plunger seal disintegration NOTE The seals are designed so that if they fail due to overpressurization they will not leak the valve will just fail to flow nitrous oxide Swelling of the nitrous solenoid plunger seal will reduce nitrous flow causing an excessively rich nitrous fuel condition and a loss of power 3 2 2 Nitrous Solenoid Plunger Disassembly and Inspection 1 Close the valve on the nitrous bottle 2 Empty the main nitrous supply line 3 Remove the retaining nut from the nitrous solenoid 4 Remove the coil and housing from the nitrous solenoid base 5 Unscrew the stem from the nitr
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