8V JTD water/meth injection installation - Alfa Romeo Forum
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(Post Link) post #1 of 67 Old 21-04-12 Thread Starter
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8V JTD water/meth injection installation

Finally decided to install WM injection kit on my 156 too.

I bought five gallon AEM HD kit with additional 130ml/min nozzle


But first something I owed myself for a long time ...




Following the installation instruction, I will place the pump next to the water tank in the spare wheel compartment and control unit in the small compartment near the steering wheel.

Electrical wiring will follow the existing loom


Water line will be placed next to the fuel lines (under the protecting rail)


Modularize everything




Nylon hose put inside nylon gooseneck for enhanced safety


Prepared wiring loom



Will be continued ...

[SIGPIC][/SIGPIC] Squadra Moravia

156SW 1.9JTD: GTB2060VKLR turbo, performance cam&head, WM injection, 6speed Q2 gearbox, 4p Brembo brakes, 2.5" stainless exhaust, FMIC, upgraded sensors, lowered & stiffened suspension, own remap
GTV 3.0V6 24v: C30-94 charger, short gearbox with Quaife ATB, big 4p Brembo brakes, SMF, lowered suspension, custom freeflow equal lenght x-pipe quad tips exhaust

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(Post Link) post #2 of 67 Old 22-04-12 Thread Starter
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Tank and pump positioning
pump+tank.jpg

AEM supplied 5/16-18 bolts are too short. At least 60mm ones are needed.

Laying the WM wiring loom
wiring.jpg

First blood comes here. I managed to break two clips while removing the door sill panel :-( eLearn is useles here
broken panel.jpg

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I like the drop down oil/egt gauges, is that MaKano I see. You could mount the water/meth on/off switch there too
Good planning on the water/meth install, looking good mate.

Wow thats a big tank!
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Good place to mount a tank yan.ko. And you have some space left in case if you will move your battery into the boot...
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Thanks guys

MaKano? Gauges are from raid hp, sport serie. WM switch will be the existing rightmost button below the gear lever. Just have to paint it red
I was thinking about moving batery into boot and putting smaller WM tank in the engine bay instead, but I have discarded this idea. I'll try tu put there original tyre repairing set with compressor next to the tank.

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Quote:
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Thanks guys

MaKano? Gauges are from raid hp, sport serie. WM switch will be the existing rightmost button below the gear lever. Just have to paint it red
I was thinking about moving batery into boot and putting smaller WM tank in the engine bay instead, but I have discarded this idea. I'll try tu put there original tyre repairing set with compressor next to the tank.
oops my spelling, the red metal brackets that hold your gauges looks like Meccano.
Meccano international website. Construction Toys from Meccano I used to love making stuff with meccano as a lad.
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Heh, something simillar. It's from Merkur - construction set I used to play with as a lad too. We have had it nearly thirty years. Jeezus, it's old

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Prepared for assembly
prepared.jpg

And fitted
mounted.jpg

I was 'handy' again today
filter.jpg

Did nearly two full turns and filter outlet cracked Had to shorten it and will cut the new thread. But now I'm waiting for 1/4-18NPT taper pipe tap.

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luggage compartment 1.jpg

luggage compartment 2.jpg

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hey I like that remote filter never seen one before, whats it like inside metal mesh?
There's a tiny mesh filter built into the jet body, but if the jet is mounted deep in the engine bay like mine it a pita to service, that filter would be the answer and leave the jet filter out...maybe?
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Yep, it is like that ...
filter 2.jpg
(Btw. it's AEM 30-3003)

Personally I'll keep both filters. This one, before pump and the jet one as well. I ordered also valve, so I'll be capable to clean the filter or disconnect the rest of system without necessity of emptying the tank.

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Yep, it is like that ... . (Btw. it's AEM 30-3003)

Personally I'll keep both filters. This one, before pump and the jet one as well. I ordered also valve, so I'll be capable to clean the filter or disconnect the rest of system without necessity of emptying the tank.
That looks like a super fine mesh, perfect! good idea for the valve.
Just ordered that filter myself now, thanks for sharing.
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The bulkhead elbow I intend to use to get out from spare wheel compartment to the underbody. Probably.
valve.jpg

Testing the tank for capacity (18.6l), weight (20kg) and leakage.
tank test.jpg

Tomorrow will do an on road sound testing to know if any additional sound insulation will be needed or not. I'm not willing to listen splashing sounds from the boot.

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Sounds seem to be acceptable, will try to listen from back seat, but it's somehow impossible now :-)
garage1.jpg
Removed for cleaning, repairing the driver seat lift mechanism and laying the WM cabling.

garage2.jpg
Stripping the head for camshaft swap, head flowing and some other stuff (yeah, bigger fuel pump finally, EWP80, preheating, inlet manifold modding).


Btw James, do you use tap water or distilled in your WM blend?

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Very nice yan-ko. It semms you to have time enough for your Alfa.
I am vere very courious for dyno comparison with/without w-m injection. What is the new camshaft from?
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Thanks Peter, you are going well with your project too. Camshaft is actually from Colombo&Barianni (https://www.alfaowner.com/Forum/tunin...ml#post4588406). I don't await massive gain from WM, main reason is lowering the EGT.
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Sounds seem to be acceptable, will try to listen from back seat, but it's somehow impossible now :-)

Removed for cleaning, repairing the driver seat lift mechanism and laying the WM cabling.


Stripping the head for camshaft swap, head flowing and some other stuff (yeah, bigger fuel pump finally, EWP80, preheating, inlet manifold modding).


Btw James, do you use tap water or distilled in your WM blend?
Good work!

Is your camshaft from colombo & bariani 272? Cnc head porting with big valves? Anybody know's the 8v jtd head are the same that 8v mjtd? I think the inlet manifols is diferent. I'm very impatient of your upgrade results.
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thanks, yep, it is. 8V JTD and JTDm heads are the same. I'm not sure about bigger inlet valves yet (neither the stock ones are small-ish). I'll get the head x-rayed first and then we'll see. Valve diameter, runners lenght and diameter, inlet manifold volume - these all should be kept proportional. I dont' want to lose low rpm power too much.

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Quote:
Originally Posted by yan.ko View Post
Sounds seem to be acceptable, will try to listen from back seat, but it's somehow impossible now :-)

Removed for cleaning, repairing the driver seat lift mechanism and laying the WM cabling.


Stripping the head for camshaft swap, head flowing and some other stuff (yeah, bigger fuel pump finally, EWP80, preheating, inlet manifold modding).


Btw James, do you use tap water or distilled in your WM blend?
nice work. I use distilled, or the cheapest bottle drinking water too.
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Headless. CR pump to go
headless.jpg

Old camshaft. Exhaust toes are pretty worn. Inlet ones only a bit.
camshaft.jpg

Head. Doesn't look bad. (btw. there's not a space for bigger inlet valves imho)
head.jpg

Simple diesel oil piston tightness test (I'm not happy a much)
test pistu.jpg

Got sidetracked a bit, I'll return to the WM installation soon, I promise :-)

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Interesting post yan.ko...

Have you ever tried to measure the compression on your engine?
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I'm going to do that after the head will be back on place.
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Good work yan.ko

Ever thought about lowering the CR ? Now you have the head off...
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Thanks JS_JTD, yep, but only by the thicker reinforced head gasket
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Continuing the installation

Almost complete - just missing last elbow
wm-1.jpg

Spare wheel compartment passage hidden behind fuel tank inlet pipe
wm-2.jpg

WM line is placed above the fuel tank
wm-3.jpg

Seems like Alfa engineers count with alternative fuel line
wm-4.jpg

Still following the fuel line
wm-5.jpg

And engine compartment routing
wm-6.jpg
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Last edited by yan.ko; 17-05-12 at 18:46. Reason: pictures relinked
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