This Mustang Parts Installation Guide Works For
Installation Time: 4 Hours
|Nitrous Management Unit||1||Red 18 Ga. Wire||10 ft.|
|10 lb. Nitrous Supply Bottle (unfilled)||1||Switch Cover||1|
|Bottle Clamp (Short)||1||5/16-18x1” Bolt||4|
|Bottle Clamp (Long)||1||5/16-18 Nut||4|
|Wet Nitrous Nozzle||1||5/16 Flat Washer||4|
|24” -3AN Braid Hose Assembly||2||8x1/2” Drill Tip/Phil Head||6|
|36” -4AN Hose Assembly||1||1/8-28 NPT RH Tap||1|
|16’ -4AN Braid Hose Assembly||1||90 Degree -4AN Swivel Adapter||1|
|.026 N20 Fuel Jet||1||1/8 NPT Bulkhead Fitting||1|
|.030 N20 Fuel Jet||1||Bulkhead Fitting Nut||1|
|.034 N20 Fuel Jet||1||Fuel Tee Fitting||1|
|.040 N20 Fuel Jet||1||-4AN to 1/8 NPT 90 Degree Fitting||1|
|.046 N20 Fuel Jet||1||-4AN to 1/16 NPT Fitting||1|
|.054 N20 Fuel Jet||1||Schrader Valve Core Tool||1|
|Arming Switch Wire Harness||1||Hose Clamp||2|
What is nitrous oxide?Nitrous oxide is a gas composed of two nitrogen atoms bonded to one oxygen atom. The scientific abbreviation for one nitrous oxide molecule is N2Owhere N is nitrogen, and O is oxygen. This is where the familiar phrase 'N-2-O' comes from when people talk about nitrous oxide.
How nitrous oxide makes power:Nitrous oxide kits make large amounts of horsepower by allowing an engine to burn more fuel. Burning more fuel creates higher cylinder pressures that will push down on the pistons with greater force. When the nitrous is injected into an engine and the initial combustion takes place, it creates enough heat to separate the nitrous oxide into its two components, nitrogen and oxygen. Once separated, the additional oxygen is then free to react with additional fuel.
To run nitrous successfully and safely, you have to introduce precise amounts of additional fuel with precise amounts of nitrous oxide.All of the extra oxygen provided by the nitrous oxide must have fuel with which to react or you may damage your engine severely. When the amount of nitrous and the amount of supplemental fuel are controlledprecisely, your engine can safely and reliably generate exceptional power increases.
Wet & dry nitrous systems:The ZEX™ Part #82023 nitrous system is a "wet" nitrous system. A "wet" nitrous system gets it¹s fuel from a connection to the engine’s fuel system. This fuel supply is then directly fed to the nitrous nozzle. This differs from a "dry" nitrous system in that a "dry" nitrous system injects the enrichment fuel through the engine’s own fuel injectors, not the nitrous nozzle.
Why our nitrous system is better:The ZEX™ nitrous system is easy to install, with all the major components, such as the solenoids, electronic throttle switch, etc. contained in an attractive enclosure. It’s a "plug and play" installation. Most current nitrous systems use a throttle arm actuated micro-switch. That means you have to fabricate a mounting bracket for the switch and adjust the placement of the switch to make it work right. Our nitrous kit utilizes a wire that you simply clip on the throttle position sensor (TPS) output voltage wire. The TPS voltage signal is sent to a programmable electronic switch that engages and disengages the system at a predetermined voltage threshold. Above the threshold determined for wide open throttle, the system activates. Below the voltage threshold, it remains dormant. The ZEX™ nitrous system’s injector nozzle is the most advanced nozzle design in the industry. The primary features are the fuel transfer tube and the self-adjusting properties of the design. The fuel transfer tube injects the enrichment fuel directly into the outer edge of the nitrous plume. This high-speed nitrous gas shears the fuel away from the tube, atomizing it to a much finer degree than other nozzle designs. This ensures perfect fuel distribution from cylinder to cylinder, especially with the higher horsepower settings. The fuel transfer tube also allows for a self-adjusting characteristic. Because a vacuum is created as the nitrous gas is being sprayed across the tube opening, as bottle pressure goes up, so does the gas speed and vacuum level. This increase in vacuum "pulls" more fuel out of the nozzle and ensures your tune-up will not go lean. This feature ensures much safer tune-ups.
How the ZEX™ Nitrous Oxide System works:The ZEX™ Part #82023 nitrous oxide injection system begins with a connection to a supply cylinder containing pressurized liquid nitrous oxide and a connection to the engine’s fuel system. These connections go to the Nitrous Management Unit, which houses the nitrous and fuel solenoids. These solenoids are normally closed, but are opened when the TPS switch senses that the nitrous system is armed and the engine is at wide-open throttle. Once these solenoids open, the nitrous and fuel are delivered to the nitrous nozzle via flexible delivery lines. The amount of nitrous and fuel that is injected through the nozzle is adjustable by means of metering jets installed in the nozzle itself. These metering jets allow for easy changes in horsepower settings.
How to adjust power levels:The ZEX™ Nitrous kit is designed for multiple power levels. These levels are controlled by metering jets installed in the nozzle’s fuel and nitrous jet fittings. To change the power output, all you need to do is install the appropriate set of jets as shown inFig.1. The correct combination of jets is listed on the tune-up sheet on the back of this instruction manual.
Work safely.Always wear eye protection and gloves when working with lines or hoses that contain pressurized nitrous oxide or fuel. Never transport nitrous cylinders loose in a trunk or the back of a pick-up truck and especially NOT within a vehicle's interior whether the cylinder is full OR empty. Always disconnect the GROUND side of the battery when working on any electrical components.
Nitrous oxide won't fix problems you already have.Before you install your nitrous system, be sure your engine is in good mechanical condition. Intermittent wiring problems, etc., can lead to erratic system performance and possible engine damage.
Never defeat the operation of the safety relief disc in the nitrous cylinder's valve stem.It's required by law and is there for your safety. Never drill, machine, weld, deform, scratch, drop, or modify a nitrous oxide tank in ANY way whatsoever!
Never overfill nitrous cylinders.That little bit extra will put you and others at risk of injury. More often than not, when the cylinder warms up, the pressure goes above the limit of the safety relief disc and you lose all the nitrous you just paid for.
All the power comes from the fuel, not the nitrous.Nitrous oxide is simply a tool that allows you to adjust how much and how quickly the engine burns the fuel. If the fuel isn’t there, the power won't be either.
Avoid detonation at all times.Nitrous enhanced detonation is much more damaging than detonation that occurs when naturally-aspirated due to the increased amount of fuel available for releasing energy and the fact that more oxygen is present.
If, when your system is activated, something doesn't feel or sound right, BACKOFF.If you hear any detonation or feel anything unusual, get off the throttle. It's a lot easier to check everything over than it is to just try to drive through it and damage expensive parts. Don't activate or have the system activated when you hit the stock rev limiter. The stock rev limiter is a fuel cut-off. If you cut fuel while you're injecting nitrous, you’re instantly very lean. This momentary lean condition has the potential of causing engine damage.
Engine modifications:The ZEX™ Nitrous System, out of the box, is designed to work as a bolt-on kit for stock or mildly modified vehicles. Mildly modified vehicles would include header upgrades, exhaust upgrades, air filter kits, etc. If major engine modifications have been performed, a fuel pump upgrade will be required for safe nitrous system operation. Major engine modifications would include turbochargers, superchargers, aftermarket cylinder heads, head porting, camshafts, intake manifolds, etc. Failure to upgrade the fuel system when using nitrous in these highly modified applications may cause serious lean conditions that can result in severe engine damage.
Spark plugs & nitrous performance:Quite often, a factory type wide-gap projected nose plug will produce a detonation condition after a few seconds of nitrous use. The detonation is not due to the heat range, it occurs because the ground strap of the spark plug becomes a glow plug instead of a spark plug. The ground strap is too long to dissipate the extra heat produced by a nitrous accelerated burn. The correct solution is to replace the plugs with units that have shorter ground straps. By doing this, you will shorten the heat path from the ground strap to the plug base. ZEX™ Hyperformance™ spark plugs are recommended for many applications.
Reading plugs & tuning the ZEX™ Nitrous Kit:If you've installed larger injectors or have otherwise increased the capacity of your fuel system, you need to read the following. Because the real limit of how much power you make with the ZEX™ Nitrous Kit is your car's fuel system, you need to tune up to that limit. Start with the lowest power level nitrous jet and corresponding fuel metering jet. Make a full throttle pass at the drag strip and read the plugs. Not enough nitrous/too much fuel results in a sooty, black plug coloration. This coloration means that the fuel mixture is too rich. Too much nitrous will exhibit high heat in the form of a bluish or rainbow-like coloring on the plug's metal surfaces. This means your engine is about to, or is, detonating. If this is observed, ensure the proper spark plugs are installed, reduce nitrous/increase fuel delivery, and ensure the proper grade of fuel is being used. When you check the spark plugs, check EVERY plug.
Don't just spot check the easiest plug you can access.Due to the wide possibility of air/fuel mixture variations, you need to check every single plug for signs of detonation or other problems. If your plugs indicate too much fuel, trim the fuel delivery down by installing a larger metering jet. If you are too lean/not enough fuel, you need to install a larger metering jet to increase fuel delivery.
Engine computer modifications:Unless provisions for retarding the ignition timing have been made, ensure that an aftermarket "chip" or a modified engine computer are NOT installed when using the ZEX™ Nitrous System. Most modified "chips" use advanced ignition curves. These advanced ignition curves can lead to detonation and severe engine damage when used with nitrous. If nitrous will be used with an aftermarket” chip", it will be necessary to install an ignition system that allows the timing to be retarded when the nitrous system is in use. In these instances, it is recommended that you retard the ignition timing 2 degrees for every 50 hp worth of nitrous used.
Clear nitrous lines after use.Close bottle valve. Use purge kit to relieve line pressure or open line fitting to let nitrous bleed off.
*Note: Ensure that the fuel connection on the Nitrous Management Unit is connected to the fuel jet fitting on the nitrous nozzle. Ensure the same for the nitrous connections.
|75 hp||100 hp||125 hp|
|Ignition Retard (deg.)||0||2||4|
Note: Premium quality fuel, 92 R/M octane or better, is required at all times for safe operation of your ZEX™ Nitrous System.