Methanol injection systems, such as the Alky Control kit, are increasingly popular among performance enthusiasts seeking to manage intake air temperatures and improve engine efficiency. The Alky Control system is designed for precision, offering high-quality components like brass fittings and MIL spec wiring, as noted by multiple users in the forums. Installation can be tailored to various engine setups, including turbocharged and supercharged configurations. This article compiles key insights and step-by-step guidance from user experiences and installation walkthroughs, focusing on the practical aspects of installing and tuning the Alky Control methanol injection system.
Overview of the Alky Control Methanol Injection System
The Alky Control methanol injection system is a comprehensive kit that includes all necessary components for a successful installation. Users have noted the inclusion of brass fittings, high-quality wiring, and detailed instructions. The system allows for precise control over methanol flow, which can be particularly beneficial in high-temperature conditions or under heavy load. The controller features a ramping function, enabling smooth tuning of the methanol flow in relation to RPM and boost pressure. This feature is especially useful for engines with external turbos or superchargers, where intake air temperatures can rise significantly.
One user reported a notable reduction in intake air temperatures (IATs) after installing the system. Without methanol injection, IATs climbed by 34°F, whereas with the system active, the increase was only 11°F. This demonstrates the system’s effectiveness in cooling the intake charge, which can help prevent knock and improve overall engine performance. The user also noted that the system provided a boost increase of approximately 0.5 psi, possibly due to denser air or a boost controller adjustment.
Key Components and Installation Steps
The Alky Control methanol injection system includes a variety of components designed to work together seamlessly. These include the methanol tank, pump, nozzles, wiring harness, and control unit. The installation process typically involves routing the methanol lines, mounting the tank, and connecting the electrical components. Below is an overview of the key installation steps based on user reports and guides:
Preparation and Planning: Before beginning the installation, users recommend carefully reviewing the included instructions and planning the routing of the methanol lines. Some users found it helpful to install the overflow tank and reroute the lines from the radiator and charge air cooler (CAC) early in the process, allowing for easier access to other components.
Mounting the Methanol Tank: The methanol tank can be mounted in a variety of locations depending on the vehicle's layout. One user attached the tank to the bracket previously used for the airbox. This involved removing the bracket, detaching the plastic duct, and securing the tank with zip ties. This method allows for a clean installation without permanent modifications.
Installing the Nozzles: The nozzles are typically mounted on the CAC. Users have noted that the CAC’s thick aluminum construction requires careful attention to the placement of washers and the application of red loctite on the nozzle threads. A small wire mesh filter is present at the nozzle tip, and care must be taken to avoid applying loctite directly onto this component. Teflon tape is recommended for the male-male fitting to ensure a secure and leak-free connection.
Routing the Lines and Pump Installation: The methanol lines are routed from the tank to the nozzles, often passing through the inner fender area. Some users rerouted the CAC lines through this space as well. The pump is typically mounted under the battery tray, with the battery and tray removed to gain access. Users also applied aluminized heat wrap to the CAC to further insulate it from heat.
Electrical Connections: The wiring harness connects the control unit to the pump and any sensors or actuators. Users emphasized the importance of following the included instructions carefully, as some steps can be confusing, especially for those unfamiliar with electrical systems. A vacuum hose connecting pipe and a 6-foot section of 5/32” vacuum hose are often required for boost reference and intake tuning.
Controller Setup and Tuning: Once the hardware is installed, the controller must be configured. Users noted that the controller allows for tuning based on RPM and boost pressure, which can be particularly useful for tuning in real-world conditions. One user reported using a single M15 nozzle and adjusting the controller to maintain an air-fuel ratio (AF) of around 11.2 when alky is active. This approach ensures safety in the event of a system failure.
Customization and Vehicle-Specific Considerations
The Alky Control system can be adapted to various engine setups, including turbocharged, supercharged, and naturally aspirated configurations. Users have shared their experiences with different installations, highlighting the flexibility of the system. For example, one user installed the system on a C7 Corvette and provided a detailed step-by-step guide, which included photos from both the manual and their own installation. The guide emphasized the importance of patience and attention to detail, especially when dealing with the intake manifold and boost reference line.
Another user who installed the system on a CTS-V noted the differences in setup due to the factory supercharger. They had to tap into the green wire from the factory MAP sensor to provide a boost reference. This required careful routing of the vacuum hose through the firewall, with the user spending extra time ensuring the grommet was properly reamed out to avoid pinching the hose. The user also mentioned the challenge of finding the correct boost reference point, as the factory system used a check valve that only allowed vacuum to pass through.
Troubleshooting and Common Issues
Despite the high-quality components and detailed instructions, users have reported a few common issues during installation. One user noted that missing a major component early in the installation process can cause delays and confusion. They emphasized the importance of double-checking the contents of the kit before starting. Another user mentioned that some parts of the instructions were unclear, particularly regarding the boost reference line and vacuum hose routing. This highlights the value of community forums and user guides in supplementing the official instructions.
Users also reported the importance of testing the system after installation. One user conducted a test run with the methanol system active, noting the drop in AF ratio and the reduction in IATs. They emphasized the need for careful tuning to balance the benefits of methanol injection with the risk of running too rich. This is especially important in high-performance applications where engine health must be prioritized.
Advanced Tuning and Performance Benefits
Tuning the Alky Control system requires a balance between cooling effectiveness and engine performance. Users have noted that the system can be tuned to provide optimal results depending on ambient conditions, boost levels, and engine load. One user mentioned that they tuned the system to maintain an AF of 12.2 without methanol and adjusted the flow to bring it down to 11.2 when alky was active. This approach maximized cooling while minimizing the risk of running too rich, which can lead to power loss or engine damage.
The ramping function of the controller allows for smooth transitions in methanol flow as RPM and boost pressure change. This is particularly useful in turbocharged engines, where boost pressure can fluctuate rapidly. Users have reported that this feature makes it easier to achieve consistent performance without overworking the system.
Safety and Maintenance
Safety is a critical consideration when installing and using a methanol injection system. Methanol is a flammable liquid, and proper precautions must be taken to ensure that the system is installed and maintained correctly. Users have emphasized the importance of using high-quality components and following the manufacturer’s guidelines to avoid leaks or other issues. The use of Teflon tape on fittings and the application of red loctite on nozzle threads are recommended to prevent leaks.
Regular maintenance is also important to ensure the system continues to function properly. Users have noted the importance of checking the methanol lines for cracks or wear and ensuring that the pump is operating efficiently. The methanol tank should also be inspected regularly for signs of corrosion or leakage. Users who have experienced issues with the system have recommended keeping spare parts on hand, such as nozzles and washers, to facilitate quick repairs.
User Experiences and Community Support
The Alky Control system has a strong presence in online forums and user communities, where enthusiasts share their experiences and offer advice. These forums have proven to be valuable resources for users who are new to methanol injection or who are encountering challenges during installation. One user mentioned that the community support helped them overcome difficulties with the boost reference line and vacuum hose routing, which were not clearly explained in the official instructions.
Users have also shared photos and step-by-step guides, which can be particularly helpful for visual learners. These resources provide a more detailed understanding of the installation process and can help users avoid common mistakes. The collaborative nature of these forums has contributed to the overall success of many installations and has helped users achieve optimal performance from their systems.
Conclusion
The Alky Control methanol injection system offers a reliable and effective solution for managing intake air temperatures and improving engine performance. With high-quality components, detailed instructions, and a range of customization options, the system can be adapted to a variety of engine setups. Users have reported positive results, including significant reductions in IATs and improved tuning flexibility. While the installation process can be complex, especially for those unfamiliar with methanol injection systems, the availability of user guides and community support makes it more accessible to a wider range of enthusiasts.
For those considering the Alky Control system, it is important to approach the installation with patience and attention to detail. Proper planning, careful execution, and regular maintenance are essential to ensuring the system functions as intended. With the right tools and knowledge, users can enjoy the benefits of methanol injection while maintaining the safety and longevity of their engines.