RE: PH Origins: Water injection

RE: PH Origins: Water injection

Monday 29th January

PH Origins: Water injection

Engine knocking at high boost levels? Time to sling some water down its throat. No, honestly...



The idea of injecting an incompressible, incombustible liquid into an engine appears, upon initial consideration, like an inadvisable move. After all, those who have watched a driver tackle deep water incorrectly will be familiar with the catastrophic rod-bending consequences of an engine ingesting lots of water.

Introducing a small and controlled quantity of water into an engine's intake system, however, can result in significant benefits - primarily by reducing the chance of detonation. This process, also called 'knocking', occurs once combustion has started and when temperatures and pressures in the cylinder get too high. This can cause the remaining fuel to self-ignite and burn in a rapid, uncontrolled fashion that results in a pronounced rise in pressure.

Detonation will reduce power, as it's not an efficient means of burning the mixture, but it can also cause significant damage to the engine's components if left unchecked. Feeding water into the engine's intake manifold, however, cools the incoming charge - which lowers the temperature in the cylinder, reducing the chance of detonation. When combustion starts, the water is converted to steam - a process that absorbs energy - and this further reduces peak temperatures and the occurrence of detonation.


Water injection is, as a result, a type of 'anti-detonant injection' - with other systems using a mix of water and methanol, straight methanol or other alcohols. While water injection alone is not a process that increases power, it compensates by permitting engines to be run with more aggressive compression ratios, fuel, boost or timing settings that result in higher power outputs.

The concept is by no means a recent development, with references to 'internal cooling' by water injection dating back to around 1900. It was then exploited during World War II, granting higher boost levels and reducing the chance of terminal detonation in force-fed aviation engines. It even outlived the introduction of the jet engine, as it was discovered that its use could cut temperatures and boost thrust - by increasing the mass moving through the turbine - when required.

Water injection is also particularly useful in turbocharged cars, where cylinder pressures and temperatures can easily reach excessive levels. The high-performance, twin-turbocharged BMW M4 GTS, unveiled in October 2015, was one such car that benefitted from a water injection system. BMW stated: 'It relaxes the thermal constraints on power and torque, and has already proved itself on race tracks around the world'. BMW also claimed that the M4 GTS was the 'first production road car fitted with such innovative technology'.


Back in the '80s, however, you could get an official Saab water injection system fitted to your 99 Turbo or 900 Turbo. The Saab-supplied water injection system, called the 'Sport kit', was offered for several years - the earliest official reference available is May 1981, the latest September 1988 - and it permitted higher boost levels. In the case of its use in early 900s, it granted a hike in boost pressure from 10 psi to 17.4 psi - with Saab claiming a subsequent power increase from 145bhp to 'at least' 160bhp.

The upgrade pack even included a subtle 'S' badge for the rear of your Saab, with the fitting instructions requiring you to 'loosen the 900 turbo emblem and move it a bit to the left' to create the necessary space. Some cars were even fitted with water injection as standard, including the rare 1980 Saab 900 Enduro - an Australian market special edition.


BMW's Bosch-sourced system, credit where it's due, did deliver many improvements over Saab's. In cold climates, for example, owners could use pure water without any real danger of ice-related damage. When shut down, the M4 GTS's water injection system drains its delivery lines so they will not split if freezing occurs - and the water tank is designed to withstand freezing. The system requires little maintenance as a result, unlike the Saab set-up which required the addition of methylated spirit to stop it icing up in winter conditions.

The Swedish solution also dispensed its water in front of the turbocharger and used the compressor wheel to atomise the water before it was ingested by the engine. This caused the compressor to erode over time. BMW avoided this problem by using a series of precise high-pressure injectors that spray a fine mist into the intake after the turbocharger.


It's worth noting, however, that neither Saab nor BMW were the first to equip their production cars with anti-detonant injection. If you include other forms of detonation suppression systems, which are often just referred to as 'water injection' systems, then the short-lived Oldsmobile Jetfire beat both to the punch in 1962 - as its all-aluminium 3.5-litre V8, topped with a single carburettor and a dinky AiResearch T5 turbocharger, benefitted from a water/methanol injection system.

The system was much needed, too, as the boosted V8 - destined to later be reinvented in naturally aspirated form as the Rover V8 - packed a then turbo-unfriendly compression ratio of 10.25:1. The 'Turbo-Rocket Fluid' used was effectively a 50/50 mix of distilled water and methanol; the water served primarily to cut temperatures and detonation, while the methanol increased the cooling effect of the mixture, served as additional fuel and protected against freezing.

All of this additional complexity and cost, and myriad engine-related developments, have resulted in water injection remaining relatively uncommon in production automotive applications. That said, aftermarket systems are popular in performance turbocharged petrol and diesel applications - with myriad companies, including Snow Performance, AEM, Aquamist and Nitrous Express offering various water and methanol injection set-ups.

Author
Discussion

Huskyman

Original Poster:

290 posts

59 months

Monday 29th January
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Good article, I was thinking about the Oldsmobile Jetifre when I started reading. I didn't know about SAAB's history with water injection though.

heisthegaffer

949 posts

130 months

Monday 29th January
quotequote all
I was thinking of the Mike Spence Uno Turbo featured in Autocar or Motor in the 80s.... I wanted one of those even more than a standard one!!

ogrodz

69 posts

52 months

Monday 29th January
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Do you think the Ford Focus RS is using a similar technology? Direct injection of water through the cylinder head gasket?

loose cannon

4,954 posts

173 months

Monday 29th January
quotequote all
heisthegaffer said:
I was thinking of the Mike Spence Uno Turbo featured in Autocar or Motor in the 80s.... I wanted one of those even more than a standard one!!
My friend used to have a E reg mike spence delta hf turbo with water injection and a big spoiler on the back and martini colours lovely thing it was back in the early 90’s
And was very quick

Edited by loose cannon on Monday 29th January 11:46

Prinny

919 posts

31 months

Monday 29th January
quotequote all
heisthegaffer said:
I was thinking of the Mike Spence Uno Turbo featured in Autocar or Motor in the 80s.... I wanted one of those even more than a standard one!!
Me too! my dad had one - he always liked small cars, and H990CVM was procured - one of the first mk2 UNO’s. About 1 year in, he took it there - I don’t know specifically what they did, and he’s forgotten, other than that it used the screenwash fluid - but it’d wrap the boost gauge needle off the dial. It was substantially quicker than the standard one above 40mph, and to this day, friends at the time remark on the legendary trip to the train station he took us on - it was certainly the fastest some of them had been at the time.

The guy across the road had an H.E. Jag XJS and it’d easily pull away from that going uphill out of town, as they both had lots of fun finding out. wink. (Mind you, said neighbour also had an RC30 - so he’s a star in my book forever!).

I learnt to drive in it (explains a lot - probably), but couldn’t get insured on it as a newly passed driver. I guess insurance companies aren’t that stupid! I remember that people used to try all sorts of shenanigans upon coming up to the back of the car in a 30 - and would position themselves ready to “go” when we hit NSL, to invariably have to pull back in, as we’d have disappeared up the road. Had lots of gobsmacked people asking WTF at the next junction, etc - as the mk2 Uno didn’t have any badging on the back by way of giving performance away - most people saw a learner Uno and assumed it’d be slow & pottering about - I have never driven like that...

It pottered on for a good few years (was over 100k miles with no engine issues) surprising all manner of stuff, before being half-inched one afternoon in E15, and was never seen again. frown
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FWDRacer

3,521 posts

156 months

Monday 29th January
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So in order to improve brake horse power per litre you have to negatively impact brake horsepower per tonne. Can't fault that Logic thumbuprolleyes

liner33

7,135 posts

134 months

Monday 29th January
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"While water injection alone is not a process that increases power"

So often see the opposite spouted on forums

Good read

Yipper

5,964 posts

22 months

Monday 29th January
quotequote all
Water injection can get you 1-20% extra power when used with a remap, but it can be a pain to fit and maintain and refill. Costs at least £500-1000 to buy and install professionally. It's never really taken off, for those reasons.

Fury1630

377 posts

159 months

Monday 29th January
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BMW should know all about it as one of the principle suppliers of water injected engines to the Nazis - perhaps not something they'd be keen to brag about though.

Water injection in jets is well known, the Harrier has a tank for distilled water behind the engine - a fifty gallon water tank. Lasts about five minutes when hovering.

Turbobanana

1,044 posts

133 months

Monday 29th January
quotequote all
Yipper said:
Water injection can get you 1-20% extra power when used with a remap, but it can be a pain to fit and maintain and refill. Costs at least £500-1000 to buy and install professionally. It's never really taken off, for those reasons.
Quite, although I remember reading about a homemade system when I was a teenager (so years back...) that involved a washer bottle from a breaker full of water being fed into the carb (!) by some copper tubing wrapped around the exhaust manifold to turn the water to steam.

Never tried it, unsurprisingly, but I often wonder if anyone ever did.

cossey

92 posts

121 months

Monday 29th January
quotequote all
The real reason for the renewed interest in water injection is the new emissions/fuel economy rules.

The new WLTC and RDE tests are testing the engines at much higher loads than before. The previous strategy was to go rich at high load to reduce the turbo inlet temperature, now this is not allowed a new method to cool the exhaust is needed. Hence water injection is likely to be quite common on engines >90kW/L.

The alternative is higher materials specs for the turbo which will be very expensive.
The effect on detonation is fairly minor as the engines are already using direct injection an having less issues because of it.



V8TFT

312 posts

115 months

Monday 29th January
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I had a "Devil's Own" system fitted a couple of years ago to a supercharged engine. I run it with a 50/50 Water/Meth mix. It has lowered the air intake temps and improved combustion.

toby-w8jtf

57 posts

24 months

Monday 29th January
quotequote all
Good written article...

I'm currently toying with the idea of running meth on my stage 2+ Golf R, its quite a common upgrade for the TFSI engines as it keeps the inlet and valves clean from the common carbon build up that plagues these engines, keeps the engine running clean and cool and I'm hoping for maybe 5% extra power too

rxe

1,841 posts

35 months

Monday 29th January
quotequote all
Got a Snow Performance system on my Diesel. Total PITA to fit (you've got to take a lot of the car apart to do it neatly), but it massively lowers EGTs (you can see it coming in on the display, 200C drop and with 25% methanol, seems to have a lot more grunt as well. I haven't mapped it properly yet, it just comes in gently when pressing on.

LandRoverManiac

280 posts

24 months

Monday 29th January
quotequote all
Good read - just goes to show how many 'new innovations' in the motor industry are actually anything but.

firebird350

254 posts

112 months

Monday 29th January
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Water injection has been used in many applications. Lancia fitted it to the supercharged Lancia Rally 037 during their early to mid-1980's World Rally Championship campaigns.

The Delta S4 may well have been similarly equipped.

aeropilot

15,812 posts

159 months

Monday 29th January
quotequote all
toby-w8jtf said:
Good written article...
Apart from the Rover V8 bit....... wink

It was the n/a Buick engine design which became the Rover V8, not the forced induction Olds Jetfire design.


NickGibbs

727 posts

163 months

Monday 29th January
quotequote all
cossey said:
The real reason for the renewed interest in water injection is the new emissions/fuel economy rules.

The new WLTC and RDE tests are testing the engines at much higher loads than before. The previous strategy was to go rich at high load to reduce the turbo inlet temperature, now this is not allowed a new method to cool the exhaust is needed. Hence water injection is likely to be quite common on engines >90kW/L.

The alternative is higher materials specs for the turbo which will be very expensive.
The effect on detonation is fairly minor as the engines are already using direct injection an having less issues because of it.


This sounds highly plausible. Silly question probably, but is this a solution just for petrol engines?
(Good article btw)

evilspike

4 posts

44 months

Monday 29th January
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The JDM Celica GT4 ST205 WRC (snazzy name!) had the water bag and plumbing installed at the factory for water injection into the intercooler, just needed activating.

I believe the RS Cosworth was the same, just needed connecting and turning on.

lufbramatt

2,965 posts

66 months

Monday 29th January
quotequote all
Fury1630 said:
BMW should know all about it as one of the principle suppliers of water injected engines to the Nazis - perhaps not something they'd be keen to brag about though.

Water injection in jets is well known, the Harrier has a tank for distilled water behind the engine - a fifty gallon water tank. Lasts about five minutes when hovering.
yup

https://en.wikipedia.org/wiki/BMW_801#801D-2_and_8...

Interesting that they also had to revert back to the water-methanol injection rather than injecting more fuel to cool the charge. Although it was down to a fuel shortage rather than emissions regs...