Our '96 F-350 tow rig has been running like a direct-injection dream ever since it got a transmission and torque-converter upgrade ("Transmission Transition," Mar. '07). Now that it has a gearbox setup that can handle more power, we decided to add a Coolingmist Varicool water/methanol injection kit that will provide an extra kick in the passing lane, lower the EGT, and stretch our mpg while towing.
To keep an eye on our transmission temperature, boost levels, and EGT, a set of Auto Meter Ultra-Lite carbon-fiber gauges was ordered. Loren Taylor at Diesel Tech in San Jacinto, California, reserved a booth for our dualie and installed the kit and gauges while sharing some hints you may find helpful while upgrading your diesel hauler.
Diesel Tech is a shop that specializes in working on Ford diesel trucks. Loren Taylor and his crew have years of experience working in Blue Oval dealerships and keep the eight bays full of 31/44- and 1-ton trucks. | 
Auto Meter provided a triple gauge pod that fits over the factory A-pillar. It was wiped clean (to prevent chipping) and painted tan to match our truck's interior. If you perform this step first, you'll have time to apply a couple of coats that will be dry when you install the part. | 
The intake tube is thin-walled, so a threaded bung was needed to mount the injector nozzle. The intake was tapped in the middle so equal amounts of mist will be sprayed into both banks of the V-8 engine. |
The plastic intake cover was removed before the V-shaped tube that leads from the turbo to the intake was pulled off. Don't lose the O-ring that seals the intake to the turbo compressor outlet. The turbo leads directly to the engine because the first generation of 7.3L direct-injection (Power Stroke) trucks didn't come with an intercooler. This is one of the best reasons to add a liquid intercooler, such as the Coolingmist water/methanol kit. | 
A hole was drilled in the truck's toolbox so the pump and reservoir tanks could be mounted in a secure place. We installed ratchet straps to tie down the reservoir tanks so they can be used for another purpose if a towing emergency occurs. | 
The water/methanol line was run away from any sharp edges and zip-tied at multiple locations to prevent wear caused by vibrations. Electrical lines for the pump were protected with flex line before being fed through the cargo box along with the water/methanol line. |
A hole was drilled in the intake and made smooth with a grinder before the bung was welded in place. | 
(continue)Two injectors were included in the kit, and we used the one with the nozzle designed for trucks making less than 500 hp. | 
(continue)A high-flow sprayer also comes with the kit for trucks in the 500-plus-horsepower category. |