30-3350 V2 Water Methanol Injection Kit Multi Input Controller
Contents
1. 4 4 INStallavliOnGNeGKISl saicses tacit dete a taeda ha 5 6 SE xs gt 7 Proglessive Controler 8 XS Kar MSD 8 External MAP Injector Duty MAF OVervVieW cccccecccseecseeeceeeceeeeseeeseeeseueeseeeseeeeeueeseeeneeesaes 9 eee 10 INJECTOR DULY 11 S 12 FFEQUCNCY WIATE _______ ___ _ 13 PUMO TANK FIUS 14 Noz le Selecion Genesee 14 NO221 MOUNUNO 15 PUMP SV SIEM 15 15 151 162. 17 9 118 nee tea eee ree 18 terete al cece se cect see ete cee eee te cet esc ae ea eran 18 Mode Selecto 18 ____ eer eee 18 gL 19 10 1 19 circuit 19 Pc Nore Linear 19 BOOST Sale ODI OME a aaa a aa 20 Solenoid 0P IONA 20 Savas 20 ENGINS cocer E 20 Important Safety Notice Regarding 21 Cold Weather Operation 21 gt 21 Optional System Wogradesuxts 53 oda tea 22 AEM ElCCIOnICS 23 Page 2 Introduction Congratulations on your purchase of the AEM Water Methanol Injection Kit This document will help guide you through the setup and installation process Please take the time to review its contents prior to installation Pay especially close attention to any bolded text as it indicates an important note or step in the process
3. BoostSafe Enabled The external input signal was oe ee Check user selected Pump will NOT continue na found to be out of range o mode and or wiring 5 Frequency Page 16 Troubleshooting Diagram Error Flashing 3 Fallow nei ae Other Error Return to Normal Circuit Error for wiring pump to aneha 2 Flashes controller Replace Fuse with another 15 fast blow fuse Controller Fuse blown Possible Short Circuit Contact Customer most likely fror purp Support directly to grourd cut Proceed to Error Code 3 trouble shooting guide Pump Short Circuit Error 3 Flashes Check pump wiring Repair all shorts Error code 3 for shorts to chassis wire pone Return to Normal Operation 0 Contact Customer Support Check that vehicle foltage out charging sysbern is of Range Error _ 5 operating correctly 4 Flashes Check Battery for replacement Other code Return to Operation Contact Customer Support The input signal was found to be out of dode Change requency Error range Power down needed error 5 Flashes check wiring and pone after change mace if restart messecary Other Code Return to Nonmal Operation Contact Customer Support Return to Norval Operatian ow Fluid Erro
4. Before beginning installation of electronic components please disconnect the ground side of the battery This is for your safety Specifications 1 Gallon tank with integral level sensor 200 PSI injection pump Progressive pump controller with Boost Safe feature High amperage pump driver with over current over voltage and under voltage protection Error protection output with over current over voltage and over temperature protection Two system status LED indicators shows pump duty cycle and system errors Pump open and short detection and indication works even if the pump 15 off Test button that manually triggers pump Two dial pump speed control Parts List Hardware Kit Spies 1 Gallon Tank With Integral Fluid 8 111 E Level Sensor 35 2147 8 113 E 10 h x 8 5 w x 4 25 d 5843 2S0D 200 PSI Pump With Integral Fittings Progressive Injection Module Bolt Hex Head 5 16 18 x 1 25 1 2115 12 ft Wiring Harness itt 2 1 2116 8 __ Screw PanHead 8x10 13048 1 3049 1 3055 1 2537 1 3051 1 3050 1 3031 6 1 3054 Injector Nozzle 35 4546 ___ __ Jet Medium 500 cc min 35451402 ___ __ Jet Small 250 cc min 35451404 4 Jet Large 1000 a 1 1 1 1 1 Butt Connector 14 16 AWG blue 8 360 9 Butt Connector 18 22 AWG 8 361 Injector Body Ring Terminal 14 16 AWD blue 8 354 1 4 Hose Routing Strip 35 4500 20 Pag
5. PERFORMANCE ELECTRONICS Muiti input Water Methanol Injection Kit P N 30 3350 30 3351 WARNING Improper installation and or adjustment of this product can result in major engine vehicle damage Use of this injection system requires proper tuning Use this system with EXTREME caution If you are uncomfortable with anything about this please refer the installation to an AEM trained tuning shop or call 800 423 0046 for technical assistance You should also visit the AEM Performance Electronics Forum at http Wwww aempower com NOTE AEM holds no responsibility for any engine damage that results from the misuse of this product This product is legal in California for racing vehicles only and should never be used upon a highway This product is legal solely for vehicles used in competition which may never be used upon a public road or highway ADVANCED ENGINE MANAGEMENT INC 2205 126 Street Unit A Hawthorne CA 90250 Phone 310 484 2322 Fax 310 484 0152 htto www aemelectronics com Instruction Part Number 10 3350 Rev A 2013 Advanced Engine Management Inc Page 1 Contents OCU GU ON ________ ___ 3 SDC CHICAT ONS 3 hee ee ee 3 Pan 3 INOZZIG _____________ 6_ _ 6 3 UNO
6. External MAP MAF pin will depend on the desired mode of operation Please follow the table in determining where to connect this wire Mode ofoperation ___ operation Dip Switch Settings Settings Pin Installation location o MAP 0V 5V ON ON ON Connect to signal output from MAF MAP where signal range is OV 5V Injector Duty 0 100 OFF OFF Connect to the injector duty signal that is active low Multi Pulse Injection as is found on some diesel applications is NOT supported Please verify a single pulse for each injection event with an oscilloscope prior to operation 40Hz 220Hz 400Hz 2200Hz 2kHz 14kHz Please consult the factory service manual to find the appropriate wire to tap for the above connections It is acceptable to make this tap close to the sensor injector or nearer to the ECU itself whichever is more convenient Page 9 External MAP 0 5V Installation Operation The 0 5 Volt external MAP mode is designed for vehicles running high boost beyond that of the Internal and HD models or for users who already have a sensor or output of their MAP with a range of 0 5 Volts See Table 1 for compatible AEM MAP sensors a Switch Settings Setup Connection To setup your system for external MAP you must first find the correct source to connect to In order to locate the correct signal the use of a volt meter will be required Once you have located your MAP senso
7. Page 22 AEM Electronics warranty Advanced Engine Management Inc warrants to the consumer that all AEM High Performance products will be free from defects in material and workmanship for a period of twelve 12 months from date of the original purchase Products that fail within this 12 month warranty period will be repaired or replaced at option when determined by AEM that the product failed due to defects in material or workmanship This warranty is limited to the repair or replacement of the AEM part In no event shall this warranty exceed the original purchase price of the AEM part nor shall AEM be responsible for special incidental or consequential damages or cost incurred due to the failure of this product Warranty claims to AEM must be transportation prepaid and accompanied with dated proof of purchase This warranty applies only to the original purchaser of product and is non transferable All implied warranties shall be limited in duration to the said 12 month warranty period Improper use or installation accident abuse unauthorized repairs or alterations voids this warranty AEM disclaims any liability for consequential damages due to breach of any written or implied warranty on all products manufactured by AEM Warranty returns will only be accepted by AEM when accompanied by a valid Return Merchandise Authorization RMA number Product must be received by AEM within 30 days of the date the RMA 15 issued Please note that be
8. about 1 2 To determine if you do in fact have the correct wire you can try and rev the engine while monitoring the voltage It should remain the same regardless of the engine speed if you are experiencing difficulty locating the signal wire refer to the vehicles service manual to locate the MAF signal wire and then try to verify again with a voltmeter you have found the correct signal wire you may tap onto and connect it to pin 11 blue of the Water Methanol controller Testing To test your setup it is recommended you finish the installation but before installing the nozzle you run the engine and ensure the system is operating as expected That is when the engine is running and the MAF sensor is outputting in a range set by the controller you will get flow You want to ensure you are not getting flow when the engine 15 turned off or when it is not expected This could be due to improper wiring or having the incorrect mode selected Page 13 Pump Tank Flush After all wires are hooked up add water to the tank and with the hose pointed into a container press and hold the TEST push button on the controller module The TEST button can be used to test the system The pump speed will gradually increase from zero to full soeed over 3 seconds and then remain full for another 3 seconds before stopping Repeat the TEST button procedure until you are sure the system 15 free of any debris that may have been in the li
9. be used Page 15 System Errors The controller will continuously check for errors when an error is detected it will be reported to the user by a flashing sequence of the external LED as well as a corresponding red flashing sequence of the status LED Damage to vehicle or engine may occur if these faults are not resolved immediately The water injection system may not operate properly or at all while an error condition exists Please refer to the table below for further information of Flashes Description Controller Pump Status Recommended Action The amount of fluid in the BoostSafe Enabled tank has been detected Pump will continue to below the level of the sensor run 1 Low Fluid Refill fluid reservoir Pump An open circuit has been BoostSafe Enabled Check for a blown 2 Open detected in the circuit wiring Pump will NOT continue controller fuse and pump Circuit that drives the pump to run wiring for disconnects Pump A short circuit has been BoostSafe Enabled Check pump wiring for 3 Short detected in the circuit wiring Pump will NOT continue ae shorts to the chassis Circuit that drives the pump to run Woltaze The voltage powering the Check power connections controller has been detected to controller and that 4 Out of Pump will NOT continue to be outside the range of een vehicle charging system is R nes 8 5V 16V operating properly
10. cooling and combustion control Air to Air Intercooler Mass Airflow Sensor MAF Nozzle installed before the throttle plate after the MAF and any intercoolers Cooler Exhaust Gas Throttle Body Cooler Inlet Lower EGT Engine In most instances the air charge piping can be drilled and tapped for 1 8 NPT to directly mount the nozzle If using thin walled tubing it s suggested that a bung be welded to the piping Mounting hole should be tapped deep enough to allow the end of the nozzle to be nearly flush with the interior of the intake once the nozzle is fully installed Pump System Check The TEST push button on the controller module can be used to test the system Press and hold the button to activate the pump The pump speed will gradually increase from zero to full speed over 3 seconds and then remain full for another 3 seconds before stopping When the button is released the controller will return to normal operation Add water to the tank and with the nozzle pointed into a container press and hold the test button The flow will start gradually and increase to a steady amount If this happens then your system is connected properly Check and repair any leaks Drain the water out of the tank and install the nozzle Fluid Compatibility Under NO circumstances should any hydrocarbon based fuel ever be used with this system Water and Methanol are the ONLY fluids to
11. upright level position as shown below Mark the four mounting points and drill with a 3 8 bit Use the supplied 5 16 18 bolts nuts and large OD flat washers for mounting the tank into your vehicle IMPORTANT Use the supplied large OD washer to spread the load on the plastic mounting ears of the tank DO NOT OVERTIGHTEN Nuts should just be snug they are locking nuts and will not loosen Over tightening will crack the plastic and cause leaks and void the warranty j CORRECT Note All tanks are tested for leaks during assembly A special sealant adhesive is used to bond the plastic tank to the metal fitting DO NOT attempt to tighten the fitting any further 7 The pump must be located in the same area as the tank and should be mounted at or below the lowest fluid level height Page 6 Take note of the direction of flow indicated by the arrows on the pump body when mounting the pump Use four 8 sheet metal screws along with the 4 small washers or the 8 32 bolts and nylock nuts to mount the pump The pump can be mounted in any position horizontally or vertically Once the tank and pump are mounted cut the appropriate length of tubing needed to connect the outlet fitting on the tank to the inlet fitting on the pump Make sure there are no sharp bends in the tubing Cut the tubing to length with a clean perpendicular slice using a sharp razor blade making sure the ends are cle
12. ack Main ground connection connect directly to battery ground Level Switch White Connect to the white wire of the fluid tank level Level Switch Connect to the black wire of the fluid tank level injecti itched 12V Arr Switch Saag Yellow Arms injection system Connect to a switched AW source 1 E Signal O 5V injector duty MAF External Signal Blue Connect to External Signal 0 5 injector duty AW frequency Power 12V 1 Main Power Connection connect directly to positive AW battery terminal Note If fluid tank is equipped with previous generation level sensor identified by having two black wires then pins 8 white and 9 brown may be connected to either of the two black sensor wires The polarity is unimportant Note If you need to extend the wires to mount the controller use at least 16 AWG wire for the pump and controller ground circuits and 18 AWG for the remainder 10 11 2 1 External LED Install Find a suitable location in the driver s line of sight to mount the external LED Mount the LED and run the wires to the controller The LED indicates the operation of the controller If the pump is off and there are no errors the LED will be off If there are no errors and the pump is on the LED intensity will vary with the pump speed If there are any errors they will be indicated by flashing the LED Page 8 External MAP Injector Duty MAF overview The connection of the
13. an and square Push in the hose at the tank and pump to install Make sure they are pushed in all the way and check with a light tug on the hose Secure the hose to the chassis using sections of the supplied hose routing strip or with zip ties Controller Install The progressive controller is NOT waterproof and should NOT be mounted in the engine bay Find a convenient location for the controller inside the driver s compartment The adjustment knobs should remain in an accessible location but still remain protected from possible water incursion If you need to extend the wires to mount the controller use at least 16 AWG wire for the pump and controller ground circuits and 18 AWG for the remainder The controller contains an externally accessible fuse no additional fuses are required Use the supplied zip ties to mount the controller Page 7 Progressive Controller Installation Pin Description Wire Color Connection 1 Pump Ground po Connect to ground black wire of pump 20 LED AWG Gray Connect to ground black wire of external LED 20 L Violet Connect to positive red wire of external LED AWG i ional fl ienaa 20 Brown White 1 5A oe Side output Connect to optional flow contro AWG solenoid Boost Safe LS 18 1 7A Low Side output Grounded when error condition Green Out AWG exists Rien Connect to the positive red wire of pump 16 AWG 20 AWG 20 G 20 G 8 G 6 G m Ground 16 Bl
14. ar and below the lowest fluid level of tank Fasten with 4 of the 8 sheet metal screws along with the 4 small washers or the 8 32 bolts and Nylock nuts Cut supplied nylon hose with a sharp razor blade and install from tank to pump Install Controller o Disconnect ground side of battery during electronic installation Find suitable location for controller inside driver s compartment Find location in driver s field of view and install external LED Follow the wire diagram and connect wires from supplied wire harness o Connect the blue wire to external input signal O Flush Tank o Connect the remainder of hose to pump DO NOT CONNECT NOZZLE Fill Tank with Water AEM recommends using Distilled Water Turn on key power to power on controller Use Test button on controller to flush the tank into a separate container Drain tank and proceed to next step O Connect Nozzle to System o Select nozzle and connect to nylon hose o Fill tank with Water Use Test button on controller to test complete system O System Check o While pushing the Test button ensure that no errors are reported and that the system is producing a gradually increasing flow out of the nozzle o This may require pressing the Test button multiple times to purge the system o Drain tank and fill with desired Water methanol mixture DONOT use hydrocarbon fuel Water Methanol are the only supported fluids Oo Install Nozzle Find a suitable location to insta
15. e 3 Installation Diagram Controller must be mounted inside the vehicle and not in the engine Common mounting location is on the dash or in the glove box The controller is NOT waterproof ars moog AZT Waw External MAP Green Blue Gray Black LEO Violet Reo ales Wales terns Level Sencar White ewe Sener Brown 3 Connect Red Pink Red Pure Pink Pump Black Connect Black to Orange Orange 1 Pink Green BR WH Violet _ Gray Orange Red Blue Yellow Brown White Black 12 ARIE 7 Level SW NOTE THIS KIT INCLUDES NEW STYLE INJECTOR NOZZLES THAT HAVE INTERNAL CHECK VALVES AN EXTERNAL CHECK IS NO LONGER NEEDED OR INCLUDED IN THIS KIT Page 4 Installation Checklist The following list of steps is an overview of the installation process A complete and more detailed list of each step including optional peripherals is defined later in this document O Install Tank Fasten with 4 of the 8 supplied 8 sheet metal screws along with the 4 large washers or the 5 16 18 bolts and Nylock nuts Install Pump o Select suitable location for pump ne
16. ecommended you finish the installation but before installing the nozzle you run the engine and ensure the system is operating as expected That is when the engine is running and the MAF sensor 15 outputting in a range set by the controller you will get flow You want to ensure you are not getting flow when the engine is turned off or when it is not expected This could be due to improper wiring or having the incorrect mode selected Page 12 Frequency MAF Installation Operation The Frequency MAF mode 15 designed for vehicles where MAF 15 used and the output of their MAF sensor is digital and a frequency Dip Switch Settings DIP Switches Common Applications Frequency MAF OFF 1 40Hz 22082 OFF ON OF 993 and older G Frequency MAF 1990 1999 Mitsu ON 400Hz 2200Hz 1G 2G DSM Frequency MAF 1994 GM N OFF OFF 2kHz 14kHz VW 2 0T etc Setup Connection To setup your system for MAF you must first find the correct source to connect too In order to locate the correct signal the use of a voltmeter will be required Once you have located your MAF sensor you can begin to check the wires for the signal wire The signal wire should remain at or near 0 Volts when the car is turned off is not running Once the vehicle is started it should remain at or near 2 5 Volts This is because the signal has a duty cycle of 50 anda voltage range of 0 5V so the average voltage will be
17. el trigger a two step 2 or perform practically any action you choose to save your Zim Ti engine lt is PC programmable with USB connectivity mp SS which eliminates the guesswork when setting min max gt threshold parameters HIGHLY RECOMMENDED for all water methanol injection systems 40 Water Methanol Injection Flow Gauge AEM 30 5141 30 5142 Displays flow rate data on a smooth moving needle type gauge that allows you to accurately monitor the status of your injection system in real time Available in max flow rates of 500 cc min or 1000 cc min with a black or white face The AEM water methanol injection filter is HIGHLY RECOMMENDED when using this flow gauge Alf AN 70 0 200 CC MIN XN N Inline filter that uses a micronic mesh screen to filter out particles as small as 40 microns Allows a cleaner flow of water methanol into the injection pump lines and nozzles increasing overall system longevity Injection filter is HIGHLY RECOMMENDED when using i the AEM water methanol injection flow gauge Additional Nozzle Kit AEM P N 30 3012 5 5 Gallon Tank AEM 30 3010 Includes one nozzle body two jet sizes and the necessary hardware to run a second nozzle in your injection system Upgrade to a 5 gallon tank to maximize your fluid holding capacity Includes level sensor mounting hardware
18. et AFR is reached It is generally recommended that the flow rate of the injection system be changed in order to reach your target AFR and NOT your primary fueling Injection flow rate adjustments can be made by changing your nozzle selection or by adjusting the Start PSI and Full PSI settings Once the injection flow rate is set to deliver your desired final AFR boost and ignition timing can be increased to take advantage of the additional air charge cooling and detonation control When injecting the correct amount a 50 50 mix of water methanol has been shown to provide an effective octane of over 110 when using a base fuel of 91 93 octane pump gas A properly tuned water methanol injection system will usually support a typical race gas engine tune Page 20 Important Safety Notice Regarding Methanol AEM strongly recommends that users never exceed a 50 methanol concentration when using any AEM Water Methanol system or component All AEM water methanol injection systems and components pump lines fittings filter flow sensor tank and nozzles are 100 chemically compatible with methanol However for safety reasons we strongly recommend that users never use more than a 50 methanol concentration in our systems Methanol is a toxic and highly flammable chemical 100 Methanol ignites easily and burns vigorously with an almost undetectable flame Methanol can be absorbed through the skin and even small amounts can cause bl
19. fore AEM can issue an RMA for any electronic product it is first necessary for the installer or end user to contact the EMS tech line at 1 800 423 0046 to discuss the problem Most issues can be resolved over the phone Under no circumstances should a system be returned or a RMA requested before the above process transpires AEM will not be responsible for electronic products that are installed incorrectly installed non approved application misused or tampered with Any AEM electronics product can be returned for repair if it is out of the warranty period There is a minimum charge of 50 00 for inspection and diagnosis of AEM electronic parts Parts used in the repair of AEM electronic components will be extra AEM will provide an estimate of repairs and receive written or electronic authorization before repairs are made to the product Page 23
20. indness or even death Using this fluid at high pressures without dilution in an under hood environment with nylon lines and push to connect fittings is very unsafe The performance advantages of using greater than 50 methanol concentrations are small if they exist at all However the safety issues are very real and far outweigh perceived benefit of running high concentrations of methanol Note AEM holds no responsibility for any engine damage or personal injury that results from the misuse of this product including but not limited to injury or death caused by the mishandling of methanol Cold Weather Operation A Water Methanol mix will also lower the freezing point of the fluid Below is a chart with freezing points for different percentages of water methanol mixtures Methanol Concentration by Temperature volume 20 deg F Maintenance The injector nozzle should be cleaned periodically Disassemble the nozzle and clean it with a suitable cleaner until all debris is removed If excessive contamination is found check the rest of the system for the source Page 21 Optional System Upgrades Water Methanol Injection FAILSAFE Device AEM P N 30 3020 30 3020M Actively monitors the entire flow curve independent of pressure continuously collecting flow vs injection rate data so that any deviation from your established flow curve will trigger an alarm output that can be used to reduce boost or timing change maps add fu
21. le AEM Pressure Sensor Kits Page 10 Injector Duty Installation Operation The Injector Duty mode is designed for vehicles where water methanol injection rate is desired to be highly coupled to the injector duty meaning the more fuel the more water methanol This mode can be used when MAF is not available or in NA vehicles Injector duty is NOT intended to work with diesel or other multi pulse injection systems a Switch Settings Setup Connection To setup your system for injector duty you must first find the correct signal wire to connect too You must locate and tap onto one of the two wires going to the fuel injector One of the wires will be switched 12V typically red and the other will be the desired signal wire from the ECU Using a voltmeter you can determine if you have the correct signal by watching the voltage as the engine is running As duty cycle increases and more fuel injected the measured DC voltage will appear lower as viewed on a voltmeter If you have an oscilloscope or a way to measure duty cycle this is even better Once you are sure you have the correct signal you can tap on to the signal and connect that to pin 11 blue wire on the controller Testing To test your setup it is recommended you finish the installation but before installing the nozzle you run the engine and ensure the system is operating as expected That is when the engine is running you want to ensure you are not getting flow when the engi
22. ll nozzle Nozzle must be mounted before the throttle plate Nozzle should also be mounted after the MAF sensor if present Nozzle must also be mounted after any intercoolers Install nozzle follow instructions for modifying intake to accept the nozzle Cut and install nylon hose from pump to nozzle Ensure that the hose is not resting near or running on any moving or parts Oo Tune Engine Engine tuning is usually required in order to maximize potential power gain 020 0 5 Pump and Tank Install Find a suitable location to mount the tank and pump The tank should be mounted such that it is below the injection point The tank and pump must be mounted in the same area Pump may be mounted on exterior of vehicle but should be mounted away from wheel wells or other areas where it will come into direct contact with water or road debris Pump failures that have clearly been caused by exposure to water mud debris will not be covered under warranty This includes but is not limited to the bed of a truck and the inside of the fender wells Find a location where the pump will remain dry Use 4 of the 8 supplied 8 sheet metal screws along with the 4 large washers or the 5 16 18 bolts and Nylock nuts to mount the 1 gallon tank Optional 5 Gallon Tank Install Before mounting the tank check the area under the desired mounting location for fuel tanks fuel lines or any other obstructions Mount the tank in an
23. ne is turned off or is not expected This could be due to improper wiring or the incorrect mode selected Page 11 0 5V MAF Installation Operation The 0 5 Volt MAF mode 15 designed for vehicles where MAF is used and the output of their MAF sensor is 0 5V and not a frequency Dip Switch Settings DIP Switches Common Applications VW Audi 1 8T Subaru WRX STi Nissan 513 514 515 3007 Setup Connection To setup your system for MAF you must first find the correct source to connect too In order to locate the correct signal the use of a voltmeter will be required Once you have located your MAF sensor you can begin to check the wires for the signal wire The signal wire should remain at or near 0 Volts when the car 15 turned off or is not running Once the vehicle is started it should continue to remain at or near 0 however it may begin oscillate up and down slightly To determine if you do in fact have the correct wire you can try and rev the engine while monitoring the voltage If the signal rises and falls with the engine speed then you have likely identified the correct wire If you are experiencing difficulty locating the signal wire refer to the vehicle s service manual to locate the MAF signal wire and then try to verify again with a voltmeter Once you have found the correct signal wire you may tap onto and connect it to pin 11 blue of the Water Methanol controller Testing To test your setup it is r
24. nes tank Drain the water out of the tank and refer to the next section on installing the nozzle Nozzle Selection and Assembly This injection kit includes three different sized injection jets that cover a very large range of horsepower levels Use the following chart to select the appropriate jet for your power level The kit comes with one medium nozzle already preassembled it nisi aa tite wa ta N A 5 BSFC F I 7 BSFC N A 5 10psi Boost 10 25psi Boost 25 psi Boost son s 220 __ 25 zo lt 41 284 661 Nozzle 1000 1000 1000 1000 5250 7343 1836 2203 The nozzles are serviceable and can be disassembled for cleaning If you find excessive debris in the screen check your tank for contamination When installing the screen it is only necessary to be slightly tighter than finger tight Do not over tighten The nylon washers are reusable but a spare is included Nylon Washer Nozzle Body a Pintle Screen Assembly Page 14 Nozzle Mounting select the location where the nozzle will be installed Nozzle should be mounted such that it is higher than the tank Nozzle must be mounted before the throttle plate Nozzle should also be mounted after the MAF sensor if present Nozzle must also be mounted after any intercoolers In most instances mounting the nozzle 6 8 ahead of the throttle body provides excellent combination of air charge
25. r 1 Flash Re Fill Fluid Tank Level Sensor ire connected Follow Guide for Contact Customer Wiring Level Sensor Support YES lf resolving all issues and controller still fails to operate correctly please contact customer support Contact Custoner Support Page 17 Controller Settings The AEM Water Methanol Injection Controller is a progressive type controller This means that fluid will be injected in proportion to the amount of boost that is detected by the external MAP input In other words higher signal input equals more fluid It is therefore imperative that the external signal connection be made properly and securely or vehicle engine damage could occur In addition the controller will automatically compensate for any fluctuations in battery voltage variations to ensure consistent flow under all conditions The two knobs on the face of the controller dictate at what signal input minimum fluid injection starts and at what signal input maximum full fluid injection occurs Fluid injection will progressively increase between these two points as set by the adjustment knobs The Start dial has a range from 0 full counterclockwise rotation to 100 full clockwise rotation The dial has a range of 0 full counterclockwise rotation to 100 full clockwise rotation It is suggested to adjust the Start value by setting the dial to approximately 25 of the vehicles ma
26. r end of the solenoid connected to switched ignition power The solenoid should be installed after the pump and before the nozzle For best results install the solenoid close to the nozzle Non Progressive Operation optional The progressive controller is capable of operating in a non progressive manner acting as a full on or full off type system To set this the Full PSI knob must set to a lower value then the Start PSI knob This means as soon as the boost exceeds the Start PSI threshold the pump will begin pumping at its maximum flow since it has passed both the start and the full requirements Engine Tuning Water methanol injection is generally not considered a bolt on power adder for forced induction gasoline applications Engine tuning 15 usually required in order to maximize potential power gain Water methanol injection allows for a more aggressive tune to be used while still using pump gas as your base fuel With conservative boost and timing establish a base AFR that is one point higher than your final target AFR For example if your final target AFR with water methanol injection is 11 0 1 set your base AFR to 12 0 1 Once the base AFR has been set start injecting water methanol and adjust the injection flow rate to achieve your final target AFR For example if before injection your base AFR 15 12 0 1 and then during injection your AFR drops to 10 5 1 reduce the water methanol flow rate until your final targ
27. r you can begin to check the wires for the signal wire The signal wire should remain at or near 0 Volts when the car is turned off is not running Once the vehicle is started it should continue to remain at or near 0 however it may begin oscillate up and down slightly To determine if you do in fact have the correct wire you can try and rev the engine while monitoring the voltage You should observe the signal rising and falling with engine speed Please note that you may need to rev the engine high enough to put it into boost Once you have found the correct signal wire you may tap onto it if it is used by other devices or connect it directly to the Water Methanol controller Pin 11 Blue Testing To test your setup it is recommended you finish the installation but before installing the nozzle you run the engine and ensure the system is operating as expected That is when the engine is running and the MAP sensor is outputting in a range set by the controller you will get flow You want to ensure you are not getting flow when the engine 15 turned off is not expected This could be due to improper wiring or the incorrect mode selected AEM Brass Sensor Kit Stainless Steel P N Sensor Kit P N 1 Bar 15PSla 30 2131 15G 30 2130 15 2 Bar 30 PSla 30 2131 30 30 2130 30 3 5 Bar 50 PSla 30 2131 50 30 2130 50 Pressure Range 5 Bar 75 PSla 30 2131 75 30 2130 75 100 PSlg 30 2131 100 30 2130 100 Table 1 Compatib
28. ture should be used ONLY with the nozzle disconnected from the engine This is to prevent unintentional pumping of fluid into the engine To operate the test button press and hold The pump speed will gradually increase from zero to full soeed over 3 seconds and then remain full for another 3 seconds before stopping Flow should begin gradually and then hold at full pressure for a total test time of 6 seconds Short circuit self diagnostics There are two modes of pump driver short circuit protection available One can detect a short at any time but produces a slight buzzing in the pump This should not be noticeable under most conditions but can be turned off if it is objectionable If turned off a short circuit can only detected when the pump is running To enable or disable this diagnostic and the buzzing Press and hold the Test button while applying power to the controller The change is acknowledged by a single long flash of the status LED output and the external LED Once the button is released the controller will continue to function normally You can also tell what mode has been selected by listening for the buzzing sound in the pump Repeating this operation will toggle between the two modes A More Linear Flow Output Water Methanol Injection system delivers a linear flow rate as pump speed increases This is unlike competitors systems that simply have a linear pump speed drive between start and full settings
29. which results in a non linear delivery of water methanol AEM s system linearizes the flow giving you better flow control and a more progressive delivery of water methanol Competitors Flow Curve AEMs Water Methanol Injection Flow Curve 100 100 90 90 80 80 70 70 60 60 50 50 Actual Flow Actual Flow 40 40 30 30 20 20 10 10 1 5 10 15 20 30 40 50 60 70 80 90 100 10 15 20 30 40 50 60 70 80 90 100 Desired Flow Desired Flow Boost Safe Output optional The progressive controller includes a Boost Safe output grounded when active that activates whenever the system 15 armed and runs out of fluid or an error code 15 flashing The green wire on the controller is the 1 7 amp switched ground This wire can be hooked up to a solenoid that will vent waste gate pressure when activated Apply 12v to the other side of the solenoid AEM P N 30 2400 or equivalent This output can also be used to trigger a timing retard function standalone ECU or a CDI whenever the system runs out of fluid thus protecting your engine It is highly recommended that this feature be utilized Solenoid Driver optional The progressive controller includes a Solenoid output Brown with White strip wire grounded when active 1 5A max that activates whenever the system is pumping The wire should be connected to the ground side of a solenoid with the othe
30. ximum signal input Adjust the full in value to your maximum possible percent for signal input These are only suggestions improper use or setting could result in engine or vehicle damage please consult your tuner Mode Selection The mode can only be selected or changed while the unit is turned off To change the mode remove the back cover exposing the three DIP switch selectors Follow the guide on the controller to select the appropriate mode for your application STATUS AE Melectron of 1575701011 t 1800 423 0046 es MAF OV SV inj Duty 0 100 NE ae a Fe MAF 40Hz 220Hz Freq MAF 400Hz 200 2 Freq MAF 2kHz 1 Serial 4551 0001 Status LED The controller has an on board Status LED This will mimic the operation of the external LED Upon startup the current mode is flashed in green on the status LED It will flash error codes in red as well as illuminate with varying intensity as a function of flow in green Page 18 Fuse The controller has an externally accessible fuse The controller itself will turn on and function but the pump will not run without the fuse If the controller is reporting an open circuit it may be that the fuse has blown and or is not installed correctly Use a 15 amp fast blow fuse for replacement purposes Test Button The Test button feature is available to test the systems functionality This fea
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