AEM 30-3350 Operating and safety instructions

ADVANCED ENGINE MANAGEMENT INC.
2205 126th Street Unit A, Hawthorne, CA. 90250
Phone: [phone] Fax: [phone]
http://www.aemelectronics.com
Instruction Part Number: 10-3350 Rev A
2013 Advanced Engine Management, Inc
Page 1
Multi-Input Water/Methanol
Injection Kit
P/N 30-3350, 30-3351, 30-3352
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
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://www.aempower.com
NOTE: AEM holds no responsibility for any engine damage that
results from the misuse of this product!

Page 2
Contents
Introduction...................................................................................................................................3
Specifications ...............................................................................................................................3
Hardware Kit: ............................................................................................................................3
Parts List:..................................................................................................................................3
Injector Nozzle Kit:....................................................................................................................3
Installation ....................................................................................................................................4
Diagram ....................................................................................................................................4
Installation Checklist .................................................................................................................5
Pump and Tank Install ..............................................................................................................6
Controller Install........................................................................................................................7
Progressive Controller Installation.............................................................................................8
External LED Install...................................................................................................................8
External MAP, Injector Duty, MAF overview .............................................................................9
External MAP 0-5V Installation................................................................................................10
Injector Duty Installation..........................................................................................................11
0-5V MAF Installation..............................................................................................................12
Frequency MAF Installation ....................................................................................................13
Pump/Tank Flush....................................................................................................................14
Nozzle Selection and Assembly..............................................................................................14
Nozzle Mounting .....................................................................................................................15
Pump/System Check...............................................................................................................15
Fluid Compatibility...................................................................................................................15
System Errors.............................................................................................................................16
Troubleshooting Diagram........................................................................................................17
Controller....................................................................................................................................18
Settings...................................................................................................................................18
Mode Selection .......................................................................................................................18
Status LED..............................................................................................................................18
Fuse........................................................................................................................................19
“Test” Button ...........................................................................................................................19
Short circuit self-diagnostics ...................................................................................................19
A More Linear Flow Output.........................................................................................................19
Boost-Safe Output (optional) ......................................................................................................20
Solenoid Driver (optional)...........................................................................................................20
Non-Progressive Operation (optional) ........................................................................................20
Engine Tuning ............................................................................................................................20
Important Safety Notice Regarding Methanol.............................................................................21
Cold Weather Operation.............................................................................................................21
Maintenance...............................................................................................................................21
Optional System Upgrades.........................................................................................................22
AEM Electronics warranty...........................................................................................................23

Page 3
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.
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 is off
Test button that manually triggers pump
Two dial pump speed control
Hardware Kit:
35-4512HW
Quantity
Description
Part #
36 in
3/8" High Temp Wire Wrap
8-169
6 in
Edge Protector
8-111-E
1
1/8” Tee Fitting
35-2147
10
6” Zip Tie
8-113-E
4
Bolt, Hex Head, 5/16-18 x 1.25”
1-2115
4
Bolt, Hex Head, 8-32 x 1.5”
1-2116
8
Screw, Pan Head #8 x 1.0"
1-3048
4
Screw, Pan Head #6 x 0.5"
1-3049
4
Nut, Nylock, 5/16-18
1-3055
4
Nut, Nylock, 8-32
1-2537
12
Washer, #8 x 3/4"
1-3051
4
Washer, #8 x 7/16"
1-3050
4
Washer, 5/16
1-3031-E
4
Washer, Fender, 5/16
1-3054
1
5mm Cockpit LED
35-4505
2
Butt Connector, 14-16 AWG (blue)
8-360
9
Butt Connector, 18-22 AWG (red)
8-361
4
Ring Terminal, 14-16 AWD (blue)
8-354
1
1/4" Hose Routing Strip
35-4500-20
Parts List:
Quantity
Description
Part #
20 ft
High Pressure ¼” Nylon Hose
35-4500-20
1
1 Gallon Tank With Integral Fluid
Level Sensor
10”h x 8.5”w x 4.25”d
35-4542
1
200 PSI Pump With Integral Fittings
5843-2S0D-
B744AM
1
Progressive Injection Module
35-4551
1
12 ft Wiring Harness
35-3451
Injector Nozzle Kit:
35-4546
Quantity
Description
Part #
1
Jet, Medium (500 cc/min)
35-4514-02
1
Jet, Small (250 cc/min)
35-4514-04
1
Jet, Large (1000 cc/min)
35-4514-05
1
Nylon Washer
35-4517
1
Injector Body
35-4515-2
1
H2O Nozzle
35-4545

Page 4
Installation
Diagram
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 5
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.
□Install Tank
oFasten 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
oSelect suitable location for pump near and below the lowest fluid level of tank.
oFasten with 4 of the #8 sheet metal screws along with the 4 small washers or the
#8-32 bolts and Nylock nuts.
oCut supplied nylon hose with a sharp razor blade and install from tank to pump.
□Install Controller
oDisconnect ground side of battery during electronic installation.
oFind suitable location for controller inside driver’s compartment.
oFind location in driver’s field of view and install external LED.
oFollow the wire diagram and connect wires from supplied wire harness.
oConnect the blue wire to external input signal
□Flush Tank
oConnect the remainder of hose to pump. (DO NOT CONNECT NOZZLE)
oFill Tank with Water (AEM recommends using Distilled Water).
oTurn on key power to power on controller.
oUse Test button on controller to flush the tank into a separate container.
oDrain tank and proceed to next step.
□Connect Nozzle to System
oSelect nozzle and connect to nylon hose.
oFill tank with Water.
oUse Test button on controller to test complete system.
□System Check
oWhile pushing the Test button ensure that no errors are reported and that the
system is producing a gradually increasing flow out of the nozzle.
oThis may require pressing the Test button multiple times to purge the system.
oDrain tank and fill with desired Water/methanol mixture.
oDO NOT use a hydrocarbon fuel. Water/Methanol are the only supported fluids
□Install Nozzle
oFind a suitable location to install 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.
oInstall nozzle, follow instructions for modifying intake to accept the nozzle.
oCut and install nylon hose from pump to nozzle. Ensure that the hose is not
resting, near, or running on any moving or “hot” parts.
□Tune Engine
oEngine tuning is usually required in order to maximize potential power gain.

Page 6
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 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.
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!
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 7
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 clean 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 8
Progressive Controller Installation
Pin #
Description
Wire**
Color
Connection
1
Pump Ground
16
AWG
Orange
Connect to ground (black) wire of pump.
2
LED -
20
AWG
Gray
Connect to ground (black) wire of external LED.
3
LED +
20
AWG
Violet
Connect to positive (red) wire of external LED.
4
Solenoid -
20
AWG
Brown/White
1.5A Low Side output. Connect to optional flow control
solenoid.
5
Boost Safe LS
Out
18
AWG
Green
1.7A Low Side output. Grounded when error condition
exists.
6
Pump Power
16
AWG
Pink
Connect to the positive (red) wire of pump.
7
Ground
16
AWG
Black
Main ground connection, connect directly to battery
ground.
8
Level Switch+
20
AWG
White
Connect to the white wire of the fluid tank level sensor*
9
Level Switch-
20
AWG
Brown
Connect to the black wire of the fluid tank level sensor*
10
Arm Switch +
20
AWG
Yellow
Arms injection system. Connect to a switched 12V
source.
11
External Signal
18
AWG
Blue
Connect to External Signal. (0-5V, injector duty, MAF
frequency)
12
Power 12V
16
AWG
Red
Main Power Connection, connect directly to positive
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.
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 9
External MAP, Injector Duty, MAF overview
The connection of the External MAP/MAF pin will depend on the desired mode of operation.
Please follow the table in determining where to connect this wire.
Mode of operation
Dip Switch Settings
Pin Installation location
MAF / MAP (0V-5V)
ON –ON –ON
*Connect to signal output from MAF/MAP where signal
range is 0V-5V.
Injector Duty (0%-100%)
OFF –OFF –ON
*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.
Frequency MAF
(40Hz - 220Hz)
OFF –ON –OFF
*Connect to the frequency MAF signal.
Frequency MAF
(400Hz –2200Hz)
OFF –ON –ON
*Connect to the frequency MAF signal.
Frequency MAF
(2kHz –14kHz)
ON –OFF –OFF
*Connect to the frequency MAF signal.
*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 10
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.
Dip Switch Settings:
ON –ON –ON
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 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 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. 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 is turned off or is not expected. This
could be due to improper wiring or the incorrect mode selected.
Pressure Range
AEM Brass Sensor Kit
P/N
AEM Stainless Steel
Sensor Kit P/N
1 Bar / 15PSIa
30-2131-15G
30-2130-15
2 Bar / 30 PSIa
30-2131-30
30-2130-30
3.5 Bar / 50 PSIa
30-2131-50
30-2130-50
5 Bar / 75 PSIa
30-2131-75
30-2130-75
100 PSIg
30-2131-100
30-2130-100
Table 1 –Compatible AEM Pressure Sensor Kits