Manuale AEM

Instruction
Manual
P/N 30-3350
Water/Methanol Injection Kit V2
Multi-Input Controller - Ext. MAP/MAF/IDC
1-Gallon Tank
STOP!
THIS PRODUCT HAS LEGAL RESTRICTIONS.
READ THIS BEFORE INSTALLING/USING!
WARNING! THIS IS A RACE ONLY PRODUCT MANUFACTURED AND SOLD FOR INSTALLATION ON VEHICLES DESIGNED TO BE
USED SOLELY FOR COMPETITION PURPOSES. ONCE THIS PART IS INSTALLED, THE VEHICLE MAY NEVER BE USED, OR
REGISTERED OR LICENSED FOR USE, ON A PUBLIC ROAD OR HIGHWAY. IF YOU INSTALL THIS PART ON YOUR VEHICLE AND
USE THE VEHICLE ON A PUBLIC ROAD OR HIGHWAY, YOU WILL VIOLATE THE CLEAN AIR ACT AND MAY BE SUBJECT TO
PERSONAL CIVIL OR CRIMINAL LIABILITY, INCLUDING FINES OF UP TO $4,819 PER DAY.
IT IS THE RESPONSIBILITY OF THE INSTALLER AND/OR USER OF THIS PRODUCT TO ENSURE THAT IT IS USED IN
COMPLIANCE WITH ALL APPLICABLE LAWS AND REGULATIONS. IF THIS PRODUCT WAS PURCHASED IN ERROR, DO NOT
INSTALL AND/OR USE IT. THE PURCHASER MUST ARRANGE TO RETURN THE PRODUCT FOR A FULL REFUND.
THIS POLICY ONLY APPLIES TO INSTALLERS AND/OR USERS WHO ARE LOCATED IN THE UNITED STATES; HOWEVER
CUSTOMERS WHO RESIDE IN OTHER COUNTRIES SHOULD ACT IN ACCORDANCE WITH THEIR LOCAL LAWS AND
REGULATIONS.
WARNING!
Improper installation and/or adjustment of this product can result in major engine/vehicle damage. For
technical assistance visit our dealer locator to find a professional installer/tuner near you.
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.
AEM Performance Electronics

AEM Performance Electronics, 2205 126th Street Unit A, Hawthorne, CA 90250
Phone: (310) 484-2322 Fax: (310) 484-0152
http://www.aemelectronics.com
Instruction Part Number: 10-3350
Document Build 10/8/2021
2 Water/Methanol Injection
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 blindness 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 any 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.
© 2021 AEM Performance Electronics

Water/Methanol Injection 3
INTRODUCTION
Congratulations on your purchase of the AEM Water/Methanol Injection V2 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 your battery. This
is for your safety.
SPECIFICATIONS
· 1.15-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

30-3350 Contents
Parts List: Hardware Kit:
Quantity Description Part # Quantity Description Part #
20 ft High Pressure ¼” Nylon Hose 35-4500-20 36 in 3/8" High Temp Wire Wrap 8-169
1.15-Gallon Tank With Integral Fluid 6 in Edge Protector 8-111-E

1 Level Sensor 35-4542
10”h x 8.5”w x 4.25”d 1 1/8” Tee Fitting 35-2147
10 6” Zip Tie 8-113-E

5843-2S0D-
1 200 PSI Pump With Integral Fittings
B744AM Bolt, Hex Head, 1-2115
4
5/16-18 x 1.25”
Bolt, Hex Head, 1-2116
1 Progressive Injection Module 35-4551 4
8-32 x 1.5”
Screw, Pan Head, 1-3048
1 12 ft Wiring Harness 35-3451 8
#8 x 1.0"
Screw, Pan Head, 1-3049
4
#6 x 0.5"
Nut, Nylock, 5/16-18 1-3055
Injector Nozzle Kit: 4
Quantity Description Part # 4 Nut, Nylock, 8-32 1-2537
1 Atomizing Pintle, Small (250 cc/min) 35-4554-1 12 Washer, #8 x 3/4" 1-3051
1 Atomizing Pintle, Medium (500 35-4554-2 Washer, #8 x 7/16" 1-3050

4
cc/min)
1 Atomizing Pintle, Large (1000 cc/min) 35-4554-3 4 Washer, 5/16 1-3031-E
1 Nozzle Filter 35-4556 4 Washer, Fender, 5/16 1-3054
1 Nozzle Body 35-4557 1 5mm Cockpit LED 35-4505
1 35-4561 Butt Connector, 8-360

Fitting, 1/4 Tube, Cliptype 2
14-16 AWG (blue)
1 35-4562 Butt Connector, 8-361
Spring 9
18-22 AWG (red)
1 35-4563 Ring Terminal, 8-354
Check Valve 4
14-16 AWD (blue)
1 Check Valve Seal 35-4570
1 Retaining Clip 35-4565

INSTALLATION
Diagram
*Viewed from Wire Side of Connector
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.

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.
q Install Tank
o The tank must be mounted such that it is below the injection point. Failure to do
so may lead to fluid leaking into the intake tract due to gravity or siphoning,
which may result in engine damage.
o 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.
q Install Pump
o Select suitable location for pump near and below the lowest fluid level of tank.
o Fasten with 4 of the #8 sheet metal screws along with the 4 small washers or the #8-32 bolts
and Nylock nuts.
o Cut supplied nylon hose with a sharp razor blade and install from tank to pump.
q Install Controller
o Disconnect ground side of battery during electronic installation.
o Find suitable location for controller inside driver’s compartment.
o Find location in driver’s field of view and install external LED.
o Follow the wire diagram and connect wires from supplied wire harness.
o Connect the blue wire to external input signal.
q Flush Tank
o Connect the remainder of hose to pump. (DO NOT CONNECT NOZZLE.)
o Fill tank with water. (AEM recommends using distilled water.)
o Turn on key power to power on controller.
o Use TEST button on controller to flush the tank into a separate container.
o Drain tank and proceed to next step.
q Connect Nozzle to System
o Select nozzle and connect to nylon hose.
o Fill tank with water.
o Use TEST button on controller to test complete system.
q 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.
o DO NOT use a hydrocarbon fuel. Water and methanol are the only supported fluids.
q Install Nozzle
o The nozzle must be mounted such that it is above the tank. Failure to do so may
lead to fluid leaking into the intake tract due to gravity or siphoning, which may
result in engine damage.
o Find 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.
o Install nozzle, following the instructions for modifying intake to accept the nozzle.
o Cut and install nylon hose from pump to nozzle. Ensure that the hose is not resting, near, or
running on any moving or “hot” parts.
q Tune Engine
o Engine tuning is usually required in order to maximize potential power gain.

Pump and Tank Install

Find a suitable location to mount the tank and
pump. The tank must be mounted such that it is
below the injection point. Failure to do so may
lead to fluid leaking into the intake tract due to
gravity or siphoning, which may result in
engine damage. 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 1.15-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.
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.
Progressive Controller Installation
Pin # Description Wire** Color Connection
1 Pump Ground 16 AWG Orange Connect to ground (black) wire of pump.
Connect to ground (black or white) wire of external

2 LED - 20 AWG Gray
LED.
3 LED + 20 AWG Violet Connect to positive (red) wire of external LED.
1.5A Low Side output. Connect to optional flow control

4 Solenoid - 20 AWG Brown/White
solenoid.
Boost Safe LS 1.7A Low Side output, grounded when error condition
5 18 AWG Green
Out exists.
6 Pump Power 16 AWG Pink Connect to the positive (red) wire of pump.
Main ground connection. Connect directly to battery

7 Ground 16 AWG Black
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*
Arms injection system. Connect to a switched 12V

10 Arm Switch + 20 AWG Yellow
source.
Connect to External Signal (0–5V, injector duty, MAF
11 External Signal 18 AWG Blue
frequency).
Main Power Connection. Connect directly to positive
12 Power 12V 16 AWG Red
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.
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 Pin Installation location

Settings
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 OFF – ON – OFF *Connect to the frequency MAF signal.
(40Hz–220Hz)
Frequency MAF OFF – ON – ON *Connect to the frequency MAF signal.
(400Hz–2200Hz)
Frequency MAF ON – OFF – OFF *Connect to the frequency MAF signal.
(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.

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 set up 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 voltmeter is required. Once you have located your MAP sensor, check the wires
to find 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, though it may begin oscillate up
and down slightly. To determine if you do in fact have the correct wire, 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 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 it is not expected. This could be due to improper wiring or having the incorrect mode
selected.
AEM Brass Sensor Kit AEM Stainless Steel

Pressure Range
P/N 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

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.
OFF – OFF – ON
Setup, Connection:
To set up your system for injector duty you must first find the correct signal wire to connect to. You must locate
and tap on to 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 wire 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 onto
the signal and connect that to pin #11 (blue wire) on the controller.
Testing:
and ensure the system is operating as expected. That is, you want to ensure you are not getting flow when the
engine is turned off or it is not expected. This could be due to improper wiring or having the incorrect mode
selected.

0–5V MAF Installation

Operation:
The 0–5 Volt MAF mode is designed for vehicles where MAF is used and the output of their MAF sensor is 0–
5V and not a frequency.
Mode DIP Switches Common Applications
VW/Audi 1.8T
0–5 Volt ON – ON – ON Subaru WRX/STi
Nissan S13/S14/S15/300ZX
Setup, Connection:
To set up your system for MAF you must first find the correct source to connect to. In order to locate the correct
signal the use of a voltmeter is required. Once you have located your MAF sensor, check the wires to find 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, though it may begin oscillate up and down
slightly. To determine if you do in fact have the correct wire, 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:
and ensure the system is operating as expected. That is, when the engine is running and the MAF sensor is
engine is turned off or when it is not expected. This could be due to improper wiring or having the incorrect
mode selected.

Frequency MAF Installation

Operation:
The Frequency MAF mode is designed for vehicles where MAF is used and the output of their MAF sensor is
digital and a frequency.
Mode DIP Switches Common Applications

Frequency MAF
OFF – ON – OFF 1993 and older GM
(40Hz–220Hz)
Frequency MAF 1990–1999 Mitsu
OFF – ON – ON
(400Hz–2200Hz) 1G/2G DSM
Frequency MAF 1994+ GM
ON – OFF – OFF
(2kHz–14kHz) VW 2.0T, etc.
Setup, Connection:
To set up your system for MAF you must first find the correct source to connect to. In order to locate the correct
signal, the use of a voltmeter is 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 or 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% and a voltage range of 0–5V, so the average voltage will be near the middle of this range. To
determine if you do in fact have the correct wire, 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
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 it and connect it to pin #11 (blue) of the Water/Methanol
Controller.
Testing:
and ensure the system is operating as expected. That is, when the engine is running and the MAF sensor is
engine is turned off or when it is not expected. This could be due to improper wiring or having the incorrect
mode selected.

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 speed within 3 seconds and then remain full for another 3
seconds before stopping. Repeat the TEST button procedure until you are sure the system is free of any debris
that may have been in the lines or tank. Drain the water out of the tank and refer to the next section on installing
the nozzle.
Nozzle Selection
This injection kit includes three differently sized atomizing pintles that cover a very large range of horsepower
levels. Use the following chart to select the appropriate pintle for your power level. The kit comes with the 500cc
pintle already preassembled.
Fuel Flow Fuel Flow W / M Flow W / M Flow W / M Flow

W / M Flow
HP N/ A F/ I 5 –10psi 10 –25psi 25+psi
N/ A
(.5 BSFC) (.7 BSFC) Boost Boost Boost
150 788 1101 95 220 275 330
200 1050 1469 126 294 367 441
250 1313 1836 158 367 459 551
300 1575 2203 189 441 551 661
350 1838 2570 221 514 642 771 Nozzle
400 2100 2937 252 587 734 881 250
450 2363 3304 284 661 826 991 500
500 2625 3671 315 734 918 1101 1000
550 2888 4038 347 808 1010 1212 1000 + 500
600 3150 4406 378 881 1101 1322 1000 + 1000
650 3413 4773 410 955 1193 1432
700 3675 5140 441 1028 1285 1542
750 3938 5507 473 1101 1377 1652
800 4200 5874 504 1175 1469 1762
850 4463 6241 536 1248 1560 1872
900 4725 6608 567 1322 1652 1983
950 4988 6976 599 1395 1744 2093
1000 5250 7343 630 1469 1836 2203

Nozzle Assembly
The nozzles are serviceable and can be disassembled for cleaning. If you find excessive debris in the screen,
check your tank for contamination.
Assembly Instructions:
1. Select your atomizing pintle of choice using the nozzle selection table. Once you have decided on the size of
the pintle for your application, use the table below to help you identify the correct pintle.
Pintle Size 250cc 500cc 1000cc
Picture (Pintle Head)
Slot Cupped End Flat
Picture (Pintle Stem)

2. The diagram below shows the assembly/disassembly process.
IMPORTANT: Inspect the check valve and check valve seal for any damage before reassembly. Damaged
internals may cause the nozzle to leak, which could result in catastrophic engine damage.
3. In case the check valve comes apart during disassembly, the diagram below shows how the check valve
snaps together. No adhesive is required. The actual EPDM valve will not come out of the valve body.
IMPORTANT: The orientation of the EPDM o-ring is critical in preventing leaks. The o-ring has a groove on one
side, which is meant to slide over the lip of the check valve body. This provides a watertight seal.

4. If the internal components are stuck inside and cannot be easily removed, use the retaining clip to push
against the pintle through the tip of the nozzle.
IMPORTANT: If the internal components remain firmly stuck, do not use excessive force to avoid the risk of
damaging the components, which may result in nozzle failure when re-assembled. Instead, follow these steps to
allow easy removal of the internal components:
1. Remove excess fluids from nozzle to best of ability.

2. Thoroughly rinse nozzle with clean water.
3. Dry nozzle with paper towel.
4. Place nozzle in a freezer for 20 minutes to allow the internal components to contract.
5. Remove nozzle from freezer.
6. Proceed to disassemble normally.

Nozzle Mounting
Select the location where the nozzle will be installed. Nozzle must be mounted such that it is higher than
the tank. Failure to do so may lead to fluid leaking into the intake tract due to gravity or siphoning,
which may result in engine damage. 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 an excellent combination of air charge
cooling and combustion control.
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 within 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 be used.

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 Error Description Controller/Pump Status Recommended Action
The amount of fluid in the
tank has been detected to - BoostSafe Enabled
1 Low Fluid Refill fluid reservoir.
be below the level of the - Pump will continue to run
sensor.
An open circuit has been
- BoostSafe Enabled Check for a blown
Pump Open detected in the circuit
2 - Pump will NOT continue controller fuse and pump
Circuit (wiring) that drives the
to run wiring for disconnects.
pump.
A short circuit has been
- BoostSafe Enabled
Pump Short detected in the circuit Check pump wiring for
3 - Pump will NOT continue
Circuit (wiring) that drives the shorts to the chassis.
to run
pump.
The voltage powering the Check power connections
- BoostSafe Enabled
Voltage Out controller has been detected to controller and that
4 - Pump will NOT continue
of Range to be outside the range of vehicle charging system
to run
8.5V–16V. is operating properly.
The external input signal - BoostSafe Enabled

Check user selected
5 Frequency was found to be out of - Pump will NOT continue
mode and/or wiring.
range. to run

Troubleshooting Diagram

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 “Full”
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 vehicle's maximum 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 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.
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 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 system's functionality. This feature 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 speed within
3 seconds and then remain at full speed 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 be 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

AEM’s 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 setting 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.
BOOST-SAFE OUTPUT (optional)

The progressive controller includes a Boost-Safe output (grounded when active) that activates whenever the
system is armed and runs out of fluid or an error code is 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 in a 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 other 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 up the “Full PSI” knob must be 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 is 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.
Using a 50/50 mix of water/methanol is recommended for the best combination of air charge cooling and
detonation control. 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 is 12.0:1 and then during injection
your AFR drops to 10.5:1, reduce the water/methanol flow rate until your final target 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.
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
20oF 13
0oF 24
-15oF 35
-40oF 46
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.

OPTIONAL SYSTEM UPGRADES

High-Flow Low-Current WMI Solenoid – AEM P/N 30-3326
AEM’s stainless steel Water/Methanol Injection Solenoid
(PN 30-3326) eliminates any chance of water/methanol
flow into the inlet when the WMI system is not engaged.
This affordable water/methanol injection accessory
features high flow capability (3,600cc/min) and an
impressively low current draw of only 0.75A that does not
require the use of an additional relay.
Water/Methanol Injection Filter – AEM P/N 30-3003

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 the AEM
water/methanol injection flow gauge.
Additional Nozzle Kit – AEM P/N 30-3315

Includes one complete nozzle, three pintle sizes (one is
preinstalled), one retaining clip, and the necessary
hardware to run a second nozzle in your injection system.
5-Gallon Tank – AEM P/N 30-3320

Upgrade to a 5-gallon tank to maximize your fluid holding
capacity. Includes level sensor and mounting hardware.

12 MONTH LIMITED WARRANTY

AEM Performance Electronics warrants to the consumer that all AEM ELECTRONICS products will be free from defects in material and
workmanship for a period of twelve months from date of the original purchase. Products that fail within this 12-month warranty period will be
repaired or replaced when determined by AEM that the product failed due to defects in material or workmanship. This warranty is limited to
the repair or replacement, at AEM’s discretion, of the AEM Electronics part. In no event shall this warranty exceed the original purchase
price of the AEM ELECTRONICS part nor shall AEM ELECTRONICS be responsible for special, incidental or consequential damages or
cost incurred due to the failure of this product.
Warranty claims to AEM ELECTRONICS must be transportation prepaid and accompanied by 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 ELECTRONICS disclaims any liability for consequential damages due to breach of any written or implied warranty on all products
manufactured by AEM ELECTRONICS.
Warranty returns will only be accepted by AEM ELECTRONICS when accompanied by a valid Return Merchandise Authorization (RMA)
number. Product must be received by AEM ELECTRONICS within 30 days of the date the RMA is issued. UEGO oxygen sensors are
considered wear items and are not covered under warranty.
Please note that before AEM ELECTRONICS can issue an RMA for any electronic product, it is first necessary for the installer or end user to
contact the 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 an RMA requested before the above process transpires. AEM ELECTRONICS will not be responsible for
products that are installed incorrectly, installed in a non-approved application, misused, or tampered with.
Fuel Pumps installed with incorrect polarity (+&- wires crossed) will not be warranted. Proper fuel filtration before and after the fuel pump are
essential to fuel pump life. Any pump returned with contamination will not be warranted.
Any AEM ELECTRONICS product, excluding discontinued products, can be returned for repair if it is out of the warranty period. There is a
minimum charge for inspection and diagnosis of AEM ELECTRONICS parts which are out of warranty. Parts used in the repair of AEM
ELECTRONICS electronic components will be extra. AEM ELECTRONICS will provide an estimate of repairs and must receive written or
electronic authorization before repairs are made to the product.
Need additional help? Contact the AEM Performance Electronics tech department at 1-800-423-0046 or email us at
tech@aemelectronics.com.

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Instruction

AEM Performance Electronics

IMPORTANT SAFETY NOTICE REGARDING

© 2021 AEM Performance Electronics

© 2021 AEM Performance Electronics

1.15-Gallon Tank With Integral Fluid 6 in Edge Protector 8-111-E

10 6” Zip Tie 8-113-E

Quantity Description Part # 4 Nut, Nylock, 8-32 1-2537

1 Atomizing Pintle, Small (250 cc/min) 35-4554-1 12 Washer, #8 x 3/4" 1-3051

1 Atomizing Pintle, Medium (500 35-4554-2 Washer, #8 x 7/16" 1-3050

1 Nozzle Filter 35-4556 4 Washer, Fender, 5/16 1-3054

1 Nozzle Body 35-4557 1 5mm Cockpit LED 35-4505

1 35-4561 Butt Connector, 8-360

1 Retaining Clip 35-4565

© 2021 AEM Performance Electronics

*Viewed from Wire Side of Connector

© 2021 AEM Performance Electronics

© 2021 AEM Performance Electronics

Pump and Tank Install

(Optional 5-Gallon Tank Install)

© 2021 AEM Performance Electronics

© 2021 AEM Performance Electronics

1 Pump Ground 16 AWG Orange Connect to ground (black) wire of pump.

Connect to ground (black or white) wire of external

3 LED + 20 AWG Violet Connect to positive (red) wire of external LED.

1.5A Low Side output. Connect to optional flow control

Main ground connection. Connect directly to battery

Arms injection system. Connect to a switched 12V

External LED Install

External MAP, Injector Duty, MAF Overview

© 2021 AEM Performance Electronics

Mode of operation Dip Switch Pin Installation location

© 2021 AEM Performance Electronics

External MAP 0–5V Installation

Dip Switch Settings:

AEM Brass Sensor Kit AEM Stainless Steel

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

© 2021 AEM Performance Electronics

Injector Duty Installation

Dip Switch Settings:

© 2021 AEM Performance Electronics

0–5V MAF Installation

Dip Switch Settings:

Mode DIP Switches Common Applications

© 2021 AEM Performance Electronics

Frequency MAF Installation

Dip Switch Settings:

Mode DIP Switches Common Applications

© 2021 AEM Performance Electronics

Fuel Flow Fuel Flow W / M Flow W / M Flow W / M Flow

150 788 1101 95 220 275 330

200 1050 1469 126 294 367 441

250 1313 1836 158 367 459 551

300 1575 2203 189 441 551 661

350 1838 2570 221 514 642 771 Nozzle

400 2100 2937 252 587 734 881 250