Element Hydramist Water/Methanol Injection System Installation Guide

Congratulations for purchasing the finest water injection system available the Element Hydramist.  The Element Hydramist was developed from the beginning to be the ultimate water/methanol injection with uncompromised performance, control, and safety.  The Hydramist is a fully integrated water/methanol injection solution controlled via the Hydra EMS. This system allows full 3D mapping of water flow based on load and rpm, automatic map switching, and unparalleled protection never seen before in any water/methanol injection system.

The Element Hydramist can be installed with basic hand tools and requires only basic mechanical skills.  The installation however takes about 8 hours to complete so prepare your time accordingly.  Take time to perform the installation with extreme care as you are dealing with electronics, wiring, and electricity.  This is meant to be a "guide" and not a step by step manual.  If at any point you are intimidated seek the help of a professional. 

Before you begin check your parts list:

Element Hydramist Kits Include:

- 150W Hydramist Pump with 125psi By-Pass valve

- 22cc Surge Arrestor Assembly

- HSV (High Speed Water Injection Valve)

- Hydramist Waterflow Guage Kit

- Water Level Sensor

- Water Jets, 0.8mm, 0.9mm and 1mm

- Water Tank Adaptor

- Hydramist Wiring Harness

- M8 Tap (For water jet)

- 5M of 6mm High Pressure Water/Methanol Line

- 2M of 4mm High Pressure Water/Methanol Line

- Stainless 100 Micron Filter

- 40A Pump Relay

- Hydramist Wiring Diagram

Required Installation Tools Not Supplied:

 

- Assorted Metric Open Ended Wrenches

- Wire Stripper

- Wire Crimper

- Razor Blade

- Drill and Drill Bits

- 17/64 drill bit for M8 tap (M8 tap supplied)

- Screw Drivers

 

Required Parts Not Supplied:

 

- Zip Ties

- 16 ft 8 Gauge Wire (Recommendation: Car Stereo Amp Wiring Kit)

- 40 Amp Fuse

- 4 Bolts and 4 nuts

Step One:  Mounting Accumulator to Hydramist Pump

Locate the 22cc Hydramist Accumulator show below. Assembly parts as shown.

Screw the 22cc Accumulator assembly into the outlet of the Hydramist Pump.

Locate Accumulator "L" bracket and screw clamp.  Mount securely to Hydramist Pump as shown. Pay careful attention to the direction of flow.  Screw Accumulator assembly to outlet.

Step Two:  Pump Location

First begin by deciding where to mount your Hydramist pump.  Take care is selecting a location that is easy to access and has clearance to drill four holes to mount the pump.  

For our application in a race car we decided the spare tire well would be an ideal location due to the pump's weight and the clearance underneath the spare tire well for drilling 4 mounting holes.  This location is also ideal as it mounts the Hydramist pump below the water tank level in the STI.  For street applications we recommend mounting your Hydramist pump to the passenger side fender well.  Mount as low as possible but again this is a good location as there is clear area in the fender well behind the suspension strut.
Caution!

- Do not mount your Hydramist Pump in the engine bay!  This pump has a thermal cut out  above 80C!  Extreme temperatures may damage the pump!

- Do not mount your Hydramist Pump more than 6ft away from your water supply!

- Take care to inspect underneath the mounting location to prevent drilling into electronics, fuel, brakes lines, etc!

- Mount the Hydramist Pump's inlet lower than the outlet when mounting pump vertically or horizontally!

- Be sure to leave room for your power and ground wires!

- Be sure to leave room for the water/methanol lines to be installed without kinks!

 

Step Three:  Wiring the Pump and Water Line

Remove your intercooler.  
You must install your Hydramist pump's power supply directly to the car's battery to provide sufficient current and voltage to the pump.  You can purchase 8 gauge or thicker wire and relay or it's just as economical but easier to purchase a car stereo amplifier wiring kit.  If your car is already wired for an amplifier you may just a junction box to feed power to your Hydramist pump. Run the 8 gauge power cable from your car's engine bay (do not connect to car battery until entire installation is completed) through the firewall and run to the vehicle's trunk.  The location we used is an existing grommet against the driver's side firewall adjacent to the brake fluid reservoir.  Take special car to route the power cable clear of your pedal assembly!  Secure power cable with zip ties to prevent the power cable from interference.  This is also a good time to run the 6 mm high pressure Hydramist hose from the engine bay to the Hydramist pump through the same grommet.
Run your power cable and 6 mm water line to the Hydramist pump.  Install the fuse holder in line before the Hydramist pump.  Run your power cable and the Hydramist 6 mm water line along door sill.  Picture shows drivers side but the passenger side may be a better location as it will allow you to mount other electronics where your Hydra EMS resides.  Secure both with zip ties. 
From this point on you may reduce your power wire to 16 gauge to supply your relay.  A 16 gauge wire spade is supplied which you crimp on to your power cable and inserted into the 40 Amp Relay Harness.  Find a suitable mounting location for the Hydramist 40 Amp Relay and mount.  Plug your 40 Amp wire harness into your relay, install the fuse and plug into the power wire (red) connector on the Hydramist pump.  Crimp a ring terminal to your Hydramist pump's black ground wire and ground to car's chassis.  We used the pump mounting bolt to ground the pump to.

Install the 6 mm high pressure hose to the outlet of your Hydramist pump until it locks.  On the STI the OEM intercooler water sprayer tank is ideal to feed your Hydramist pump.  Simply disconnect the OEM rubber water sprayer hose at a coupler and insert your Hydramist 6 mm inlet hose about 3/4 of an inch into the rubber hose.  This feed line is not under pressure so this connection will be more than secure enough.  Press the 6 mm inlet hose into your Hydramist pump's inlet until it locks.

You must install a water level sensor for the Hydramist to function properly.  When installation is completed plug the connector into the Hydramist 40 Amp relay assembly. Drill a 22 mm hole into your water tank as low as you can go, insert the water level sensor and rubber gasket.  Tighten the nut until a leak free seal is made.

Once everything is laid out to your liking drill the 4 holes to mount your Hydramist pump.  Take extra care when drilling through the sheet metal to prevent drilling into items such as the fuel tank, brake lines, fuel lines, etc.  Insert bolts and secure with nylon locking nuts (not supplied).  Only tighten the bolts enough to secure the pump to prevent crushing the rubber mounting grommets as these isolate the chassis from pump noise.

If you own a WRX and not an STI you will need to purchase a water tank to mount in your trunk.  You can purchase the STI tank, the Spec C tank, or you can use a 1 gallon fuel cell from a JR. Dragster.  The fuel cell works very well for racers as it comes with fuel cell foam to prevent sloshing.  If you want to use your OEM windshield washer tank you may do so but make sure you do not mount your Hydramist pump in the engine bay.  You can mount it in your fender well or bumper cover area.

Step Four:  Mounting the water Jets

Drill 2 17/64 holes into the intercooler next to the throttle body outlet.  Tap both holes with the M8 tap supplied in the kit.  Since the Hydramist water jets are o-ring sealed I like to chamfer the hole to allow the o-ring to seal better.  Without a chamfer the o-ring doesn't have any support and can tear.  Be sure to remove all metal filings from inside your intercooler.  You can use compressed air or even a garden hose to completely flush out the intercooler. Select the two Hydramist jets that fit your needs.  For sub 350 whp use one .9 and one .8 mm jet.  For 350+ whp use one .9 and one 1 mm jet.  The water flow can be increased or decreased within your Hydra EMS 3D PWM Hydramist map.  Thread both jets into your intercooler.
Insert 4 mm high pressure hose onto water jets and combine with the supplied "Y" fitting.

Step Five:  Mounting the High Speed Valve and Water Flow Sensor

Locate the Hydramist High Speed Valve (HSV) and Water Flow Sensor for installation.  We decided to use zip ties to mount the HSV and Flow Sensor to the AC line.  Take note of the water flow direction of the HSV.  The Flow Sensor has not specific in or out so mount whatever way is most convenient.  Connect the HSV and Flow Sensor with a short section of 4 mm high pressure hose.  The 6 mm high pressure hose from step 3 will be inserted into the inlet of the HSV.

Locate the pins for the HSV connector and crimp them to the matching brown and red wires.  Insert the pins and wires into the HSV connector making note of wire colors.  Run wires through the firewall grommet.

Run the cable from the Water Flow Sensor through the firewall grommet also.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Step Six:  Installing the Hydramist DDS3 Display Gauge and DDS3 Junction Box

Find a suitable mounting location for the 52 mm Hydramist gauge.  This usually requires mounting in a gauge pod or roll bar mount (not supplied).  Locate the Hydramist DDS3 gauge wiring harness and strip a small amount of wire sheathing off the end (approximately 3 mm).
Locate your Hydramist DDS3 Junction Box.  Insert the Hydramist DDS3 display gauge wiring harness into the corresponding screw terminals.  Match location and wire colors and securely screw down terminals. Run the rest of your wires from your HSV, Water Flow Sensor, and Pump to your Hydramist DDS3 Junction Box.  Match location and wire colors and securely screw down terminals.
This harness pins two wires into your Hydra EMS Wiring Harness and provides the signal for map switching and PWM control of the High Speed Valve. These two pins will be inserted into the small blue Hydra connector.  Remove the dark blue locking tab with a flat blade screw driver and insert pins into the correct location.  Your Hydramist is provided with a wiring diagram.

Step Seven:  Finishing Up

Double check to make sure all your electrical connections are secure and all wires and harnesses have been plugged in to the Hydramist DDS3, Hydramist Pump, Hydramist HSV, Hydramist Water Flow Sensor, Hydramist Water Level Sensor, Hydra EMS, and Hydramist 40 Amp Relay.  Reinstall your intercooler and whatever interior panels were removed.  The final step of the installation is to connect the main power cable to the positive terminal of your car's battery.

Step Eight:  Mapping your Hydra EMS

Assign 3D PWM Map 11 as your Hydramist HSV map.  This map is load vs. RPM and the values denote duty cycle of the HSV for a given boost and rpm. The load and rpm sites are 0% to 100% and signify the minimum and maximum range in your fuel map.  So if the greatest boost level in your fuel and spark maps are 31 PSI then the 100% load site = 31 psi.  Element Tuning customers can be provided with this map.
Caution!

When a boost and rpm level is reached in this map and the HSV has a duty cycle higher than 10% this will automatically activate the Hydramist pump.  If within 2 seconds the Hydramist Water Flow sensor does not register water flow on the Hydramist DDS3 gauge the system will automatically revert back to the regular fuel and spark maps in the Hydra EMS. 

While the Hydramist is active fueling is controlled by the Fuel Auxiliary Trim Map.  This map is a function of the main fuel map.  At the desired boost and rpm point you will use this map to subtract fuel from your main fuel map.  Element Tuning customers can be provided with this map.
Caution!

It's important to reduce fuel in this map only when water flow is realized.  So if your Hydramist turns on at 10 psi do not remove fuel until after 10 psi.  This map shows 2 degrees of timing added into the idle areas.  This was used just for testing to ensure the map switching operation was functional.

While the Hydramist is active ignition timing is controlled by the Spark Auxiliary Trim Map.  This map is a function of the main spark map.  At the desired boost and rpm point you will use this map to add ignition timing to your main spark map.  Element Tuning customers can be provided with this map.
Caution!

It's important to add ignition timing into this map only when water flow is realized.  So if your Hydramist turns on at 10 psi do not add ignition timing until after 10 psi.  This map shows 2 degrees of timing added into the idle areas.  This was used just for testing to ensure the map switching operation was functional.

Step Nine:  Adjusting your Hydramist DDS3 Display Gauge

To activate your Hydramist system you must press (red) the "on" button.  When "on" the Hydramist is active and your Auxiliary Maps are enabled. If within 2 seconds of your HSV injecting water flow is not realized then the Hydra will revert to the standard fuel and spark maps.  When the Hydramist DDS3 Diplay Gauge is "off" the Hydra reverts to the standard fuel and spark maps.

W.Injection = Display's when system is on

Water Level = Illuminates when water level is low.  Pump will be turned off

Flow =  Shows flow from water flow sensor

B = Illuminates when Hydra Auxiliary Maps are enabled

SC = Adjusts the range of flow display

WL = Water flow low fault

WH = Water flow high fault

Depending on when you purchased your Element Tuning Hydra EMS your Hydra may not already be configured to run the Hydramist.  Don't worry as this can be adjusted in the software with the correct unlock pass code.  All Element Tuning customers will need to email info@elementtuning.com with your Hydra EMS serial number so we can provide you with the unlock pass code to access PWM Map 11.  Once this feature is unlocked you can upload a copy of your map and email it to use where we can insert base settings for your Hydramist.

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