Installing and learning how an HHO System works is a rewarding experience
We have developed this simplified checklist to assure anyone can learn to install their
own HHO system, or can have the support they need for another helper or mechanic
to be successful.
This is the public access version of the Installation steps. As a customer, you are provided
with a hidden link to more comprehensive information and a large library of reference photos.
Enjoy, and take each step slowly for excellent results!
> First Step >
1) Review Components
Every HHO System comes complete with a Packing List. It's a good idea to read through the list first to make sure all the parts are included properly. However, the added benefit of reading through it is you quickly learn some basic terms that are used throughout the installation and tuning process.
Match the different components with their names, and take some time to learn the meanings of certain terms you will be using as an HHO enthusiast.
Generally the systems are presented in these following groupings:
The generator (or 'cell') will sometimes include fittings, electrical crimp connectors, and 'jumper' wires.
Water Tank and Hoses
The water reservoir tank will vary in size depending on your system. It will generally have three fittings installed on it for hoses. The hose supplied is called 'braided' PVC. The nylon braiding inside the walls makes it very strong, and PVC plastic is rated safe for hydrogen.
This pack will include the need wire of the correct thickness (called 'gauge') along with switch, circuit breaker, crimp connectors, and any related jumper wires.
The accessory pack usually contains the relay or solenoid for system activation as well as an amp gauge. These are generally considered required equipment for higher end systems.
We call them accessories so we can mix and match components and add them to our basic packages. These items can sometimes be replaced when sophisticated electronics are added, such as our PWM.
Reservoir Install Pack
This pack contains hardware to mount the cell and tank, along with components for the water supply line. We also include packets of our potassium based electrolyte.
Please continue to the next step of planning your system.
See our Glossary for more common words.
2) Locations For System Install
The first task is to find good placement for the HHO Generator and the Water Tank.
Many of the other components are fairly easy to find installation space.
The most popular space for newer cars is directly behind the front grille, and in front of the radiator. Often there is a 'vanity' panel or another type of removable plastic cover that allows access to this space. Our cells are designed to work with the restrictions of modern vehicles.
Consider you best overall location based upon visibility and heat. We obviously do not recommend installing any cell near the exhaust manifold or exhaust pipes of the vehicle. If you are planning on using the vehicle as for demonstration purposes, you may choose to install it in a very visible area to show.
Many locations exist including:
In front of the radiator and behind the front grille
Under the hood, near the firewall
Along the chassis rails, generally accessible from under the vehicle
Under the battery box
Inside fender wells
Inside the front bumper
Near windshield washer tanks
In the trunk or rear hatchback
If a truck or van:
Behind the cab
In the truck bed
In the cargo area
In the rear of the vehicle (but mounted inside a toolbox to disguise)
3) Locate and Mount the HHO Generator
We start by looking for a good location that will provide a secure mounting surface. The brackets attached to the HHO generator are very strong and can also be modified or attached to other mounting plates.
Don't worry too much about access. When running properly, the unit will need little attention. Initially it is good to be able to visually inspect it and later to make sure it's not picking up too much road dirt or debris.
When necessary, the unit can be mounted horizontally or at a slight angle. It is important to orient the 'top' output elbow so it is at the highest point possible. This allows the water level to remain high inside the cell and produce make the maximum contact with the plates.
Consider the following when choosing your mounting point:
The water reservoir tank will need to be higher than the HHO generator, as the system uses water gravity to feed the unit. Yes, this can be a small amount of difference, but the bottom of the water tank should always be higher than the top of the cell.
After you decide on your mounting location, we need to mark holes for drilling. Two bolts are adequate support, but using all four will increase its security.
After the generator is mounted, check that you are able to route and attach your hoses to each side of the unit. Also, the wires leading to it for the electricity should be able to follow a secure surface or run along with other existing harnesses.
4) Locate and Mount the Water Reservoir
The water reservoir comes in different sizes depending upon your HHO system.
Typically, it can be fit within the engine compartment, sometimes mounted flat against the firewall, but many times next to another accessory or a a right angle to open areas.
You will need to be able to 'top off' the water level after every few tanks of gas.
It is important to mount the tank higher than the HHO generator. It does not have to be much higher, but the bottom of the tank should be above the top of the fuel cell.
The tank can be mounted directly above the cell, but make sure there is good ventilation so heat does not artificially raise the operating temperature of the water or the overall system.
5) Route and Attach the Hoses
There are three hoses to consider for your system.
First, the water supply line runs from the reservoir tank to the HHO generator. Next, the return hose from the top fitting of the cell runs back to the upper fitting on the reservoir. Finally, the third line runs from the opposite top fitting on the reservoir to the HHO Dryer and on toward the engine. This engine hose has expanded instructions in the next step, but please reserve at least three feet of hose for use with this line.
Water Supply Line
The first hose to route is the water supply line that leads from the reservoir tank to the lowest fitting on the HHO generator. When running this line, also plan to install any additional items along its path including the check valve and the quick disconnect. If you choose not to use the check valve, your water tank will create 'foam' from the bubble back and you will need to purchase an anit foaming agent from a pool supply store.
HHO Return Line
As the water flows into the cell, the HHO gas is then produced and rises from the upper most fitting on the cell. This fitting should have a hose that leads back to the reservoir.
This is important because along with the HHO gas, the bubbles push water up this line. The hose needs to allow for the water to 'drip' back into the reservoir tank, allowing the gas to escape through the opposite fitting on the top of the tank.
Reservoir to HHO Dryer
We recommend this hose from water tank to the dryer be about three feet long before reaching the dryer. This is important when you 'tune' the system for optimum results. Initially if the system is running too hot or producing steam, the longer hose will allow the water to condense along the walls of the hose and not reach the engine. It also allows for a good visual inspection for troubleshooting.
6) Connect the HHO to the Air Intake System
It's important to find the 'best' connection point available for good results and a professional looking installation.
Generally on gasoline powered engines, we are looking for a point between the the air filter box and the throttle body. The throttle body is a butterfly valve that opens and closes via cables and linkage from the accelerator pedal.
The system does not require much vacuum pressure, but we do need to make sure the HHO is being pulled into the engine and not getting lost or dispersed beforehand. A hole drilled into the intake system before the throttle body is the best approach. The hole can be from 6 inches to 18 inches away depending on the amount of vacuum pressure.
Start with a test hole as close to six inches as the design of the air system will allow. If the hole seems to provide a slight vacuum pull both at idle and when accelerating the engine, go ahead and increase the size of the hole to accommodate your connector fitting.
Most modern systems are manufactured using a rubberized plastic material. This material allows you to 'screw' the connector into the hole usually without the need to thread or 'tap' the hole first. A secure fit can be accomplished without the need for any glues or adhesives.
In earlier days, people were encouraged to introduce the HHO supply line after the MAF (mass air flow) sensor. This was simply because some earlier systems would leak steam or solution into the engine and it would damage the MAF sensor. Today's Advanced HHO systems have several features to prevent water from reaching the engine, so more time can be spent on finding the perfect location to introduce the hydrogen gas.
7) Route and Connect the Electrical to the System
Wiring your system can be very intimidating at first. We believe you will do well with this single page overview as we break this section into five basic steps. Please follow them in order for best results. As questions arise, there is more support for each step available as needed.
7-1 The basic wiring concept is to run two wires from the battery to the HHO generator. The heavy gauge wire supplied is colored for the positive wiring and black for the negative (ground) wire.
Begin by finding a route for the wire to follow from the battery to the cell. It does not matter which 'tab' on the cell you use for positive or negative. (Please be sure your cell is not filled with water at this stage of installation.)
9) Initial Testing of Your HHO System
At this stage of the installation, you have conquered many of the fundamentals of HHO system installation. To be successful, it is now time to perform quality control actions to assure yourself of good results, and to make the fine tuning of the system easier.
Many obvious points should now be inspected:
Are all the fittings secure and leak free?
Recognize all the connectors are high grade fittings that can be removed and replaced with standard plumbing Teflon tape.
Are all the wires securely attached and are they running cool?
Loose wires will cause heat and shorts. Check all your crimp connections and confirm the wires are not dangling loose or touching parts of the vehicle that can melt or damage them.
Review your ignition on choice and any electronics.
Make sure your system only comes on when you want, and not when somebody puts the key in the 'accessory' position to listen to the radio. Also, if you are using an EFIE or similar electronic device, make certain its power supply is tied into the HHO system. If one turns off, they both should.
Can you notice any difference at idle?
By switching the system 'on' after the engine is started, you can notice a difference in the engine's idle speed or it becoming smoother.
Do you notice a power increase?
The number one response to these systems is 'it has much more power'. You should be able to notice this as well, and often a lower octane gasoline will run without 'knocking'.
Is the current draw staying within a predictable window?
Unless you have also installed electronics or a PWM, the amperage of the unit should start lower when it's first started and rise as the operating temperature increases. We can expect this draw to double on the high side, so start with it low and allow yourself time to see how your vehicles heat and use change this.
Are you checking the water level?
Ideally the water level should be kept between half and two thirds full. If it's too high, you run the risk of sending water to the engine, and when it's on the low side, your HHO production may decrease.
The easiest way to maintain your electrolyte is to mix your 'recipe' into a gallon jug of distilled water and keep this in the garage or in the vehicle's rear cargo area. This allows for easy topping off and keeping the solution strength consistent over time.
Welcome to the Club
Many vehicles respond quickly to the addition of HHO. Others require fine tuning the system to find the 'sweet spot' needed for that engine size. For these and a any really troublesome vehicles, we have several trouble shooting checklists to standardize results for everyone
Please see the our Frequently Asked Support Questions
Please search the knowledge base using keywords or
terms related to your question.