installation of AEM intake

[Anonymous]

COLD
AIR
SYSTEM

Installation Instructions for:
Part Number 21-462
2000-2003 Toyota MR-2 Spyder

 
Congratulations!  You have just purchased the finest Air Induction & Filtration system for your car at any price!
The AEM Cold Air System is the result of extensive development on a wide variety of cars.  Each system is engineered for the particular application.  The AEM Cold Air System differs from all others in several ways. We take the inlet air from outside of the engine compartment where the inlet air is considerably cooler than the hot underhood air.  The cooler inlet air temperature translates to more power during the combustion process because cool air is denser than warm air.  AEM has conducted extensive inlet air temperature studies and we have seen temperature reductions of up to 50 degrees by pulling air from outside of the engine compartment. The air mass flow to the engine is increased because of the increased airflow and reduced inlet temperature, which translates to more power. The AEM Cold Air Systems are 50 states Street Legal (some models and years still pending) and come with complete instructions for ease of installation.
Our system is constructed of lightweight aluminum and then painted with a zirconia based powder coat for superior heat insulating characteristics. The aluminum will not crack in extended use like plastic and it is actually lighter than plastic. The tube diameter and length are matched for each engine to give power over a broad rpm range. Unlike the plastic systems that use a continually diverging cross section, we take advantage of the acoustical energy in the duct to promote cylinder filling during the intake valve-opening event.
Our Dyno testing as well as independent dyno tests (see 7/97 Sport Compact Car Magazine) prove that the AEM Cold Air System produces as much as twice the power gain than any other system on the market.



Bill of Materials for: 21-462                  
1   2-471   Inlet Pipe
1   21-201   2.50" AEM Air Filter
1   30217   2.75" 90 Degree Elbow
2   103-BLO-4420   2.75" Hose Clamp
18   65116   Breather Hose 1/2"
2   99024.032   1" Hose Clamp
2   1-2028   Bolt M4 x .7 x 20mm
1   1-2030   Bolt M6 x 1 x 16mm
3   444.460.04   6mm Nut
1   559999   6 x 25 x 1 Washer
1   1228599   Rubber Mount
1   10-276   Instructions
1   10-400W   License Plate Frame
2   10-922S   Decal, AEM Silver         





Read and understand these instructions BEFORE attempting to install this product.

Note:  This inlet pipe kit requires the removal and reinstallation of emissions related components.  If you are not familiar with the installation and/or the operation of these components then please refer this installation to a qualified professional.

1)   Getting started
a)   Make sure vehicle is parked on a level surface.
b)   Set parking brake.
c)   Disconnect negative battery terminal.
d)   If engine has run within the past two hours let it cool down.
2)   Removing the rear suspension upper brace
a)   Loosen the two nuts and two bolts securing the rear suspension upper brace. Remove the rear suspension upper brace from the car a set aside in a safe place.
3)   Removing the rear bumper cover-This step may require two people
a)   Remove the taillights by loosening the two bolts on each light assembly and disconnecting the wire connector. Set the taillights aside in a safe place.
b)   Remove the license plate and license plate frame.
c)   Remove the bolts on the underside of the bumper that attach the bumper cover to the rear engine under cover. Allow the rear engine under cover to hang freely.
d)   Remove the bolt from inside the wheel well, one on each side. (Fig. 1)
e)   Remove the bumper cover bolts in the taillight openings, two on each side. (Fig. 2)
f)   Remove clips from the top edge of the bumper cover.
g)   Put a blanket under the bumper cover to protect the paint.
h)   Pull back the bumper cover far enough to allow access to the license plate lights. Remove the license plate lights from the bumper cover by twisting the socket counter-clockwise and pulling the socket from the bumper cover. BE CAREFUL NOT TO LET THE BUMPER COVER FALL BEFORE REMOVING THE LICENSE PLATE LIGHTS.
i)   Guide the sides of the bumper cover around the wheel well splashguards and remove bumper cover from vehicle. Set the bumper cover aside in a safe place.
4)   Removing the stock air inlet system
a)   Before removing any of the O.E. components, label each individual part so that no components become mixed up during the installation process.  There are two Vacuum Switching Valves (VSV), and one air flow meter that have electrical and/or vacuum connections going to them.  Be sure to label these connections before disconnecting them.  Refer to the following diagrams for the identification of these components. (Fig.3)
b)   Remove the air flow meter connector, then remove the air flow meter by loosening the two phillips screws.  Be extremely careful with this component as it can be damaged easily.  Set the air flow meter aside in a safe place.
c)   Disconnect the wire connector and the two vacuum lines from the Vacuum Switching Valve (VSV) for EVAP on the stock intake air hose. Loosen the hose clamp at the throttle body end of the intake air hose.
d)   Disconnect and remove the vacuum line between the VSV for Canister Closed Valve and the stock intake pipe.  Disconnect the vacuum line between the VSV for CCV and the metal hard line.  This hose will be reused upon installation of the AEM CAS.  Remove the wire connector from the VSV for CCV.
e)   Release the two clips on the front side of air cleaner cap assembly.  Pull the air cleaner cap assembly and the intake air hose out of the vehicle with the two VSV 's still attached.
f)   Remove the bolt holding the air cleaner lower case in place. Remove the plastic screw on the intake tube located under the radiator overflow tank. (Fig. 4) Remove the air cleaner lower case assembly.
g)   Remove the VSV for EVAP from the stock intake air hose by pulling the metal bracket out of the plastic intake air hose.  Remove the VSV for CCV from the air cleaner cap assembly by removing the mounting bolt. (Fig. 5) Set these components aside in a safe place.
5)   Installing the AEM Cold Air Intake
a)   When installing the Cold Air Intake System, DO NOT completely tighten the hose clamps or mounting tab hardware until instructed to do so later in these instructions.
b)   Install the 90 degree elbow coupling onto the throttle body with the two hose clamps.
c)   Thread one end of the rubber mount into the underside of the rear core support. Use the hole that was originally used for the bumper cover mounting screw. (Fig. 6)
d)   Check to see that the inside of the AEM inlet pipe and air filter are clean and free from any foreign objects and/or obstructions.
e)   Feed the pipe up into the engine compartment from the rear of the vehicle. The throttle body end of the pipe is the end with the air flow meter adapter. (Fig. 7)
f)   Insert the inlet pipe into the 90 degree coupling on the throttle body.
g)   Install the washer and retaining nut onto the rubber mount stud but do not tighten.


h)   Install the AEM filter on to the end of the inlet tube.  Push the filter on around 2 inches over the inlet pipe and install one hose clamp to secure the filter on to the inlet pipe.  Once fitment is checked, you can either push the filter on to the inlet pipe more or less depending on clearances.  Tighten the hose clamp after this is done.
i)   Mount the VSV for CCV onto the mounting tab on the AEM inlet pipe using the supplied M6 bolt and nut.  Run the 18" section of vacuum hose, supplied in the kit, between the bottom of the VSV for CCV and the nipple on the inlet pipe. (Fig.  s8) s8)  Secure both ends of the vacuum hose with hose clamps. Reconnect the vacuum line between the VSV for CCV and metal hard line removed in step 4d.  Reconnect the VSV for CCV wire connector.
j)   Using a very small amount of lubricant on the o-ring, install the air flow meter into the inlet pipe, then reconnect the air flow meter connector.  Use the two M4 bolts that are supplied in the kit to secure the air flow meter.  Be sure that the O-ring on the air flow meter is seated correctly in the air flow meter adapter.   BE CAREFUL DO NOT OVER TORQUE THESE BOLTS.
k)   Mount the VSV for EVAP and bracket to the mount on the AEM inlet pipe using the M6 bolt that was originally used to hold the bumper cover on. This bolt has been replaced by the supplied rubber mount and nut. Reconnect the two VSV for EVAP vacuum lines and wire connector. (Fig. 9)
l)   Position the inlet pipe for best fitment. Be sure that the pipe or any other components do not contact any part of the vehicle. Tighten the hose clamps at the throttle body and then tighten the nut on the rubber mount.
m)   Check for proper hood clearance.  Readjust pipe if necessary.
n)   Start vehicle and check for proper operation of all the components that were removed.
i)   Note:  If vehicle was started without one of the VSV's or the air flow meter connected then the "Check Engine" light may come on.  If this happens turn the engine off and disconnect the battery for one minute.  Reconnect the battery and restart the engine.
o)   Install bumper cover and taillights in reverse order of removal. Use the supplied M6 nut to secure the bumper cover to the exposed stud of the rubber mount. (Fig. 10)


I got pics as well but i havent anywhere to post them, any1 got any space???

Got this from TDI they have install this on a few sypders and have had a lot of sucsess, gains range from 3-9 bhp gains, Havent had prices of yet tho