COLD AIR INTAKE SYSTEM. Installation Instructions for: Part Numbers & Honda Civic EX M/T Honda Civic DX/LX M/T

Transcription

1 COLD AIR INTAKE SYSTEM Installation Instructions for: Part Numbers & Honda Civic EX M/T Honda Civic DX/LX M/T ADVANCED ENGINE MANAGEMENT INC TH Street, Unit A Hawthorne, CA Phone: (310) Fax: (310) Instruction Part Number: The applications listed are covered by at least one of the following EO numbers: 2001 Honda Civic EX M/T D17A2 C.A.R.B. E.O. #D Honda Civic EX M/T D17A2 C.A.R.B. E.O. #D Honda Civic DX/LX M/T D17A1 C.A.R.B. E.O. #D Honda Civic DX/LX M/T D17A1 C.A.R.B. E.O. #D Honda Civic DX/LX M/T D17A1 C.A.R.B. E.O. #D Honda Civic EX M/T D17A2 C.A.R.B. E.O. #D Honda Civic DX/LX M/T D17A1 C.A.R.B. E.O. #D Honda Civic EX M/T D17A2 C.A.R.B. E.O. # D Copyright 2009

2 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 under-hood 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: Bill of Materials for: Inlet Pipe Inlet Pipe Inlet Pipe Inlet Pipe Mounting Bracket Mounting Bracket Rubber Mount Rubber Mount mm Nylock Nut mm Nylock Nut x 25 x 1 Washer x 25 x 1 Washer Bolt M6 x 1 x 16mm Bolt M6 x 1 x 16mm AEM Air Filter & 2.75 AEM Air Filter & Clamp Clamp BLO Hose Clamp BLO Hose Clamp BLO Hose Clamp BLO Hose Clamp Connector Hose 2.5 x Connector Hose 2.5 x Reducer Hose 2.75 to Reducer Hose 2.75 to /8 Breather Hose /8 Breather Hose Hose Clamp Hose Clamp Rubber Grommet Rubber Grommet 2

3 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) Make sure you have the anti-theft code for the radio. d) Disconnect negative battery terminal. e) If engine has run within the past two hours let it cool down. 2) 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 is one breather hose and one Intake Air Temperature (IAT) sensor. Refer to the following diagrams for the identification of these components. (Fig. 1) b) Remove the battery cables from the fuse box, and remove the wire harness clamp from the Intake Air Duct. (Fig. 2) c) Remove the Intake Air Duct by loosening the bolt at one end and then pulling the other end up out of the mounting tab. (Fig. 3) d) Remove the two Intake Air Duct mounting tabs from the fenderwell. Remove the ground cable bolt from the transmission bracket. (Fig.3) e) Remove the four bolts securing the intake resonator and pull the intake resonator out of the car. (Fig. 4) f) Remove the bolts securing the clutch line bracket to the transmission bracket. (Fig 5) g) Disconnect the Back-Up Light Switch connector. Use a 27mm deep socket to remove the Back-Up Light Switch from the transmission. Be careful not to lose the washer. Set switch aside in a safe place. Cover the Back-Up Light Switch hole to prevent foreign objects from falling into the transmission. (Fig. 6) h) Loosen the two mounting bolts and remove the transmission bracket. (Fig. 7) Reinstall the Back-Up Light Switch and washer. i) Remove the IAT sensor connector, and then remove the breather hose. Loosen the hose clamp on the throttle body. Remove the Air Cleaner Housing by removing the two bolts securing it. (Fig. 8) j) Remove the IAT sensor from the Air Cleaner Housing by gently pulling straight back. Set the IAT sensor aside in a safe place. k) Jack the front of the vehicle and support using properly rated jack stands. 3) 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) Remove the transmission mount bracket nut closest to the front of the car. Install the AEM supplied transmission bracket over the stud and replace the nut. Refer to the picture for correct orientation. Torque the transmission mount bracket nut to 54 N-m (5.5 kgf-m, 40 lbf-ft). (Fig. 9) c) Install the 2.50 x 2 hose on to the throttle body with two 2.50 hose clam mps. d) Check to see that the inside of the AEM inlet pipes and air filter are clean and free from any foreign objects and/or obstructions. e) Place the primary intake pipe into the hose on the throttle body. The throttle body end is the end with the IAT sensor hole and breather hose nipple. f) Thread supplied washer and bolt through the inlet pipe mounting tab into the factory Intake Resonator mounting bracket. Do not tighten. (Fig. 10) g) Install the supplied 2.50 to 2.75 reducer hose on to the primary intake pipe with a 2.50 hose clamp. h) Install the supplied grommet into the IAT sensor hole in the AEM primary intake pipe. Install the IAT sensor into the grommet and plug in the IAT sensor connector. (Fig. 11) i) Install the supplied 5/8 breather hose from the nipple on the AEM primary inlet pipe to the nipple on the valve cover. Use the supplied 1 hose clamp on the AEM intake pipe nipple and the original hose clamp on the valve cover nipple. j) Attach the ground cable to the new transmission bracket using the original bolt. 3

4 k) Attach the clutch line bracket to the new transmission bracket using the supplied rubber mount. (Fig. 12) l) Place the secondary intake pipe into the reducer hose using the 2.75 hose clamp. m) Install the washer and retaining nut on to the rubber mount stud but do not tighten. Note: Please refer to the picture below for correct rubber mount installation. For Civic EX: Rubber mount threads into transmission bracket from top. For Civic LX/DX: Rubber mount threads into transmission bracket from bottom. n) Install the AEM filter on to the end of the inlet tube from underneath the car. Push the filter on around 2 inches over the inlet pipe and install one hose clamp to secure the filter onto the inlet pipe. Once fitment is checked, you can either push the filter onto the inlet pipe more or less depending on clearances. Tighten the hose clamp after this is done. o) Check that the filter is not touching any part of the vehicle. (Fig. 13) p) Position the inlet pipes for best fitment. Be sure that the pipes or any other components do not contact any part of the vehicle. Tighten the hose clamps at the throttle body and reducer coupling. Tighten the nut on the rubber mount and the bolt on the Intake Resonator mounting bracket. q) Check for proper hood clearance. Re-adjust pipes if necessary. 4) Re-assemble the vehicle a) Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are properly tight. b) Reconnect the battery cables to the fuse box. c) Start the vehicle and check for proper operation of all the components that were removed. 4

5 Note: If vehicle was started without the IAT sensor connected, 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. For Technical Inquiries Us At Reference Diagrams: Fig. 1 Fig. 2 Fig. 3 Fig. 4 5

6 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 6

7 Fig. 11 Fig. 12a: Rubber mount installation for Civic EX Fig. 12b: Rubber mount installation for Civic LX/DX Fig. 13 Fig. 14a: Installed view of Civic EX Fig. 14b: Installed view of Civic LX/DX 7