COLD AIR INTAKE SYSTEM. Installation Instructions for: Part Number Mitsubishi Lancer Ralliart Manual Transmission Only

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1 COLD AIR INTAKE SYSTEM Installation Instructions for: Part Number Mitsubishi Lancer Ralliart Manual Transmission Only ADVANCED ENGINE MANAGEMENT INC TH Street, Unit A Hawthorne, CA Phone: (310) Fax: (310) Instruction Part Number: Mitsubishi Lancer Ralliart 2.4L C.A.R.B. E.O. #pending Cold Air Intake Systems that are pending CARB approval are illegal in California except on racing vehicles which may never be used on public highways. Copyright 2005

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 model 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. Bill of materials for: Quantity Part Number Description Upper Intake Pipe Lower Intake Pipe BLO-4420 #44 Hose Clamp " Reinforced Coupler Rubber Mount 1" X 8MM mm Nylok Nut mm Flat Washer ½ Duck-bill drain ¾ Hose Clamps x5 Air Filter 12" /8" Breather Hose Maf Bolts 8-32 x 1/2" " Zip Ties, Tree-Push Instructions S AEM Silver Decal W License Plate Frame 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 both positive and negative battery terminals. 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. b) Remove plastic intake duct from the front of the engine by removing the plastic clips and pulling the duct straight forward. To remove the clips, use a pointed device and push in the middle of the clips. Throttle Cable c) Remove the breather hose from the valve cover by pulling it off. d) Unclip the throttle cable from the side of the air filter housing. 3

4 e) Unclip the Mass Air Flow (MAF) sesnor wiring harness from the air filter housing. These clips can be removed undamaged from the harness using a small flat head screwdriver. f) Unscrew the Inlet tube from the throttle body and pull the inlet tube off the throttle body. g) Unplug the MAF sensor from the engine harness. h) Remove the two bolts securing the stock air filter housing to the engine bay. Remove the air filter housing and the inlet tube. i) Remove the two bolts securing the MAF sensor to the air filter housing and remove the MAF sensor. Be careful not to damage the sensor. j) Unclip the wiring harness from the air box bracket behind the batery. 4

5 k) Remove the three bolts securing the air box bracket to the car. Remove the bracket. l) Remove the splash shields attached to the bottom of the bumper on the driver s side. Remove the splash shield separating the engine bay from the inner fender area by removing the three plastic retaining clips. 3) Installing the AEM CAS Intake 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. a) Remove the driver s side bolt securing the slave cylinder bracket to the transmission. Thread in the supplied rubber mount as shown. b) Check to see that the inside of the AEM CAS upper inlet pipe and air filter are clean and free from any foreign objects and/or obstructions. Install the 2.75 silicone coupler over the throttle body end of the pipe using the 2.75 hose clamp. 5

6 c) Install the previously removed MAF sensor into the upper intake pipe using the two supplied Allen bolts. d) Slide coupler attached to the upper intake pipe over the throttle body using the supplied 2.75 hose clamp. Attach silicone coupler to this end Filter end of lower intake pipe e) Check to see that the inside of the AEM CAS lower inlet pipe and air filter are clean and free from any foreign objects and/or obstructions. Install the 2.75 silicone coupler over the end of the pipe using the 2.75 hose clamp. f) Install the supplied duck-bill drain into the ½ hole on the lower intake pipe. This drain prevents water from building up in the bottom of the intake pipe due to the angle in which the filter is placed. 6

7 g) Attach the upper and lower pipes together with the coupler installed in the previous step. Note: If installing AEM Air Bypass Valve, cut off exactly 1 from the end of the upper intake pipe. Next cut exactly 5/8 from the end of the lower intake pipe. h) Align the intake mounting bracket with the rubber mount installed in step 2a. Secure using the supplied washer and Nylok nut. Be sure that the bracket and intake are not in contact with the clutch lines or slave cylinder. Hose clamp i) Install the AEM filter on to the end of the inlet tube. Push the filter over the inlet pipe until the stop in the filter is reached and install one hose clamp to secure the filter onto the inlet pipe. Once fitment is checked, tighten the hose clamp. j) Plug in the MAF sensor and secure the wiring harness using the supplied tree mount zip tie. Install the supplied 3/8 breather hose onto both the valve cover nipple and the pipe nipple. Use the supplied ¾ hose clamps to secure. Trim for proper fitment. Secure the throttle cable using the supplied tree mount zip tie. Trim the excess plastic zip strap. 7

8 k) For best fitment, it may be necessary to loosen the spring clamp on the lower radiator hose and rotate the hose away from the lower intake pipe. l) Check that the filter is not touching any part of the vehicle. Position the AEM intake for best fitment. Be sure that the pipe or any other component is not in contact with any part of the vehicle. Tighten the hose clamps at the throttle body and silicone coupling. Tighten the nut on the mounting bracket. Re-adjust the pipe if necessary. Reinstall the inner fender liner fasteners and the passenger side wheel. Before After 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 battery (always connect positive first). c) Start the vehicle and check for proper operation of all the components that were removed. For Technical Inquiries Us At 8