Brute Force Intake System Equipped with AEM DRYFLOW Filter. No oil required Installation Instructions for: Part Number 21-8013 2001-2004 Chevy Silverado 2500HD & 3500 2001-2004 GMC 2500HD & 3500 6.6L Duramax Turbo Diesel V8 Note: This kit only works on early 2004 diesels with number 1 in the 8 th digit of the VIN. ADVANCED ENGINE MANAGEMENT INC. 2205 126 TH Street, Unit A Hawthorne, CA. 90250 Phone: (310) 484-2322 Fax: (310) 484-0152 www.aempower.com Instructions Part Number: 10-8009 2001-2003 Chevy 2500HD & 3500 6.6L V8 Turbo Diesel C.A.R.B. E.O. #D-392-24 2001-2003 GMC 2500HD & 3500 6.6L V8 Turbo Diesel C.A.R.B. E.O. #D-392-24 2004 Chevy 2500HD & 3500 6.6L V8 Turbo Diesel C.A.R.B. E.O. #D-392-27 2004 GMC 2500HD & 3500 6.6L V8 Turbo Diesel C.A.R.B. E.O. #D-392-27 Copyright 2009
Congratulations! You have just purchased the finest Air Induction & Filtration system for your car at any price! The AEM Brute Force Intake System is the result of extensive development on a wide variety of cars. It is the most advanced short pipe air intake system on the market. Each system is specifically engineered for its particular application. All AEM Brute Force Intake Systems deliver maximum performance gains through the lightweight, allaluminum, mandrel-bent tubing that is tuned in both length and diameter. The tube length and diameter are matched for each specific engine to give power over a broad RPM range. Every intake is coated with a high-gloss, heat-reducing Zirconia based powder coating. This special blend of powder coating helps reduce heat penetration, which in turn reduces the temperature of the inlet air charge. The cooler inlet air temperature translates to more power during the combustion process because cool air is denser than warm air. The air mass flow to the engine is increased because of the increased airflow and reduced inlet temperature, which translates to more power. Bill of Materials for: Part #21-8013 1 21-2049D 3.50" x 9" Dryflow Filter 1 2-80131 Inlet Pipe 1 20-8013 Heat Shield 1 1228560 Rubber Mount, M8 x 1" 2 559960 Washer, M8 2 444.460.08 Locknut, M8 1 784634 Grommet, 1/2" 1 5-350 Coupler, 3.50" 3 9456 #56 Hose Clamp 2 1-2023 Bolt, 8-32 x 1/2" 1 1-124 Tool, T20 Tamper Resistant Torx 1 10-8013 Instructions 2 10-922S AEM Decal
Read and understand these instructions BEFORE attempting to install this product. 1) Getting Started a) Make sure vehicle is parked on a level surface. Set parking brake. b) Disconnect negative battery terminal from both batteries. c) If engine has run within the past two hours, let it cool down. 2) Removal of the stock intake system. a) On 2001 models, loosen the bolt securing the engine cover, then remove the engine cover. Skip to step 2d. b) On 2002+ models, remove the bolt securing the top of the intake resonator. Unplug Remove c) Loosen the hose clamp securing the intake resonator to the air intake tube. Remove the intake resonator from the engine bay. d) Unplug the wire harness from the Mass Air Flow (MAF) sensor. Remove the two screws retaining the MAF sensor with the supplied tamper-resistant Torx tool. Carefully remove the MAF sensor.
e) Loosen the hose clamp at the air box side of the air intake tube. f) Loosen the hose clamp at the turbo inlet side of the air intake tube. Remove the air intake tube from the engine bay. Remove g) Remove the air box by pulling straight up. Remove the air box mounting tray by removing the five bolts. Save the bolts for use during the installation of the AEM heat shield. h) Remove the air filter restriction gauge from the factory air box. Make sure the rubber grommet stays in the air box. Reset the gauge by pressing the button on the top. 3) Installation of the AEM Brute Force Intake System. 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. Use Original Bolts b) Install the supplied rubber mount on to the AEM heat shield using one each of the supplied washers and locknuts. Center the rubber mount in the slot until the intake is adjusted for final fitment later in the installation. c) Install the AEM heat shield, using three of the original air box mounting tray bolts.
d) Assemble the AEM inlet pipe, air filter and coupler as shown. The air filter goes on the end of the pipe nearest the mounting bracket. e) Install the MAF sensor using the supplied 8-32 screws. Use caution to avoid damaging the o-ring. f) Install the supplied rubber grommet in to the AEM inlet pipe. Insert the air filter restriction gauge into the grommet, being careful not to push the grommet all of the way through the hole. g) Install the open end of the reducer coupler on to the turbo inlet. h) The mounting bracket on the AEM inlet pipe will line up with the rubber mount installed in step 3b. Loosely secure the bracket with the remaining washer and locknut. Refer to the diagram on the next page for proper rubber mount installation. i) Reconnect the MAF sensor wire harness.
Lock Nut M8 Washer Rubber Mount Inlet Pipe Mounting Bracket Heat shield 4) Re-assemble the vehicle a) Position the filter for best fitment. Be sure that the filter or any other components do not contact any part of the vehicle or heat shield. b) Tighten all hose clamps. c) Tighten the lock nuts on the rubber mount. d) Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are tight. e) Reconnect the battery terminals. f) Start engine and perform a final inspection before driving the vehicle. Before After For Technical Inquiries E-Mail Us At tech@aempower.com