Brute Force Intake System Installation Instructions for: Part Number 21-8402 1999-2002 Toyota 4Runner 3.4L V6 1999-2004 Toyota Tacoma 3.4L V6 ADVANCED ENGINE MANAGEMENT INC. 2205 126 TH Street, Unit A Hawthorne, CA. 90250 Phone: (310) 484-2322 Fax: (310) 484-0152 www.aempower.com Instruction Part Number: 10-8402 1999-2003 Toyota 4Runner 3.4L V6 CARB E.O. # D-392-27 1999-2004 Toyota Tacoma 3.4L V6 CARB E.O. #D-392-27 Brute Force 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 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, all-aluminum, 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, heatreducing 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: 21-8402 1 2-84021 Intake Pipe 1 20-8402 Heat Shield 1 21-202D 2.75" x 5" Dryflow Filter 1 5-272 Silicone Hose 2 9444 #44 Hose Clamp 1 9448 #48 Hose Clamp 1 99024.032 1" Hose Clamp 16" 65014 1/4" ID Vacuum Hose 4" 65004 5/8" ID Hose 1 8-120 5/8" 90 degree Barbed Elbow - Black 1 1228599 Rubber Mount 2 444.460.04 6mm Serrated nut 2 559999 6mmx25mmx1mm Washer 2 1-2034 Hex Bolt M8 x 1.25 x 20 2 1-3020 M8 Washer 2 1-2023 Bolt, Socket 8-32 x 5/16 SS 21" 8-119 Heat Shield Molding 2 10-922S AEM Decal 2
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) If engine has run within the past two hours let it cool down. 2) Removing the stock air inlet system Note: Be sure to save the stock air inlet system components should the need arise to reinstall them. Hose # 3 Hose #2 MAF Hose #1 a) Remove the three bolts that hold the factory air box in place. b) Unplug the Mass Air Flow (MAF) sensor and loosen the hose clamp around the throttle body. Unplug the three hoses connected to the air inlet system. Hose #1 is connected to the airbox. Hose #2 is connected to the intake resonator. And Hose #3 is connected directly to the intake tube. c) Unhook the wiring harness from the air inlet system. d) Remove factory air inlet system from engine bay. 3
e) Remove the MAF sensor from the air inlet system by removing the two screws shown in the figure. Push Blue Tab 3) Installing the AEM Intake Note: When installing the Intake System, DO NOT completely tighten the hose clamps or mounting tab hardware until instructed to do so later in these instructions. 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. a) Remove the factory vacuum hose, shown in the picture, and replace it with the ¼ vacuum hose in the AEM kit. b) Install the MAF sensor into the AEM pipe using the Allen-head bolts included in the kit. Do not overtighten the bolts. 4
Igniter c) Insert the rubber mount into the pre-drilled hole in the fender well next to the igniter. Secure the rubber mount to the fender well by installing a 6mm nut and fender washer (included in kit) to the reverse side inside the wheel well. d Insert heat shield. Secure the heat shield to mounting tab located behind the passenger headlight with provided M8 washer and bolt. e) Secure the remaining mounting tab underneath the igniter tab with the factory M6 bolt. Secure the other side with the provided M8 washer and bolt. 5
f) Attach coupler and secure to the throttle body with provided hose clamp. The other hose clamp should be loose. g) Insert the inlet pipe into the coupler. Line up the bracket to the installed rubber mount. See step h. h) Once the bracket is lined up for fitment, tighten the hose clamp at the throttle body securing the inlet pipe. i) Secure the bracket with provided washer and serrated nut. Refer to diagram below. Lock Nut Fender Washer Rubber Mount Inlet Pipe Support Tab Mounting 6
Note) If you have a 2001+ vehicle, the accessory hose shown in step j will have a connector attached to it. In this case, remove the connector and insert the barbed fitting included in the kit into the hose. Attach the length of 5/8 hose included in the kit to the other end of the barbed fitting. Slide the other end of the tube onto the nipple and secure it in place with the 1 hose clamp. The figure at right shows the layout of this assembly. A B j) On 2000 and earlier models refer to figure A. On 2001+ refer to figure B for vacuum hose routing. k) Reattach breather hose and secure with spring clamp. l) Attach the ¼ hose to the nipple at the throttle body from step a. 7
m) Attach filter and secure with hose clamp. n) Attach rubber gasket to the top edge of the heat shield. o) Reconnect the MAF wiring harness to the MAF sensor in the pipe. q) Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are tight. r) Start vehicle and check for proper operation of all the components that were removed. s) Make sure the intake pipe does not contact the heat shield during start up or while the engine is running. If this happens, adjust the position of the pipe. For Technical Inquiries E-Mail Us At tech@aempower.com 8