COLD AIR SYSTEM Installation Instructions for: Part Number 21-547 2003-2006 Nissan 350Z 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: 10-383 2003 Nissan 350Z VQ35DE C.A.R.B. E.O. #D-392-21 2004 Nissan 350Z VQ5DE C.A.R.B. E.O.#D-392-24 2005 Nissan 350Z VQ5DE C.A.R.B. E.O.#Pending 2006 Nissan 350Z VQ5DE C.A.R.B. E.O.#Pending Copyright 2003
Congratulations! You have just purchased the finest Air Induction & Filtration system for your car at any price! The AEM Cold Air Intake System is the result of extensive development on a wide variety of cars. It is the most advanced Cold Air Intake System on the market. Each system is specifically engineered for its application. All AEM Cold Air Intake Systems deliver maximum performance gains through lightweight, all-aluminum, mandrel-bent tubing that is tuned in both length and diameter. The aluminum will not crack in extended use like plastic. The tube length and diameter are matched for each specific engine to give power over a broad RPM range. Unlike plastic systems that use a continually diverging cross-section, we take advantage of the acoustical energy in the inlet duct to promote cylinder filling during the intake valve-opening event. 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 filter element has also been extensively developed. An integral part of all our filter elements is a built-in velocity stack. This velocity stack is specifically engineered to improve the aerodynamic efficiency of the intake system. We have seen airflow gains on a flow bench of 12-15% by using this velocity stack. 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: 21-547 Quantity Part Number Description 1 2-527* UPPER INTAKE PIPE 1 2-544* LOWER INTAKE PIPE 1 2-641 NISSAN MAF SENSOR ADAPTOR 1 5-323 HOSE,ADAPTER 3.25/3.00 X 2.25" BLK 2 5-300 HOSE,SILICONE 3.00X3" AEM BLK 5 103-BLO-4820 HOSE CLAMP,2.56-3.50" 1 103-BLO-5220 HOSE CLAMP,2.81-3.75" 1 559999 Washer, Flat M6x25x1 1 444.460.04 Nut, Nylock 6mm 1 1228599 Mount, Rubber 1" 4 1-2030 BOLT,HEX M6 X 1 X 16 4 1-3018 WASHER, M6 ZINC-PLATED STEEL 1 2-125 SPACER,.625OD X.295 ID X.185 1 1-2053 BOLT,FLAT HD M8 X 30 1 444.460.08 NUT,NYLOK 8MM 1 7-7388* Wiring Harness Bracket 1 21-203 AIR FILTER ASMBLY 3.0 5" & Clamp 1 10-383* Installation Instructions 1 10-922E EMBLEM,CAS/SRS 1 10-400W License Plate Frame 1 10-905 Warning Decal 1 11-547 EO Decal 2 10-922S Regular AEM Sticker
Read and understand these instructions BEFORE attempting to install this product. Note: This inlet pipe kit may require 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. This installation will also require access to the underside of the vehicle. If a lift is not available, jack up the front of the vehicle and support it with jack stands. Make sure vehicle is stable before working under it. 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 stock air inlet system a) Remove the fasteners holding the strut tower bar in place from both sides. Unclip the electrical wiring loom connections and remove the bar from the engine bay. b) Loosen the hose clamps shown in the picture. Unplug the Mass Air Flow (MAF) sensor and detach the MAF wiring harness from the sensor. c) Pop out and remove the plastic fastener on the front air duct. Unsnap the duct and slide it forward. Remove the bolt circled in the diagram.
d) From the underside of the intake tube, detach the breather hose then remove the intake tube from the engine bay. e) Remove the bolt holding the air filter housing assembly in place. f) Gently pull directly upward on the air filter housing assembly until it unsnaps from its mounts and remove it from the engine bay. g) Unsnap the wiring loom fasteners from the inner fender. h) Looking where the factory air filter housing was, pull the wheel speed sensor plug shown in the picture from its mount. Do not unplug the sensor. i) Remove the A/C line bracket bolt shown in the picture.
FRONT j) Remove the MAF sensor from the air filter assembly by removing the four mounting bolts. k) From the underside of the car, remove the bolts shown in the picture. l) Pull down on the splash guard to reveal two plastic fasteners. Remove these fasteners. m) It is now possible to gain access to the area behind the front bumper. This is where the air filter will be located. 3) Installing the AEM Cold Air Intake System 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. RUBBER MOUNT a) Install the rubber mount into the hole for the A/C line bracket bolt. Use the included spacer underneath the rubber mount to space it upward to clear the bracket. Tighten by hand. SPACER
b) Attach the breather hose to the fitting in the AEM upper intake pipe (the shorter one in the kit). Put the 3 ¼ to 3.0 silicone reducer on the end of the pipe closest to the bend. Place the 3 ¼ side of the silicone coupler over the throttle body. c) Using the four bolts and washers included in the kit, attach the AEM MAF adaptor to the Nissan MAF sensor. d) Place the 3 silicone coupler around the MAF sensor, not the AEM MAF adaptor, and insert onto the upper intake pipe. Use the #52 hose clamp around the throttle body and the #48 hose clamps for the 3 diameter tubing. Do not tighten the hose clamps. e) Install the 8mm bolt and washer included in the kit into the hole from the removed bolt from step C of the previous section. Attach the AEM wiring harness bracket to the bolt on the underside and secure it in place with the included 8mm Nylok nut. f) Snap the factory wiring harness into the bracket as shown. Insert the other plastic wiring loom holder into the hole from the bolt removed in step E of the previous section.
g) Inside the cavity behind the bumper, unsnap the wiring loom from the body. h) Tuck the wiring up and out of the way. i) Install the air filter on the end of the lower intake pipe closest to the 7/8 hole. Install the recessed plastic plug in the hole if not done so already. j) Install the 3 coupler and two #48 hose clamps on the end of the MAF adaptor. Insert the upper end of the lower intake pipe into the coupler. Nut Rubber Mount Fender Washer Support Bracket i) Line up the tab on the intake pipe with the rubber mount. Run the wheel speed sensor wire underneath intake pipe support tab. Make sure the plug and wire not in a place where they will be pinched or damaged. Install the nut and washer according to the diagram at right.
j) Position the pipes and filter in such a way that no part of them touch the vehicle or the plastic fender liner. Make sure the intake does not come into contact with any of the adjacent A/C hard-lines. Contact may result in failure of the A/C system and costly repairs. After they have been positioned correctly, tighten all hose clamps and the mounting tab hardware. Plug in the MAF sensor and re-install the strut-tower bar. Re-install the splash-guard and fender liner. Re-connect the battery and start the engine. Perform a final inspection before driving. Note: If an AEM air bypass valve is to be used, install it in the section of pipe circled in the diagram above. For Technical Inquiries E-Mail Us At tech@aempower.com