BRUTE FORCE AIR INTAKE SYSTEM Installation Instructions for: Part Number 21-8108 1997-2000 Ford Ranger 4.0L V6 With O.E. panel style air filter 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: 10-8108 1997-2000 Ford Ranger 4.0L V6 w/o.e. panel style air filter C.A.R.B. E.O. #D-392-29 2009 Advanced Engine Management, Inc.
Congratulations! You have just purchased the finest Air Induction & Filtration system for your vehicle at any price! The AEM Brute Force Intake System is the result of extensive development on a wide variety of vehicles. 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: 21-8108 Quantity Part Number Description 1 2-81081 Inlet Pipe, Upper 1 2-81082 Inlet Pipe, Lower 3 103-BLO-5220 HOSE CLAMP,3.25" 2 103-BLO-4820 HOSE CLAMP,3.00" 1 103-BLO-4420 HOSE CLAMP,2.75" 1 4093-6 HOSE CLAMP, 1 1/16" NARROW 1 5-492 HOSE,ELBOW 3.00" X 2.75" BLK 1 5-326N HOSE,SILICONE 3.25 X 2.0" NO LOGO 1 5-323 HOSE,ADAPTER 3.25/3.00 X 2.25" BLK 1 20-8109 HEAT SHIELD, RANGER 01-ON 4.0L 2 2-670 ALUM STAND, HEAT SHIELD F150 4 1-2038 BOLT,HEX/FLANGE M6 X 20 2 1-2002 BOLT,HEX M6 X 1.0 X 35 6 444.460.04 NUT,NYLOK 6MM 4 559999 WASHER,6MM SOFT MOUNT 1 2-689 ADAPTER,FORD RANGER MAF ADAPTER 2 2-9207 MAF ADAPTER GASKET RANGER 9" 8-119 GASKET,SPONGE RUBBER 1 21-209-D AIR FILTER 6.0 5" ELEMENT W/ CLAMP 3 8-111 Rubber Edge Trim 2" 65004 Hose,5/8ID 1 21-110 FILTER CLEANER KIT, DRY FILTER 2 10-922S DECAL,AEM LARGE SILVER 1 10-8108 INST, 21-8108 2
Read and understand these instructions BEFORE attempting to install this product. 1) Getting started a) Make sure vehicle is parked on a level surface. b) Set parking brake. c) Disconnect both battery terminals. d) If engine has run within the past two hours let it cool down. 2) Removing the stock air inlet system a) Stock intake system. b) Remove the two screws that secure the throttle body cover. Remove the throttle body cover. c) Loosen the hose clamp at the throttle body. Disconnect the harness from the air temp sensor and pull the sensor out of the intake tube. d) Unplug the Mass Airflow (MAF) sensor and loosen the hose clamp. Release the retaining clip and pull the breather hose from the inlet pipe. 3
e) Remove the inlet pipe. Remove the air box by first pulling it up and then towards the center of the vehicle. f) Remove the silencer behind the headlight. Remove the air box support plate. 3) Installation of AEM Brute Force Intake System Do not tighten the hose clamps or mounting hardware until instructed to do so later in these instructions. a) Install the gasket material to the top of the heat shield. Lock Nut Washer Support Plate Stock Rubber Grommet Aluminum Support Heat Shield Tab Washer Bolt b) Secure the air box support plate to the heat shield with the supplied hardware. Refer to step d. c) Proper heat shield hardware alignment. 4
d) Remove the MAF sensor from the air box. e) Place one of the supplied gaskets onto each side of the large hole in the heat shield. f) Secure the MAF sensor and MAF sensor adapter to the heat shield with the supplied bolts and lock nuts. g) Install the AEM air filter onto the MAF sensor adapter as shown. IAT Grommet #52 Clamp #48 clamps #44 Clamp h) Place the heat shield/air filter/maf sensor in the engine bay. Secure it to the chassis with the original bolts. Install the thin hose coupler over the MAF sensor housing as shown with the #52 hose clamps. 5 i) Assemble the two pipes as shown with the couplers, clamps, and grommet. Leave the hose clamps loose for fine adjustments.
j) Place the inlet pipe in the engine bay as shown. k) Secure the breather hose to the inlet pipe with the supplied hose and hose clamp. Install the MAF sensor wiring harness support into the tab on the pipe. Plug the wiring harness into the MAF sensor l) Push the IAT sensor into place and connect the wire harness. m) Align all the pipes and securely tighten all the hose clamps. Reinstall throttle body cover. AEM Brute Force System installed. 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. a) Position the pipe and filter so that they do not touch any other surface and tighten all hose clamps. b) Reconnect battery terminals. c) Start engine and perform a final inspection before driving the vehicle. 5) Service Information and Optional Accessories a) Service your AEM filter element with AEM's Filter Cleaning System (Part # 21-110) at least every 20,000 miles or 15 months to maintain optimum performance. 6