Equipped with AEM DRYFLOW Filter No oil required! Kit Part Number: 21-568 2005-2006 Scion TC 2.4L *Legal in California only for racing vehicles which may never be used upon a highway. 2009, Advanced Engine Management, Inc. AEM is a registered trademark of Advanced Engine Management, Inc. All rights reserved. Advanced Engine Management Inc. 2205 126 th Street, Unit A Hawthorne, CA 90280 Phone: 310.484.2322 http://www.aempower.com
9440 (4) 9444 21-568 Page 2 of 11 01.30.2009 Rev 2
Bill of Materials QTY PART DESCRIPTION PART # QTY PART DESCRIPTION PART # 1 Upper Intake Pipe 2-712 1 M5 Split Lock Washer 1-3046 1 Lower Intake Pipe 2-564 2 Bolt, 8-32X5/16 SS 1-2023 1 1 2.50 X3.00 Hump Hose 2.50 X2.00 Silicone Coupler 5-525 1 5-252 1 Bolt,Hex M5 X.8, 12MM 2.50 X5.00 Dryflow Filter 1-2098 21-201D 4 #40 Hose Clamp 9440 5 ½ Helical Wrap 8-143 3 1 6mm Rubber Mount 1228599 1 M6 Star Washer 1-3041 4 6mm Serrated Nut 444.460.04 2 AEM Decal 10-922S 3 6mm Washer 559999 1 Instructions 10-7070 1 #44 Hose Clamp 9444 21-568 Page 3 of 11 01.30.2009 Rev 2
1. Preparing Vehicle a) Make sure vehicle is parked on a level surface. b) Set parking brake. c) If engine has run in the past two hours let it cool down d) Disconnect the negative battery terminal. e) Remove front drivers side wheel. 2. Removal of Stock System a) Remove the two nuts securing the plastic engine cover to the valve cover. Remove the plastic engine cover from the engine bay. Recommended Tools: 10mm Socket 5/16 Nut Driver Pliers Extension Ratchet 10mm Wrench Installation Time: 2 hours b) Pull the EVAP purge hose free from the two rubber clips on the intake hose. Remove the crankcase breather hose from the intake tube. Save the factory clamp for use later in the installation. c) Unplug the mass air flow (MAF) sensor connector. Remove d) Free the EVAP vacuum switching valve (VSV) from the intake tube by pulling straight up. Remove the screw that secures the mounting bracket to the wire harness clip and to the VSV itself. Save the screw for reuse if the stock intake system is ever reinstalled. 21-568 Page 4 of 11 01.30.2009 Rev 2
e) Remove the two screws securing the MAF sensor. Remove the sensor, use care to avoid damaging it. Save the screws for reuse if the stock intake system is ever reinstalled. f) Release the two upper air box clips. g) Squeeze the spring clamp on the intake tube at the throttle body. Pull the tube clear of the throttle body. Remove the intake tube/upper air box as one assembly. h) Remove the air filter element to expose the lower air box mounting bolts. Remove the three bolts and lift the lower air box. i) Free the wire harness loom clip by gently squeezing the sides in. Remove the lower air box from the engine bay. Squeeze Tab j) Remove the fuse box cover by squeezing the tab and lifting upwards. 21-568 Page 5 of 11 01.30.2009 Rev 2
k) Remove the two plastic rivets securing the lower air duct. Remove the lower air duct from the engine bay. Replace the fuse box cover. l) Remove the self-tapping screw and plastic rivet from the plastic fender liner. m) Remove the three selftapping screws from the underside of the fender liner. Pull the liner back and tuck it behind the brake rotor. n) Remove the ground strap bolt located beneath the driver s side headlight. Save the bolt for reuse if the stock intake system is ever reinstalled. 21-568 Page 6 of 11 01.30.2009 Rev 2
3. Installation of Cold Air Intake a) When installing the intake system, DO NOT completely tighten the hose clamps or mounting tab hardware until instructed to do so. b) Install two of the supplied rubber mounts in the threaded holes shown in the picture to the left. Install hump hose at throttle body EVAP line c) Install the rubber hump hose on to the throttle body. Loosely secure with two #40 hose clamps. Wrap the supplied helical plastic wrap around the EVAP line where it will pass over the upper intake pipe. d) Insert the 90 degree bend of the upper intake pipe (the long one) into the fender from the engine bay. e) Install the upper intake pipe into the coupler at the throttle body. Leave the hose clamps loose for adjustment. f) The pipe brackets will line up with the rubber mounts installed in step 3b. Loosely secure the first one to the rubber mount with a washer and nut g) Loosely secure the second bracket to the rubber mount with a washer and nut. 21-568 Page 7 of 11 01.30.2009 Rev 2
h) Connect the breather hose to the nipple located on the intake pipe near that throttle body. Nut i) Install the remaining rubber mount in to the hole left vacant in step 2n. On the exposed thread on the backside of the mount, install the star washer, ground strap terminal, and locknut (in that order). Ground Strap Star Washer j) Attach the supplied coupler to the end of the upper intake pipe located in the fender well. Use the supplied hose clamps to secure it loosely in place for adjustment later. k) Install the lower intake pipe into the coupler. The bracket will line up with the rubber mount. Loosely secure the bracket with a washer and locknut. l) Install the AEM air filter on to the end of the pipe. Secure with the supplied hose clamp. m) Secure the MAF sensor to the AEM intake pipe with the supplied 8-32 screws. Use care to avoid damaging the o-ring. 21-568 Page 8 of 11 01.30.2009 Rev 2
n) Plug in the MAF sensor wire harness. Mount the EVAP VSV to the bracket on the upper intake pipe using the supplied M5 screw and washer. Insert the screw through the wire harness clip, the intake pipe bracket, and then thread it into the VSV. Adjust the wires so that they are not in tension. o) Adjust inlet pipes and couplers for best fitment. Make sure the AEM intake system does not come into contact with the vehicle anywhere. Tighten all hose clamps and mounting bracket locknuts. p) Reinstall plastic engine cover. q) Reinstall lower splashguard and plastic fender liner using the original factory hardware. Re-install driver s side tire and torque to proper specification. Remove jack stands and lower vehicle. Note: Failure to install the plastic splashguard and fender liner will result in diminished performance and increase the potential for engine damage due to water ingestion in rainy conditions. 4. Re-assemble Vehicle a) Position the inlet pipes for best fitment. Be sure that the pipes or any other components do not contact any part of the vehicle. Tighten the rubber mount, all bolts and hose clamps. b) Check for proper hood clearance. Re-adjust pipes if necessary and retighten them. c) Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are properly tight. d) Re-connect the negative terminal on the battery. e) Start engine. Let car idle for 3 minutes. Perform a final inspection before driving the vehicle. 21-568 Page 9 of 11 01.30.2009 Rev 2
5. Service and Maintenance a) It is recommended that you service your AEM Dryflow filter every 20,000 miles for optimum performance. Use AEM Dryflow cleaning kit part # 21-110. b) Use aluminum polish to clean your polished AEM intake pipe. c) Use window cleaner to clean your powder coated Intake pipe. (NOTE: DO NOT USE Aluminum polish on a powder coated Intake pipe) For technical inquiries e-mail us at tech@aempower.com or call us at 310.484.2322 Option #3 12 MONTH LIMITED WARRANTY AEM warrants that its intake systems will last for the life of your vehicle. AEM will not honor this warranty due to mechanical damage (i.e. improper installation or fitment), damage from misuse, accidents or flying debris. AEM will not warrant its powder coating if the finish has been cleaned with a hydrocarbon-based solvent. The powder coating should only be cleaned with a mild soap and water solution. Proof of purchase of both the vehicle and AEM intake system is required for redemption of a warranty claim. 21-568 Page 10 of 11 01.30.2009 Rev 2
AEM S DYNAMOMETER TESTING PROCEDURE AEM performs dynamometer testing on a Mustang Dyno, model MDSP 7000. Three power pulls are performed on our dynamometer; horsepower and torque are recorded each time. The raw data of the three pulls is then corrected to the Society of Automotive Engineers (SAE) standard correction factor. The corrected values are averaged and graphed to rpm. The SAE standard (SAE J1349 Reaffirmed June 1995) for an internal combustion engine atmospheric correction factor is used to create standard power output numbers at any altitude, ambient air temperature and humidity. As with any test there are many variables in the testing of the power outputs, so your test results may not match those of AEM. 21-568 Page 11 of 11 01.30.2009 Rev 2