AEM Dryflow Kurzanleitung

AEM Induction Systems 1 (800) 992-3000 WWW: http://www.aemintakes.com

Equipped with AEM®Dryflow™ Filter

No Oil Required!

INSTALLATION INSTRUCTIONS

PART NUMBER: 21-447

1998-2001 CHEVROLET Cavalier L4-2.2L Manual trans. Requires 20-455 C.A.R.B. E.O. # D-670-6

2000-2002 PONTIAC Sunfire L4-2.2L Manual trans. Requires 20-455 C.A.R.B. E.O. # D-670-6

The installation of this AEM®intake system on manual transmission model year vehicles will also require

the installation of the AEM® clutch reservoir bracket, part # 20-445. The clutch reservoir bracket is

necessary as it is needed to properly support the clutch fluid reservoir.

* NOTE: Legal in California only for racing vehicles which may never be used upon a highway

PARTS LIST

Description

Qty.

Part Number

Element Parts Kit 2.75 X 5" Dry Ele.

21-202DK

Lower Pipe

2-552

Upper Pipe

2-553

Hose, Silicone 2.75x3" Blk.

5-275

Hose, Hump 2.75/2.75x3.00"

5-575

Hose; 1/2"ID X 12"L

5-5012

Mount, Rubber 5/8" X 6mm

1228598

Grommet, 1/2"

784634

Zip Tie,8" Tree Push-Mnt.

1-127

Spacer, 1.00 OD X .250 ID X .6

2-647

Neoprene, 1/16" X 6" X 1" Adhes.

8-121-1

Bolt, Hex M6-1 X 35mm

1-2002

Washer; 1"D X 1/4 Hole Fender

08160

Nut, M6 Hex Serrated

444.460.04

1/2" Bnd. Hose Clamp, 2.31-3.25"

9444

Hose Clamp, 3/4"

4093-5

1/2" Bnd. Hose Clamp,2.56"-3.50"

9448

Read and understand these instructions BEFORE attempting to install this product.

Failure to follow installation instructions and not using the provided hardware may

damage the intake tube, throttle body and engine.

The AEM®intake system is a performance product that can be used safely during mild

weather conditions. During harsh and inclement weather conditions, you must return

your vehicle to stock OEM air box and intake tract configuration. Failure to follow these

instructions will void your warranty.

1. Preparing Vehicle

a.Make sure vehicle is parked on level surface.

b.Set parking brake.

c. If engine has run in the past two hours, let it cool down.

d.Disconnect negative battery terminal.

e.Raise the front of the vehicle with a jack. Refer to your owner’s manual for proper jack and jack stand

placement to properly support vehicle. Support your vehicle using properly rated jack stands before wheel

removal or while working under the vehicle.

NEVER WORK UNDER A VEHICLE WITHOUT USING JACK STANDS.

f. Remove front driver side wheel.

g.Do not discard stock components after removal of the factory system.

2. Removal of stock system

a. Factory air box system installed.

b. Release the clip on top of the inlet pipe.

c. Loosen the hose clamp at the air box.

d. Remove bolt. Release the breather hose from the

valve cover.

e. Loosen the hose clamp at the throttle body.

f. Gently pull the inlet air temperature (IAT) sensor from

the inlet pipe. Remove the upper air box from the

vehicle.

NOTE: Do not pull by wires.

g. Remove the battery by first releasing the tie down

bolt.

h. Release the two wire clips on the air box.

i. Remove the plastic clip that secures the fuse block.

j. If equipped with a manual transmission, remove the

clutch fluid reservoir from the air box. Secure it to the

firewall with AEM®part # 20-445 (sold separately).

Remove the air box from the vehicle.

l. Release the two wire clamps on the back of the

washer fluid bottle.

k. Remove the left fender liner to expose the lower air

box / washer bottle assembly.

m. Unplug the washer motor. Pull the washer fluid

hose off of the motor and drain the fluid into a clean

suitable container.

n. Remove the bolt that secures the washer bottle to

the fender.

p. Remove the upper bolt near the front of the washer

bottle. This picture was taken through the front grill.

q. Remove the washer bottle from the vehicle. Loosen

the bolt connecting the bottle to the lower air box.

r. Loosen the positive lead on the fuse block. Rotate it

as shown. Tighten the lead.

o. Remove the lower bolt near the front of the washer

bottle.

3. Installation of AEM®intake system.

a.When installing the intake system, do not completely tighten the hose clamps or mounting hardware until

instructed to do so.

b. Install supplied bolt and washer through fender as

shown. This picture was taken from inside the fender

well.

c. Install spacer as shown. Install the lower pipe in the

engine bay. Center the pipe in the hole in the fender

and tighten the nut on the spacer.

Mark pipe here.

And here.

e. Reinstall the washer bottle without the lower air box.

Reattach the washer fluid hose and plug in the washer

motor.

d. Mark the pipe approximately ½” above and below

the hole in the fender. Remove the pipe and apply the

adhesive neoprene material as shown. Reinstall the

intake pipe as previously directed.

f. Install the supplied silicone hose as shown. Orient

the hose clamp screws away from the battery tray as

shown.

g. Attach the rubber mount to the tab near the washer

bottle filler neck using the supplied washer and lock

nut.

h. Install the hump hose to the throttle body as shown.

Cruise control only.

i. Install the supplied grommet in the hole on the upper

pipe. Insert the zip tie into the hole on the upper pipe

bracket (use two zip ties if the car has cruise control).

j. Place the upper intake pipe in the engine bay as

shown.

k. Secure the throttle/cc cable(s) to the upper pipe with

the zip tie(s) installed earlier. Cut off excess material.

l. Insert the IAT sensor through the grommet in the

upper pipe. Do not push the grommet into the pipe.

m. Install the supplied breather hose between the valve

cover and intake pipe. Secure it with the supplied hose

clamps.

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