Short and sweet CAI install instructions.
These instructions assume you know what you are doing.
I recommend printing them out, then following the pictures on the main page and taking any notes you may later need.
You will need the following equipment:
- If you have the bypass valve: Hacksaw and scotch tape.
- Philips Screwdriver
- Flat head Screwdriver
- Socket wrench, with extension. (Mine was about 1-2" long")
- pliers
- 12 mm socket
- 1/4 inch socket (optional).
- Soapy water makes sliding stuff together easier.
Do not use a lubricant which may eat away at the rubber sleeves.
Steps:
-

Bypass valve: cut out the template of the last page of the AEM valve
instructions. Tape it to the tube and cut via hacksaw.
Use metal mesh or a screwdriver to clean up the edges of the cut.
Clean out the inside of the tube best you can.
-
Unscrew the two screws, and unbolt the two bolts.
Remove the 40 pound battery to reach the left bolt.
Use a screwdriver to pry off the spring clamp in the red rectangle.
Pull out the entire air box, leaving just the resonator tube sticking up.
- If you haven't done so yet, jack up the front driver's side.
-
Undo the two fasteners and the screw of the splash guard and pull it down.
-
Reaching up from underneath, Unbolt the two circled bolts of the resonator.
Pull out the resonator.
- Remove this black plastic thing:
- And the cross bar behind it:
- Pull the pipes off of the accordian tube thing, leaving this.
Using the pipes included with the AEM CAI, reattach those tubes to the AEM CAI.
-
- Attach the rubber sleeve:
- Lube the AEM rubber sleeve
- slide metal clamps on sleeve
- slide aem pipe (the part with the prongs) into sleeve, and slide onto
engine. Note that the aem tube pretty much touches the engine's
intake pipe.
- Tighten -slightly-.
-
- Attach the pipe raiser:
- Lower the other section of the CAI through the resonator hole
- Stick the rubber screw thing on the "U" of the CAI
- tighten the screw enough so that it doesn't pop out of the car, but not
so tight that you cant move the CAI section
- Lube the inside of the bypass and slide both sections of the CAI into it.
You may need to do various adjustments to get it to fit well.
-
- Disconnect the rightmost (circled) pipe. (S1)
-
- Remove the top circled plastic connector.
- Disconnect the bottom circled pipe. (S2)
-
- Remove this cover via the circled connectors.
-
- Disconnect this pipe. (L1)
-
- Connect the 2 foot 1/2" pipe to L1 & L2 (one of the tube prongs)
- Connect the 2 foot 5/16" pipe to S1 & S2
- Connect this grey pipe to the pipe prong.
- Once everything is happy, tighten all clamps and screws.
- Reach underneath the splash guard and stick the Air filter on the end of the CAI.
- Refasten everything (the splash guard, the engine cover)
- mail wanfr01 (hotmail.com) with any problems you had with these instructions.
- Enjoy!