AEM 21-8402 Installation Instructions Manual

Brand: AEM

Model: 21-8402

Type: Installation Instructions Manual

Brute Force

Intake

System

Installation Instructions for:

Part Number 21-8402

1999-2002 Toyota 4Runner 3.4L V6

1999-2004 Toyota Tacoma 3.4L V6

ADVANCED ENGINE MANAGEMENT INC.

2205 126

Street, Unit A Hawthorne, CA. 90250

Phone: (310) 484-2322 Fax: (310) 484-0152

www.aempower.com

Instruction Part Number: 10-8402

1999-2003 Toyota 4Runner 3.4L V6 CARB E.O. # D-392-27

1999-2004 Toyota Tacoma 3.4L V6 CARB E.O. #D-392-27

Brute Force Air Intake Systems that are pending CARB approval are illegal in California except on racing vehicles which may

never be used on public highways.

Congratulations! You have just purchased the finest Air Induction & Filtration system for your

car at any price!

The AEM Brute Force Intake System is the result of extensive development on a wide variety of

cars. 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, 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 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: 21-8402

1 2-84021 Intake Pipe

1 20-8402 Heat Shield

1 21-202D 2.75" x 5" Dryflow Filter

1 5-272 Silicone Hose

2 9444 #44 Hose Clamp

1 9448 #48 Hose Clamp

1 99024.032 1" Hose Clamp

16" 65014 1/4" ID Vacuum Hose

4" 65004 5/8" ID Hose

1 8-120 5/8" 90 degree Barbed Elbow - Black

1 1228599 Rubber Mount

2 444.460.04 6mm Serrated nut

2 559999 6mmx25mmx1mm Washer

2 1-2034 Hex Bolt M8 x 1.25 x 20

2 1-3020 M8 Washer

2 1-2023 Bolt, Socket 8-32 x 5/16 SS

21" 8-119 Heat Shield Molding

2 10-922S AEM Decal

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

Note: This inlet pipe kit requires 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.

1) Getting started

a) Make sure vehicle is parked on a level surface.

b) Set parking brake.

c) If engine has run within the past two hours let it cool down.

2) Removing the stock air inlet system

Note: Be sure to save the stock air inlet system components should the need arise to reinstall them.

Hose # 3

Hose #1

Hose #2

MAF

a) Remove the three bolts that hold the factory air

box in place.

b) Unplug the Mass Air Flow (MAF) sensor and

loosen the hose clamp around the throttle body.

Unplug the three hoses connected to the air inlet

system. Hose #1 is connected to the airbox. Hose

#2 is connected to the intake resonator. And Hose

#3 is connected directly to the intake tube.

c) Unhook the wiring harness from the air inlet

system.

d) Remove factory air inlet system from engine bay.

3) Installing the AEM Intake

Note: When installing the Intake System, DO NOT completely tighten the hose clamps or mounting tab

hardware until instructed to do so later in these instructions. Check to see that the inside of the AEM inlet pipe

and air filter are clean and free from any foreign objects and/or obstructions.

Push

Blue Tab

e) Remove the MAF sensor from the air inlet system by

removing the two screws shown in the figure.

a) Remove the factory vacuum hose, shown in the

picture, and replace it with the ¼” vacuum hose in the

AEM kit.

b) Install the MAF sensor into the AEM pipe using

the Allen-head bolts included in the kit. Do not over-

tighten the bolts.

Igniter

c) Insert the rubber mount into the pre-drilled hole in the fender well

next to the igniter. Secure the rubber mount to the fender well by

installing a 6mm nut and fender washer (included in kit) to the

reverse side inside the wheel well.

e) Secure the remaining mounting tab underneath

the igniter tab with the factory M6 bolt. Secure the

other side with the provided M8 washer and bolt.

d Insert heat shield. Secure the heat shield to

mounting tab located behind the passenger headlight

with provided M8 washer and bolt.

g) Insert the inlet pipe into the coupler. Line up the

bracket to the installed rubber mount. See step h.

f) Attach coupler and secure to the throttle body with

provided hose clamp. The other hose clamp should

be loose.

i) Secure the bracket with provided washer and

serrated nut. Refer to diagram below.

h) Once the bracket is lined up for fitment, tighten the

hose clamp at the throttle body securing the inlet

pipe.

Lock Nut

Fender Washer

Rubber Mount

Inlet Pipe Support Tab

Mounting

Note) If you have a 2001+ vehicle, the accessory

hose shown in step j will have a connector

attached to it. In this case, remove the connector

and insert the barbed fitting included in the kit

into the hose. Attach the length of 5/8” hose

included in the kit to the other end of the barbed

fitting. Slide the other end of the tube onto the

nipple and secure it in place with the 1” hose

clamp. The figure at right shows the layout of

this assembly.

A B

j) On 2000 and earlier models refer to figure A. On 2001+ refer to

figure B for vacuum hose routing.

l) Attach the ¼” hose to the nipple at the throttle

body from step a.

k) Reattach breather hose and secure with spring

clamp.

n) Attach rubber gasket to the top edge of the heat

shield.

m) Attach filter and secure with hose clamp.

o) Reconnect the MAF wiring harness to the MAF

sensor in the pipe.

q) Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are tight.

r) Start vehicle and check for proper operation of all the components that were removed.

s) Make sure the intake pipe does not contact the heat shield during start up or while the engine is running. If

this happens, adjust the position of the pipe.

For Technical Inquiries

E-Mail Us At

[email protected]

AEM 21-8402 Installation Instructions Manual

AEM 21-8402 Installation Instructions Manual

AEM 21-8402 Installation Instructions Manual

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