Brute Force Intake System

Brute Force
Intake
System
Equipped with AEM DRYFLOW Filter. No oil required!
Installation Instructions for:
Part Number 21-8205
2002-2004 Dodge Ram 4.7L Magnum V8
ADVANCED ENGINE MANAGEMENT INC.
2205 126TH Street, Unit A Hawthorne, CA. 90250
Phone: (310) 484-2322 Fax: (310) 484-0152
www.aempower.com
Instructions Part Number: 10-8205
2002-2004 Dodge Ram 4.7L Magnum V8 C.A.R.B. E.O. #D-392-29
Excluding Bullet
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.
© Copyright 2006
Congratulations! You have just purchased the finest Air Induction & Filtration system
for your car at any price!
The AEM Performance Air Induction 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 lightweight, allaluminum, 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. Unlike plastic systems that use a continually diverging cross-section, we
take advantage of the acoustical energy in the inlet duct to promote cylinder filling
during the intake valve opening event. 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: Part #21-8205
1
1
1
1
1
1
1
22"
34"
1
1
1
1
2
16"
1
1
1
2
2-82051*
AEM BFS Inlet Pipe
21-2059D
AEM Air Filter, 4.00" x 9" & Clamp
103-BLO-7020N
Narrow Hose Clamp, 4.00"
5-324*
Reducer Coupler, 3.25" to 4.00"
103-BLO-5220
Hose Clamp, #52
103-BLO-6421
Hose Clamp, #64
20-P4510920
Heat Shield
8-119
Sponge Rubber Gasket
8-111
Edge Trim, Rubber
784640
Rubber Grommet, 1" ID
1228560
Rubber Mount, M8
559960
Fender Washer, M8
444.460.08
Locknut, M8
4093-6
Hose Clamp, 1.0625"
65116
Breather Hose, 1/2"
784634
Grommet, 1/2"
8-129*
Hole Plug, 3/4"
10-8205*
Instructions
10-922S
AEM Large Decal - Silver
Read and understand these instructions BEFORE attempting to install this product.
1) Getting Started
a)
b)
c)
d)
e)
f)
g)
Make sure vehicle is parked on a level surface.
Set parking brake.
If engine has run with in the past two hours let it cool down.
Disconnect negative battery terminal.
Raise front of truck and support with properly rated jack stands.
Remove passenger side tire.
Do not discard stock components after removal of the factory system.
2) Removal of the stock intake system.
Push through
a) Loosen the hose clamp at the air box. Pull the
rubber air hose away from the air box lid.
b) From inside the passenger side fender well,
release the ABS wire holder (if so equipped).
Push the wire holder through the hole, towards
the engine. Remove the plastic fender liner by
removing the eight self-tapping screws.
Remove
c) Remove the two bolts securing the bottom
half of the air box.
d) From inside the engine bay, remove the two
remaining bolts securing the air box. Remove
the air box from the engine bay.
Unplug
e) Unplug the inlet air temperature (IAT) sensor
located on the back side of the intake air
resonator (except 2002 models).
f) Remove the two bolts retaining the intake air
resonator. One is located on the driver’s side
(pictured), the other is located near the oil
dipstick.
Remove
g) Disconnect the breather hose from the back
of the resonator. Remove the resonator from the
engine bay. Remove the breather hose from the
tee near the back of the intake manifold. This
hose will be replaced with one supplied with the
AEM Brute Force intake kit.
h) Remove the inlet air temperature (IAT)
sensor from the intake resonator by gently
twisting counter-clockwise (except 2002
models). Remove the o-ring from the IAT
sensor. Keep the o-ring for use if the vehicle
ever needs to be returned to stock.
Remove
j) Remove the rubber adapter from the throttle
body.
k) Remove the ground bolt located in front of the
hood prop cylinder.
3) Installation of the AEM Brute Force Intake System.
a) When installing the Brute Force Intake System, DO NOT completely tighten the hose clamps or
mounting tab hardware until instructed to do so later in these instructions.
Cut Here
b) Install the supplied rubber mount through the
ground loop and into the hole left open from
step 2j.
c) On 2004+ trucks equipped with the optional
under hood light on the passenger side, cut the
corners of the notch in the AEM heat shield
using a hacksaw or other suitable tool. Bend the
tab back and forth until it breaks free. Clean up
any sharp edges with a file. For installation on
all other trucks, proceed to next step.
Remove
d) Install the rubber edge trim where shown in
the picture. Trim length to fit.
e) Remove the upper radiator fan shroud bolt
located behind the windshield washer reservoir.
Install the heat shield from inside the fender
well. The front mounting tab will line up with the
bolt just removed. Loosely secure the front
mounting tab with the original bolt.
Use Original
Bolt
f) The lower heat shield mounting tab will line
up with the lower air box mounting hole.
Loosely secure the mounting tab with one of
the original bolts.
g) The rear mounting tab on the heat shield
will line up with one of the lower air box
mounting holes. Install one of the original
bolts. Adjust the heat shield for best fitment
then tighten the three mounting bolts.
Install IAT
h) Install the supplied polyethylene plug into
the hole in the AEM inlet pipe. (2002 models
only)
i) Install the supplied IAT grommet into the
AEM inlet pipe. Insert the IAT sensor into the
grommet (except 2002 models). Use care to
avoid pushing the grommet into the pipe.
i) Loosely install the coupler and hose clamps
on to the end of the AEM inlet pipe nearest
the vacuum nipple.
k) Install the bracket end of the AEM inlet pipe
through the cutout in the heat shield. Install
the coupler on to the throttle body. The
bracket will line up with the rubber mount
installed in step 2b. Loosely secure the
bracket with the supplied washer and locknut.
Refer to the diagram below for proper rubber
mount installation.
Locknut
Flat Washer
Rubber Mount
Inlet Pipe
Bracket
l) Reconnect the wire harness to the IAT sensor
(if applicable). Do not push the grommet through
into the pipe.
m) Install the supplied breather hose and secure
with the two supplied hose clamps.
n) Install the foam rubber gasket material along
the top of the heat shield. Trim excess as
necessary.
o) Install the AEM air filter from inside the
fender well. Slide the air filter on to the pipe until
it stops. Secure with the supplied hose clamp.
Make sure the windshield washer wires and
hose do not come into contact with the air filter.
If the AEM air filter is rubbing the windshield washer hose and wires, remove the
filter and follow the instructions below. If the air filter does not rub the lines and
wires, proceed to step 4.
Grommet
Hole in Heat
Shield
p) Unplug the wire connectors going to the
windshield washer fluid pump and level
indicator. Unplug the washer fluid hose. Block
the nipple on the pump to prevent the washer
fluid from draining.
q) Pass both connectors through the supplied
large grommet and then through the hole in the
heat shield. Reconnect wire connectors and
washer fluid hose to the washer fluid reservoir.
r) Install the rubber grommet in to the hole in the
heat shield. Make sure the groove in the
grommet is properly seated in the heat shield.
s) Reinstall the AEM air filter. Adjust the
windshield washer hose and wires so they do
not rub against the AEM air filter.
4) Re-assemble the vehicle
a) Position the filter for best fitment. Be sure that the filter, tube, or any other components do not
contact the heat shield or any part of the vehicle.
b) Tighten all hose clamps.
c) Tighten the bolts and nuts on the mounting bracket and heat shield.
d) Reinstall the plastic fender liner.
e) Install tire and torque lug nuts properly.
f) Inspect the engine bay for any loose tools and check that all fasteners that were moved or
removed are tight.
g) Start engine and perform a final inspection before driving the vehicle.
Before
After
For Technical Inquiries
Please E-Mail Us At
[email protected]