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AEM 21-8100, Installation Instructions Manual

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AEM 21-8100 Installation Instructions Manual Download Page 2

 

2

Congratulations!  

You have just purchased the finest Air Induction & Filtration system for your truck at 

any price! 

The 

AEM

 Brute Force System is the result of extensive development on a wide variety of trucks.  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 Systems deliver maximum performance gains through 

lightweight, all-aluminum, mandrel-bent tubing that is tuned in both length and diameter.  The aluminum 
will not crack in extended use like plastic.  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, 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:  Part #21-8100 

Quantity  Part Number

Description 

1 5-430 

4"-3" 

coupler 

2 5-435 

4"-3.5" 

coupler 

1 

2-81001 

Inlet Pipe Large Bend 

1 

2-81002 

Inlet Pipe Small Bend 

1 

9452 

#52 Hose Clamp 

2 

9456 

#56 Hose Clamp 

4 

9464 

#64 Hose Clamp 

1 784364 

Gromet 

1/2" 

1 

21-2059D 

A/F Assy 4.0”X9" Dry 

22" 

65004 

Hose 5/8ID  

26" 65002 

Hose 

3/4ID 

2 

4093-6 

Hose Clamp 1 1/16" 

2 

4093-8 

Hose Clamp 1 1/4" 

2 4093-5 

Hose 

Clamp 

3/4" 

1 

8-125 

3/8" Straight Barb Fitting 

10" 65128 

3/8" 

Hose 

1 20-81001 

Heat 

Shield 

1 2-669 

MAF 

Adapter 

11" 

8-111 

Rubber Protective Lining 

1 

1-127 

Heat Shield Mounted Zip-tie 

1 2-6691 

Maf 

Adapter 

gasket 

8" 

8-111 

Rubber Protective Lining 

4 

1-2038 

Bolt,Hex/Flange M6 X 20 

4 

444.460.04 

Nut, Serrated 6mm 

4 

1-3018 

Washer, M6 ZINC-Plated Steel 

1 10-8100 

Instructions 

2 

559999 

Washer, 6mm Fender 

2 

1-3028 

 Washer, 1/4 SAE Flat 

2 

1-2072 

Bolt, 1/4-20-UNC x 1 3/4 

2 

1-2074 

 Lock Nut, '1/4-20 

2 

1-2073 

 Nut, '1/4-20 

2 

2-670 

Heat Shield Spacer 

Summary of Contents for 21-8100

Page 1: ...awthorne CA 90250 Phone 310 484 2322 Fax 310 484 0152 www aempower com Instructions Part Number 10 8100 1997 2003 Ford F Series Exc Super Duty Lightning 5 4L V8 C A R B E O D 392 19 1997 2003 Ford Expedition 5 4L V8 C A R B E O D 392 19 1998 1999 Lincoln Navigator 5 4L V8 C A R B E O D 392 19 2004 Ford Expedition 5 4L V8 C A R B E O D 392 27 Brute Force Intake Systems that are pending CARB approva...

Page 2: ...duces 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 8100 Quantity Part Number Description 1 5 430 4 3 couple...

Page 3: ...it cool down e Do not discard stock components after removal of the factory system 2 Removal of the stock intake system Loosen and remove bolt 3 a Your stock intake system should look like this b Loosen and remove left bolt on the throttle body cover Loosen and remove bolts Loosen hose clamp d With the throttle body cover off loosen the hose clamp at the throttle body c Loosen and remove the two r...

Page 4: ...let tubing up to the throttle body e Remove IAC and Crank case breather tubes from the upper air inlet tube Unlock Remove inlet tubing Loosen hose clamp Remove both breather tubes Remove IAT sensor f Remove the IAT sensor from the air inlet tube i Unlock the MAF sensor from its housing ...

Page 5: ...using j With the assembly open locate the MAF sensor Disconnect the MAF sensor and pull the connector from the housing The MAF sensor housing will not be reused l Remove air filter k The stock MAF sensor assembly should look like this 5 ...

Page 6: ...ce Make sure this mounting surface is flat for the heat shield installation m Remove the air filter housing Air filter housing Mounting Surface p Check valve removed o Remove this portion of the IAC breather tube from the vehicle The tube will be removed and the check valve will be reused 6 ...

Page 7: ...g tab hardware until instructed to do so later in these instructions Attach coupler c Insert grommet into upper inlet pipe b Attach reducer coupler and hose clamp to the throttle body Insert upper inlet pipe Loosen all three bolts e Loosen all three bolts to the power steering reservoir d Insert upper inlet pipe Secure with hose clamp 7 ...

Page 8: ...Loosen and remove f Loosen and remove the two bolts on the stock MAF assembly g This part of the stock MAF sensor assembly will not be reused 8 ...

Page 9: ...1 Gasket 4 M6x20 bolts 4 nylok nuts 4 M6 washers and the MAF sensor adapter Insert IAT sensor i The assembly should look like the above photo The order is nylok nut washer MAF sensor gasket MAF sensor adapter and bolt head j Insert IAT sensor into grommet in the upper inlet pipe 9 ...

Page 10: ...ow is pointed to the right on the MAF sensor m Insert the second inlet pipe The bracket will be inserted underneath the tab on the power steering reservoir 10 n This is the hardware that attaches the heat shield to the mounting surface 1 20 bolt washer heat shield spacer and 20 nut o Insert the bolt and washer from underneath the rubber grommet Insert the heat shield spacer and secure with the nut...

Page 11: ...ntrol on the right Note Heat shield may differ from one pictured some require the removal of two bolts on the cruse control module and the installation of the Heat Shield zip tie to secure throttle cable r Secure breather hose for the IAC to the upper nipple on the pipe q Attach breather hose for the IAC and secure to check valve If your check valve is located in front next to the throttlebody you...

Page 12: ... the other end of the crank case breather tube to the nipple on the crank case and secure v Attach filter the inlet pipe Check for clearance Secure filter Note some models will have the coolant reservoir behind the filter These models will require the coolant hose be extended using the supplied barb fitting and 3 8 hose Use the hose clamps to secure 12 ...

Page 13: ...et pipes for best fitment Be sure that the pipes or any other components do not contact any part of the vehicle or heat shield Tighten all bolts and hose clamps Check hood clearance 4 Re Assemble the vehicle a Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are properly tight b Start engine and perform a final inspection before driving the vehicle...

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