1999.5 - 2005 Volkswagen Golf/GTI 2.0L 4 Cyl. Cold Air System Installation

Installing the AEM Cold Air System
a) When installing the AEM intake, DO NOT completely tighten the hose clamps, MAF sensor assembly or the mounting tab hardware until instructed to do so later in these instructions.
b) Install the rubber mount in the outermost (towards driver’s side of vehicle) hole to the rear of the large opening behind the headlight. Insert the rubber mount from below (Fig. 16) and secure it with a large fender washer and lock nut from the top. (Fig. 17)
c) Place a large fender washer on the stud that originally secured the lower intake tube in place. (Fig. 18)
d) Re-install the MAF sensor into the plastic intake hose, rotating the electrical connector to the original position. Use the original spring hose clamp. Note: it is possible to install the MAF sensor backwards. DO NOT INSTALL BACKWARDS. Make sure that the end with the flange (originally in the airbox) is still facing away from the throttle body. If you are still unsure, there is an arrow with the word “flow” molded into the MAF sensor body. (Fig. 19)
e) Install the silicone hose onto the upper end of the AEM inlet pipe with one of the 2.75” hose clamps. The upper end is the end with the AEM decal. Loosely install the second 2.75” hose clamp onto the silicone hose.
f) Feed the AEM inlet pipe into the engine bay and fender well. The lower bracket should line up with the rubber mount installed in step 3b. The upper mount should line up with the stud originally used to mount the lower intake tube.
g) Install a large fender washer and lock nut onto both the rubber mount and the stud. (Fig. 20 & 21) Refer to the following diagram for proper rubber mount installation.
h) Insert the MAF sensor into the into the silicone hose on the AEM inlet pipe. Make sure the MAF sensor is still rotated correctly in the factory position. Plug in the MAF sensor wire connector.
i) Install the AEM air filter onto the bottom of the AEM inlet pipe using the supplied hose clamp. Make sure the filter does not contact the horn or the plastic fender liner. (Fig. 22)
j) Adjust the inlet system for best fitment and snug the hose clamps and locknuts down. (Make sure that no part of the inlet system comes into contact with any part of the vehicle.)
k) Connect the factory breather hose to the AEM vacuum hose adapter. Line the clips on the plastic hose up with the flats machined into the adapter. (Fig. 23) It may be helpful to lubricate the o-ring with a small amount of clean engine oil. Use caution to avoid damaging the o-ring.
l) Install the supplied 5/8” vacuum hose section from the AEM adapter to the nipple on the back of the AEM inlet pipe with the two supplied 1” hose clamps. Route the hose in a broad arc under the AEM inlet pipe to avoid kinks. (Fig. 24)
m) Re-assemble the vehicle in the reverse order of disassembly. The large plastic cover behind the headlights that was retained by the three plastic rivets does not need to be reinstalled.
n) At this point the entire intake tube and filter can be re-adjusted for position and alignment. Make sure that no part of the AEM intake rubs anywhere along its length. Critical points to check are on the corner of the plastic battery box and at the bend in the pipe just above the air filter.

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1999.5- 2004 Volkswagen Golf/GTI VR6 Cold Air System Installation

The AEM Cold Air System is the result of extensive development on a wide variety of cars. Each system is engineered for the particular application. The AEM Cold Air System differs from all others in several ways. We take the inlet air from outside of the engine compartment where the inlet air is considerably cooler than the hot underhood air. The cooler inlet air temperature translates to more power during the combustion process because cool air is denser than warm air. AEM has conducted extensive inlet air temperature studies and we have seen temperature reductions of up to 50 degrees by pulling air from outside of the engine compartment. The air mass flow to the engine is increased because of the increased airflow and reduced inlet temperature, which translates to more power. The AEM Cold Air Systems are 50 states Street Legal (some models and years still pending) and come with complete instructions for ease of installation.

Our system is constructed of lightweight aluminum and then painted with a zirconia based powder coat for superior heat insulating characteristics. The aluminum will not crack in extended use like plastic and it is actually lighter than plastic. The tube diameter and length are matched for each engine to give power over a broad rpm range. Unlike the plastic systems that use a continually diverging cross section, we take advantage of the acoustical energy in the duct to promote cylinder filling during the intake valve-opening event.

Our Dyno testing as well as independent dyno tests (see 7/97 Sport Compact Car Magazine) prove that the AEM Cold Air System produces as much as twice the power gain than any other system on the market.

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1998-2002 Honda Accord 4 Cyl. Cold Air System Installation

The AEM Cold Air System differs from all others in several ways. We take the inlet air from outside of the engine compartment where the inlet air is considerably cooler than the hot under hood air. The cooler inlet air temperature translates to more power during the combustion process because cool air is denser than warm air. AEM has conducted extensive inlet-air temperature studies and we have seen temperature reductions of up to 50 degrees by pulling air from outside of the engine compartment. Because of the increased airflow and reduced inlet temperature, the air-mass flow to the engine increases, this translates to more power.

Our system is constructed of lightweight aluminum and then painted with a zirconia based powder coat for superior heat insulating characteristics. The aluminum will not crack in extended use like plastic and it is actually lighter than plastic. For each engine, we match the tube’s diameter and length to promote power over a broad rpm range. Unlike the plastic systems that use a continually diverging cross section, we take advantage of the acoustical energy in the duct to promote cylinder filling during the intake valve-opening event.

Read and understand these instructions BEFORE attempting to install this product.
1. Make sure vehicle is parked on a level surface.
2. Set parking brake.
3. Disconnect negative battery terminal.
4. If engine has run within the past two hours let it cool down.
5. The following items will be removed from the vehicle.
(a) The OE inlet tube
(b) The air filter case
(c) Intake air noise resonators.
6. Removal of intake air tube.
(a) Disconnect the breather hose from the intake tube. The hose consists of a section of metal tubing between the intake tube and the cam cover.
7. Removal of air filter case.
(a) Remove the two mounting bolts for the air filter case and lift the case out.
8. Preparing the vehicle to accept the Cold Air System.
(a) From underneath the vehicle, remove the engine splash shield and the front left plastic fender liner.
i) The front plastic under-tray can be removed entirely for installation of the Cold Air System and the fender liner can be temporarily folded such that it does not interfere with the installation.
(b) Remove the bolts holding the lower resonator assembly and pull the assembly out from underneath the vehicle.
(c) Remove the two bolts securing the diagonal fender brace that is mounted between the battery and the passenger-side fender.

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1992–1995 Honda Civic Cold Air System Installation Instructions

The AEM Cold Air System is the result of extensive development on a wide variety of cars. Each system is engineered for the particular application. The AEM Cold Air System differs from all others in several ways. We take the inlet air from outside of the engine compartment where the inlet air is considerably cooler than the hot underhood air. The cooler inlet air temperature translates to more power during the combustion process because cool air is denser than warm air. AEM has conducted extensive inlet air temperature studies and we have seen temperature reductions of up to 50 degrees by pulling air from outside of the engine compartment. The air mass flow to the engine is increased because of the increased airflow and reduced inlet temperature, which translates to more power. The AEM Cold Air Systems are 50 states Street Legal (some model and years still pending) and come with complete instructions for ease of installation.

Removing the stock air inlet system
a) Remove the stock air box assembly and attaching hardware from inside the fender well.
b) Disconnect breather hose from the air inlet tube.
c) Disconnect the water bypass hose from throttle body or the fast idle thermo valve, where equipped, located at the lower portion of the throttle body. Disconnect the opposite side of the water bypass hose, which runs to either the intake manifold or the water outlet neck. Remove the entire water bypass hose and breather hose assembly from the vehicle.
d) Loosen and remove the air inlet tube from the throttle body.
e) Jack the front of the vehicle and support using properly rated jack stands.
i) Remove the lower front splashguard.
ii) Remove the front right tire and remove the inside splashguard (inner fender liner).
f) Remove the resonator from underneath the vehicle.

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