Scion | 2004 xB | INSTALLATION INSTRUCTIONS

Equipped with AEM® Dryflow™ Filter
No Oil Required!
INSTALLATION INSTRUCTIONS
2006
2004-2005
PART NUMBER: 21-567
SCION xB L4-1.5L
SCION xB L4-1.5L
C.A.R.B. E.O. # D-670-2
AEM® bypass valves are not compatible with this intake system (part number 21-567)
DO NOT attempt to install an AEM bypass valve on this intake system!
LEGAL IN CALIFORNIA ONLY FOR RACING VEHICLES
WHICH MAY NEVER BE USED, REGISTERED
OR LICENSED FOR USE UPON A HIGHWAY.
See aemintakes.com for CARB status on each part for a specific vehicle
AEM Induction Systems
1 (800) 992-3000
WWW: http://www.aemintakes.com
Description
PARTS LIST
Air Filter Assy. 2.25 x 5” Dry Ele.
Inlet Pipe
Elbow, 2.25” 10 Degree
Hose; 5/8”ID x 14”L
Mount, Rubber 1” x 6mm
Nipple,.625 OD x .65wL x 1.5”
Bracket, VSV Mt.
Bracket, Rub. Mt.
Bolt, Socket 8-32 x 5/16 SS
Washer, 6mm Soft Mount
Nut, M6 Hex Serrated
Hose Clamp, 2.25
Hose Clamp, 1 1/4” Narrow
1/2’ Bnd. Hose Clamp, 2.15-3.00”
Qty.
1
1
1
1
1
1
1
1
2
2
2
2
1
1
2
Part Number
21-200DK
2-554
5-221
5-7014
1228599
7-7016
7-7201
7-7202
1-2023
08160
444.460.04
9436
08420
9440
Read and understand these instructions BEFORE attempting to install this product.
Failure to follow installation instructions and not using the provided hardware may
damage the intake tube, throttle body and engine.
The AEM® intake system is a performance product that can be used safely during mild weather
conditions. During harsh and inclement weather conditions, you must return your vehicle to
stock OEM air box and intake tract configuration. Failure to follow these instructions will void
your warranty.
1. Preparing Vehicle
a.Make sure vehicle is parked on level surface.
b.Set parking brake.
c.If engine has run in the past two hours, let it cool down.
d.Disconnect all negative battery terminals.
e.Do not discard stock components after removal of the factory system.
2. Removal of stock system
a. Remove the four nuts securing the plastic engine
cover to the valve cover. Remove the plastic engine
cover from the engine bay.
b. Disconnect the wire harness connected to the
mass-air flow (MAF) sensor.
c. Release the wire harness from the air cleaner cover
by squeezing the plastic clip from the top and bottom.
Carefully remove the plastic clip to allow the MAF
and VSV connector harnesses to be routed separately. Remove the breather hose from the vehicle by
squeezing the spring clamps on both the intake tube
and at the valve cover. Save the spring clamps for
use later in the installation.
d. Remove the vacuum switching valve (VSV) from
the air cleaner cover by gently prying the tab with a
slotted screwdriver and then lifting straight up. Be
careful not to over extend the vacuum hoses or wire
harness going to the VSV. It is not necessary to
disconnect the vacuum lines or wire harness.
3
e. Loosen the hose clamp at the throttle body. Release the two spring clips at the front edge of the air
cleaner cover. Remove the air cleaner cover, intake
tube, and MAF sensor from the engine compartment.
f. Loosen the three bolts that retain the lower air
cleaner housing in the engine bay.
g. Remove the bolt retaining the lower intake air duct.
This bolt and duct are located between the radiator support and the battery. Remove the lower air
cleaner housing and lower intake air duct from the
engine bay.
h. Remove the MAF sensor by loosening the two
Phillips head screws. Save the screws for use if the
vehicle is ever returned to stock condition. Handle the
MAF sensor with care to avoid damage.
4
i. Raise the front of the vehicle with a jack. Refer to
your owner’s manual for proper jack and jack stand
placement to properly support vehicle. Support your
vehicle using properly rated jack stands before wheel
removal or while working under the vehicle.
NEVER WORK UNDER A VEHICLE WITHOUT USING JACK STANDS. Remove the bolts and plastic
rivets that secure the fender liner. Pull the fender
liner back to gain access to the area behind the front
bumper.
3. Installation of AEM® intake system.
a.When installing the intake system, do not completely tighten the hose clamps or mounting hardware until instructed
to do so.
b. Install the MAF sensor into the AEM® intake pipe.
Use the supplied 8-32 cap head screws. Use care to
avoid damaging the o-ring.
c. Remove the two bolts securing the resistor ballast
beneath the driver’s side headlight.
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d. Install the supplied rubber mount bracket as shown
and secure the resistor ballast using the original bolts.
Install the supplied rubber mount using one fender
washer and one lock nut.
e. Loosely install the coupler onto the throttle body
using the two #36 hose clamps. Orient the nipple so
that it is pointed approximately 45° back towards the
firewall. This will be adjusted later in the installation.
f. Install the AEM® intake pipe from underneath the
vehicle. Insert the end near the MAF sensor into the
coupler on the throttle body. The mounting bracket on
the intake pipe should line up with the rubber mount
installed in step 3d.
g. Loosely secure the mounting bracket with the
remaining fender washer and lock nut. Refer to the
diagram below for proper rubber mount installation.
h. Install the AEM® air filter onto the end of the intake
pipe.
i. Rubber mounting bracket diagram.
6
j. Adjust the inlet pipe and coupler for best fitment. Make sure the AEM® intake system does not come into contact with
the vehicle anywhere. Adjust coupler at throttle body to ensure that both the throttle body and the AEM® inlet pipe are
seated flush up to the lip inside the coupler. Tighten the hose clamps and lock nut on the rubber mount.
k. Reinstall lower splashguard and plastic fender liner using the original factory hardware. Remove jack stands and lower vehicle.
NOTE: Failure to install the plastic splashguard and fender liner will result in diminished performance and
increase the potential for engine damage due to water ingestion in rainy conditions.
l. Install the supplied vacuum nipple into the throttle
body coupler. Secure the nipple with the supplied
hose clamp.
m. Install the supplied breather hose between the
nipple on the throttle body coupler and the valve cover. Secure the hose with the original spring clamps.
NOTE: Due to manufacturing variances, it is sometimes necessary to adjust the main engine
wiring harness to allow the harness to reach the MAF sensor. If there is any tension on the
MAF sensor wires at all, follow the instructions below. If there is a sufficient amount of slack
in the harness, skip ahead to step 3q.
n. Gently pry back the plastic tab and remove the
plastic clip on the wire harness from the metal bracket
next to the valve cover. The clip will lift straight up off
of the bracket.
o. Repeat for the next plastic clip on the wire harness
towards the firewall.
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q. Install the VSV mounting bracket using one of the
factory air box bolts as shown.
p. Place a small screwdriver in the slot of the clip and
gently pry downwards. Split the housing of the clip
open. Slide the clip down the wire harness a couple
of convolutions to free up more harness towards the
MAF sensor. Repeat for the second wire harness clip.
Reinstall both clips to the bracket on the engine. Plug
in the MAF sensor wire harness and make sure the
wires are not stretched.
r. Clip the VSV on to the bracket. If the VSV does
not clip on tightly, gently bend the tab on the VSV to
increase the tension.
Factory air box system installed
AEM® intake system installed
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4. Reassemble Vehicle
a.Position the intake pipes for the best fitment. Be sure that the pipes or any other components do not contact any
part of the vehicle. Tighten the rubber mount, all bolts, and hose clamps.
b.Check for proper hood clearance. Re-adjust pipes if necessary and re-tighten them.
c.Inspect the engine bay for any loose tools and check that all fasteners that were moved or removed are properly
tightened.
d.Reconnect negative battery terminals and start engine. Let the vehicle idle for 3 minutes. Perform a final inspection
before driving the vehicle.
NOTE: If vehicle was started without the VSV or the MAF sensor connected, the “Check Engine” light may
come on. If this happens turn the engine off and disconnect the battery for one minute. Reconnect the bat
tery and restart the engine.
e.Please note that AEM® bypass valves will not work with this application (part number 21-567). The use of a
bypass valve could have adverse effects on the performance of the system.
5. CARB Sticker Placement
a.The C.A.R.B. exemption sticker, (attached), must be visible under the hood so that an emissions inspector can see
it when the vehicle is required to be tested for emissions. California requires testing every two years, other state
may vary.
6. Service and Maintenance
a.It is recommended that you service your AEM® Dryflow™ filter every 20,000 miles for optimum performance. Use
AEM Dryflow cleaning kit part # 21-110.
b.Use aluminum polish to clean your polished AEM intake tube.
c.Use window cleaner to clean your powder coated AEM intake tube. (NOTE: DO NOT USE aluminum polish on
powder coated AEM intake tubes)
For technical inquiries
e-mail us at
sales@aemintakes.com
or
call us at
800.992.3000
AEM Air Intake System Warranty Policy
AEM® warrants that its intake systems will last for the life of your vehicle. AEM will not honor this warranty due to mechanical damage (i.e. improper installation or fitment), damage from misuse, accidents or flying debris. AEM will not warrant
its powder coating if the finish has been cleaned with a hydrocarbon-based solvent. The powder coating should only be
cleaned with a mild soap and water solution. Proof of purchase of both the vehicle and AEM intake system is required for
redemption of a warranty claim.
This warranty is limited to the repair or replacement of the AEM part. In no event shall this warranty exceed the original
purchase price of the AEM part nor shall AEM be responsible for special, incidental or consequential damages or cost
incurred due to the failure of this product. Warranty claims to AEM must be transportation prepaid and accompanied with
dated proof of purchase. This warranty applies only to the original purchaser of product and is nontransferable. Improper
use or installation, use for racing, accident, abuse, unauthorized repairs or alterations voids this warranty. AEM disclaims
any liability for consequential damages due to breach of any written or implied warranty on all products manufactured by
AEM. Warranty returns will only be accepted by AEM when accompanied by a valid Return Merchandise Authorization
(RMA) number. Credit for defective products will be issued pending inspection. Product must be received by AEM within
30 days of the date RMA is issued.
If you have a warranty issue, please call (800) 992-3000 and our customer service department will assist you. A proof of
purchase is required for all AEM warranty claims.
LEGAL IN CALIFORNIA ONLY FOR RACING VEHICLES
WHICH MAY NEVER BE USED, REGISTERED
OR LICENSED FOR USE UPON A HIGHWAY.
See aemintakes.com for CARB status on each part for a specific vehicle
9
10-7024D
03/14/14
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