How to Install an AEM Cold Air Intake

System on a Mitsubishi Eclipse GS

Written by: Nick Kalil, Robert E Malone, Joseph Aniekwe, and Spencer Boyd
Introduction iii
Table of Contents
Contents
Table of Contents ........................................................................................................................... iii
Introduction ..................................................................................................................................... v
Preparing the Vehicle ...................................................................................................................... 7
Chapter 1 ......................................................................................................................................... 3
Preparing the Vehicle. ................................................................................................................. 3
Preparing for Removal of Stock System ............................................................................. 3
Tools needed for Installation of the AEM Cold Air Intake .............................................. 3
Disconnecting the Power ...................................................................................................... 3
Taking out Stock System ................................................................................................................ 4
Chapter 2 ......................................................................................................................................... 5
Taking out Stock Intake .............................................................................................................. 5
Learning the Stock Intake Parts .......................................................................................... 5
Disconnecting the Stock Intake System .............................................................................. 5
Installation of the Cold Air Intake .................................................................................................. 8
Chapter 3 ......................................................................................................................................... 9
Installation of the Cold Air Intake .............................................................................................. 9
The following is a list of the parts included with the Intake Kit....................................... 9
Connecting the 90 Degree coupling (elbow coupling) to the Upper Intake Pipe: ........... 9
Installing Upper Intake Pipe to Throttle Body ................................................................ 10
Preparing to install the Mass Airflow Sensor................................................................... 11
Installing the MAF .............................................................................................................. 11
Installing the Lower Intake Pipe ....................................................................................... 12
Finishing and Testing the System ................................................................................................. 14
Chapter 4 ....................................................................................................................................... 15
Finishing and testing the system ............................................................................................... 15
Attaching the Red Breather Tube ..................................................................................... 15
Installing Lower Intake Pipe.............................................................................................. 15
Reapplying the MAF........................................................................................................... 16
Attaching the Positive Terminal and Restarting the Car................................................ 16
Glossary ........................................................................................................................................ 17
iv How to Install Cold Air Intake
Index ............................................................................................................................................. 18













Introduction v
Introduction

Please read and fully understand these instructions BEFORE attempting to install the AEM Cold
Air Intake. Failure to do so may result in damage to the Intake, Throttle Body, Engine, or any
other part exposed in the engine bay. This instruction manual will cover all necessary steps to
professionally install the AEM Cold Air Intake. (Warning: Engine may be HOT!).







Preparing the Vehicle
3
Figure 1: Tool Kit
Figure 2: Disconnected Battery
Chapter 1
Preparing the Vehicle.

In this chapter the reader will learn the safety steps and procedures to make sure the installation
goes smoothly and safely. We will also provide a list of tools that will be required to complete
the installation of the Intake.
Preparing for Removal of Stock System:
1. Park the car on a level, even surface.
2. Apply the Emergency Brake (In Manual Vehicle) or put into park (for Automatic
transmissions).
3. Open the hood of the car and secure it open with the hood stand.
4. Let car sit for at LEAST 2 hours to cool down.

Tools needed for Installation of the AEM Cold Air Intake:
(See Figure1: Tool Kit)
Small Ratchet
Small Ratchet Extension
Small 7mm Socket
Medium Ratchet
Medium 10mm Socket
10mm wrench
Flat head screw driver
10mm Bolt (x2)
10mm Nut
If the car has been on recently allow a minimum of TWO hours for engine too cool down. This
reduces the chance of accidental burning. (Warning: Contents may be HOT!)
Disconnecting the Power:
1. Use the 10mm Socket with Medium
Ratchet to loosen the Terminal Bolt. (See
Figure 2: Disconnected Battery)
2. Disconnect the Positive battery terminal.
(Warning: this will prevent future shocks
while working on the vehicle.)

4 How to Install Cold Air Intake






Taking out Stock System

5
Stock Intake System 1
Chapter 2
Taking out Stock Intake

In this chapter you will learn the names and location of the stock intake system. You will then
learn how to identify the stock intake system and proceed to disassemble it. Once disassembled
you can continue to Chapter 3 to begin the installation process.

Learning the Stock Intake Parts: (See Stock Intake figure for Display)
1. Bottom Half of Air Box
2. Air Box Nut
3. Air Box Bolt
4. Air Box Close Clip
5. Air Box Mounting Bolt
6. Air Box Mounting Bracket
7. Mounting Bracket Spacer
8. Mounting Bracket Nut
9. Lock Washer
10. Stock Air Filter
11. Top Half of Air Box
12. Mass Airflow Sensor (MAF)
13. MAF Mounting Bracket
14. Stock Intake Piping
15. Stock Inlet Piping
16. Stock Outlet Piping
17. Air Inlet Funnel


Disconnecting the Stock Intake System:
1. Disconnect the breather hose from the Stock Intake Piping.
2. Remove the hose clamps identified by part 15 & 16 on the Stock Inlet and Outlet Piping.
3. Disconnect the MAF sensor harness from the MAF.
4. Disconnect and pull off Stock Intake Piping. ( Part 14 )
5. Remove the 2 Plastic plugs holding down the Air Inlet Funnel using the Flat Head
Screwdriver. (Part 17)
6. Disconnect and Remove Stock Inlet Funnel from the Air Box.
7. Use the 10 mm Socket with Medium Ratchet to remove the bolts holding the Stock Air
Box to the Mounting Bracket. (Parts 5&6)
8. Disconnect and remove the Stock Air Box from the frame.
6 How to Install Cold Air Intake
9. Use the 10mm Socket with the Medium ratchet to remove the two bolts holding the
Mounting bracket to the frame. (Part 6)
10. Pull off the Mounting Bracket from the frame.
11. Remove the (4) Bolt(s) holding the MAF to the Stock Air Box using the 10mm Socket on
the Medium Ratchet. (Warning: MAF is fragile, handle with Care!)
12. Take off the MAF from Stock Air Box and set aside for Installation with AEM Cold Air
Intake.

7

8 How to Install Cold Air Intake




Installation of the Cold Air Intake
9
Figure 3: Intake Layout
Figure 4: Upper Pipe Connection

Chapter 3
Installation of the Cold Air Intake

In this chapter the reader will learn and understand the components of the AEM Cold Air Intake
system. The reader will then learn the proper and professional way to install the Intake System
safely without damaging parts or self-harm.
The following is a list of the parts included with the Intake Kit:
From top to bottom:
90 Degree rubber coupling
Upper Intake Pipe
Red rubber breath tube
3 diameter rubber coupling (x2)
Lower Intake Pipe
Bracket
AEM cone filter
7 Hose clamps
The layout represents the order in which the parts are to be installed
Top to Bottom. This is also what the Intake will look like once fully
installed in the Eclipse.
(See Figure 3: Intake layout) for visual aid

Connecting the 90 Degree coupling (elbow coupling) to the Upper Intake Pipe:

1. Grab the Upper Intake Pipe.
2. Grab the Elbow coupling.
3. Slide the top end of Upper Pipe into the
Elbow coupling as far as it will go.
4. Place Hose clamp on both ends of the
coupling.
5. Use the 7mm socket with the small
ratchet to tighten clamp on the Upper
Pipe.
6. Leave the other hose clamp loose.
10 How to Install Cold Air Intake
Figure 5: Throttle Body Inlet
Figure 6: Placement of Upper
Pipe
Figure 7: Complete Look
(See Figure 4: Upper Pipe connection)


Installing Upper Intake Pipe to Throttle Body

1. Find the open Inlet hole of the Throttle Body.
(See Figure 5: Throttle Body Inlet for visual)
2. Slide the open end of the Elbow coupling over
the silver Inlet hole of the Throttle body. (See
Figure 6: Placement of Intake Pipe)
3. Tighten the hose clamp on the Inlet hole of
the Throttle Body using the 7mm socket with
the small ratchet.
4. Make sure the clamps are secured tightly.
(See Figure 7 for complete installation of Upper Intake Pipe)









11
Figure 8: Tightening Clamp on MAF
Figure 9: Completed MAF Set up
Figure 10: Installing MAF


Preparing to install the Mass Airflow Sensor (MAF):
1. Insert the 3 Diameter rubber coupling on
top side of the Mass Airflow Sensor.
2. Slide a hose clamp on each side of the
rubber coupling.
3. Use the 7mm socket with the small ratchet
to tighten the hose clamp on the MAF.
(See Figure 8 for reference) (Warning:
Do NOT tighten the clamp too tight on the
MAF because it is a fragile and expensive part!)
4. Repeat steps 1-3 to Install 2
nd
Coupling on the
bottom of the MAF.
(Refer to Figure 9 for completed MAF assembly)






Installing the MAF to the Upper Intake Pipe:
1. Slide the open Top end of the MAF
to the bottom opening of the Upper
Intake Pipe.
2. Use the 7mm socket with the small
ratchet to tighten the hose clamp
around the rubber coupling onto the
bottom of the Upper Intake Pipe.
(For steps 1&2 refer to figure 10)
3. Leave the bottom hose clamp loose
to prepare for the installation of the
Lower Intake Pipe.
4. Shake the Intake gently to make sure
everything is secured properly.

12 How to Install Cold Air Intake
Figure 11: Cone Filter on Lower Intake Pipe
Figure 12: Connecting MAF to Lower Pipe
Figure 13: Placement of Filter



Installing the Lower Intake Pipe to the MAF:
1. Place the last hose clamp around the inlet
hole of the High Flow Cold Air Filter.
2. Slide the bottom inlet hole of the Lower
Intake Pipe inside of the Cone Filter about
1-3.
3. Tighten the hose clamp on the Filter to the
Lower Intake Pipe using the 7mm socket
on the small ratchet. Make sure it is firmly
secure. (See Figure 11 for visual)
4. Slide the Top Inlet hole of the Lower Intake
Pipe into the coupler of the MAF. (See
Figure 12)
5. Tighten the hose clamp on the rubber
coupling to the Lower Intake Pipe using the
7mm socket on the small Ratchet. (Refer to
Figure 12)
6. Make sure the clamp firmly secures the
Lower Intake Pipe. (You do not want this
piece to fall off while driving!)
7. Properly angle the Filter to where it fits in
front of the drivers side wheel well. You
will be able to see filter through the fog light
hole in the bumper. (Example in Figure 13)







13



14 How to Install Cold Air Intake






Finishing and Testing the System
15
Figure 14: Intake Breather
Hole Location
Figure 16: Breather Tube
Placement
Figure 15: Bracket
Installation
Chapter 4
Finishing and testing the system
In this chapter you will learn the final steps to completely install the Intake System. This
includes the breather tube, Lower Pipe Bracket, checking all connections, and restarting the car.
Although it seems like you are almost done now is not the time to skip steps and get sloppy. All
steps are equally important.

Attaching the Red Breather Tube:
1. Locate the breather hole on the Upper Intake Pipe. (See Figure
14 for location)
2. Adjust Breather hole to point twords the Engine.
3. Slide one end of the Red Rubber Tube onto the Breather hole on
the Upper Intake Pipe.
4. Slide the opossite end of the red tube to the Engine Breather
hole. (See figure 15 for Propor placement)









Installing Lower Intake Pipe Bracket:
1. Bolt down one end of the bracket where the originol air box was
located.
2. Use the 10mm socket with the Medium ratchet to tighten down the
10mm bolt and bracket.
3. Allign the Bracket with the bracket that is welded down on the
Lower Intake Pipe.
4. Place the bolt through both of the brackets.
5. Secure brackets and bolt with the 10mm nut.
16 How to Install Cold Air Intake
Figure 17: MAF Plug Location
Figure 18: Final Intake Top View
Figure 19: Positive Terminal of battery
6. Use the 10mm socket with the medium ratchet to tighten down the bolt and nut leaving
the Intake secure to the car. (See Figure 16 for proper installation)


Reapplying the MAF Plug:
1. Gently move the MAF Plug to the MAF. (Refer
to Figure 16 to see the plug)
2. Slowly slide the plug onto the inlet of the MAF.
(See Figure 18 for Final view)









Attaching the Positive Terminal and Restarting the Car:
1. Place Positive terminal over the positive nub on the battery. (Warning: Do NOT touch
positive to negative! WILL cause a short
circuit!)
2. Tighten the 10mm nut on the terminal with
the 10mm socket with the medium ratchet.
(See Figure 19 for reference)
3. Start up the car and make sure there are NO
maintenance required or Check Engine
lights on.

17


Glossary

Air Box Bolt- A 10mm bolt that secures down the air box.
Air box Mounting Bracket- The bracket between the frame of the car and the air box that holds
the air box in place.
AEM cone filter- High flow air filter that allows more air flow to the throttle body.
Air inlet funnel- A funnel that directs the airflow from the outside of the car to the air box.
Breath tube- A hose that directs a small amount of air to the engine to allow engine to breath.
Bottom half of air box- Part of the air box that holds the stock air filter in place.
Coupling- Air tight rubber connecter that seals the intake.
Hose clamps- Metal clamps that secures the rubber couplings on the intake.
Intake- The system that brings air to the throttle body and engine for the air to fuel ratio.
Lower intake pipe- Part of the intake that directs the air flow to the MAF.
MAF mounting bracket- Mounting bracket that secures the MAF to the aftermarket Intake.
Mass airflow sensor (MAF)- A sensor that reads how much air is flowing to the throttle body
that tells the engine CPU how much air and fuel to put in the engine.
Ratchet- A tool used to tighten and loosen bolts on the stock and aftermarket intake.
Socket- Connects to the ratchet and fits directly over the bolts to tighten or loosen them.
Stock air filter- The air filter that comes factory with the car. Does not allow much air to flow
through it.
Stock intake piping- The factory pipe that leads from the MAF to the throttle body.
Stock outlet piping- The factory pipe that leads from the MAF to the factory air box.
Throttle body- Pushes a mixture of air and fuel into the engine for the cylinders and pistons to
combust.
Upper intake pipe- Aftermarket intake pipe that directs air from the MAF to the throttle body.

18 How to Install Cold Air Intake
Index
10mm Socket .............................................................................................................................. 3, 6
7mm Socket .................................................................................................................................... 3
Air Box Bolt .............................................................................................................................. 5, 16
Coupling .................................................................................................................................. 11, 16
Hose clamps .............................................................................................................................. 9, 16
Lower Intake Pipe .................................................................................................... iii, 9, 11, 12, 14
MAF ............................................................................................................... iii, 5, 6, 11, 12, 15, 16
Mass Airflow Sensor............................................................................................................ iii, 5, 11
Ratchet ........................................................................................................................ 3, 5, 6, 12, 16
Socket ........................................................................................................................................ 5, 16
Throttle body ........................................................................................................................... 10, 16
Upper Intake Pipe .................................................................................................... iii, 9, 10, 11, 14