COLD AIR

SYSTEM

Installation Instructions for: Part Number 21-493

1999.5 - 2005 Volkswagen GTI 1.8L 1999.5 - 2006 Volkswagen Golf 1.9L Turbo Diesel

1999.5 – 2005.5 Volkswagen Jetta 1.8L Turbo & 1.9L Turbo Diesel

ADVANCED ENGINE MANAGEMENT INC. 2205 126TH Street, Unit A Hawthorne, CA. 90250

Phone: (310) 484-2322 Fax: (310) 484-0152 www.aempower.com

Instruction Part Number: 10-353 1999.5 - 2004 Volkswagen GTI 1.8L Turbo C.A.R.B. E.O. #D-392-24

1999.5 – 2004 Volkswagen Jetta 1.8L Turbo C.A.R.B. E.O. #D-392-24 2005 Volkswagen GTI 1.8L Turbo C.A.R.B. E.O. # D-392-30

2005-2005.5 Volkswagen Jetta 1.8L Turbo C.A.R.B. E.O. # D-392-30 1999.5-2005.5 Volkswagen Jetta 1.9L Turbo Diesel C.A.R.B. E.O. # D-392-30 1999.5 - 2006 Volkswagen Golf 1.9L Turbo Diesel C.A.R.B. E.O. # D-392-30

Cold 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 2009

Congratulations! You have just purchased the finest Air Induction & Filtration system for your car at any price! 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.

Bill of Materials for: Part Number 21-493

QTY PART # DESCRIPTION 1 2-512 Inlet Pipe 1 21-202D 2.75”X5” Dry Filter 3 444.460.04 M6 Serrated Nut 4 559999 6mm x 25mm x 1mm Washer 1 1228599 6mm Soft Mount 1 5-272 2.75” Silicone Hose 1 2-649 Vacuum Hose Adapter 2 9444 #44 Hose Clamp 1 9448 #48 Hose Clamp

19” 65004 5/8” Vacuum Hose 2 99024.032 1” Hose Clamps 1 10-353 Instructions 1 10-905 Warning Decal 2 10-922S AEM decal 2 1-113 Zip Tie, 6” 1 8-163 Vacuum Cap for Diesel 2 8-114 Vacuum Connector

14” 65532 Vacuum Line

2

Read and understand these instructions BEFORE attempting to install this product. 1) Getting Started Started

a) Make sure vehicle is parked on a level surface. a) Make sure vehicle is parked on a level surface. b) Set parking brake. b) Set parking brake. c) Jack the front of the vehicle and support with properly rated jack stands. c) Jack the front of the vehicle and support with properly rated jack stands. d) Lift the plastic battery cover and disconnect both battery terminals. d) Lift the plastic battery cover and disconnect both battery terminals. e) If engine has run within the past two hours let it cool down. e) If engine has run within the past two hours let it cool down.

2) Removing the stock air inlet system 2) Removing the stock air inlet system

Remove

a) Pull the battery box cover straight up off of the battery box. Squeeze the tabs on the sides of the wire harness tray and lift.

b) Remove the wire harness tray from the vehicle.

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c) Remove the four screws along the top of the radiator support. Remove the two plastic covers.

d) Remove the battery hold down bolt and remove the battery from the vehicle.

4

Squeeze

Remove

Slide Up

Remove

Loosen

Unplug

f) Squeeze the top and bottom of the breather hose. Pull the breather hose clear of the air box. (N/A for diesel.)

e) Unplug the wire harness from the MAF sensor. Loosen the hose clamp on the engine side of the MAF sensor. Pull the rubber tube off of the MAF

Vacuum reference for Diesel only.

g) Remove the two bolts that retain the air box. Remove the air box and MAF sensor from the vehicle.

h) Remove the nut that secures the lower air duct to the fender well. Remove the lower air duct.

i) Slide the wire channel upwards and remove it from the back of the battery box.

j) Remove the four bolts that hold the battery tray in. Remove the battery tray from the vehicle.

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n) Squeeze the tabs on the plastic cradle that used to hold the wire harness connector in the engine bay. Remove the plastic cradle.

Wire Harness Connector

Lift Straight Up

Plastic Clip

k) Lift the wire harness connector out of the plastic cradle on the inner fender well.

l) Move the wire harness removed in the previous step to the opposite side of the plastic ground cable clip.

Remove

m) Remove the screws retaining the plastic wheel well liner. Pull the plastic liner back to expose the area behind the front bumper.

Plastic Rivet

Plastic Rivets

o) Remove the two plastic rivets along the top edge of the radiator support. These rivets are released by pushing the center through with a small, blunt object.

p) Remove the one plastic rivet underneath the headlight housing.

q) Pull the plastic guard from the engine bay. This piece will not be reused with the AEM inlet system.

3

6

Remove

) Installing the AEM Cold Air Intake T completely tighten the hose clamps, MAF sensor assembly or the do so later in these instructions.

a) When installing the AEM intake, DO NOmounting tab hardware until instructed to

b) Using one supplied washer and one M6 nut, install the supplied rubber mount into the hole beneath the battery tray that is towards the fender.

c) The rubber mount should be installed from the bottom, with the washer and M6 nut on top.

e) Install the MAF sensor back into the stock rubber intake hose using the factory hose clamp. Loosely install the coupler onto the other end of the MAF sensor with the supplied hose clamps.

d) Loosen the two Phillips head screws that secure the MAF senso . r to the air box

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g.) Note for Diesel only. Gas vehicles proceed to i.): Attach the 5/8” Vacuum cap onto the nipple.

f) Place one of the supplied washers on the stud that the lower air duct used to be mounted to.

h.) Note for Diesel only: Secure the vacuum cap with the 6” zip tie. Trim excess.

i) Insert the AEM inlet pipe from the engine bay down into the fender well. Loosely secure the MAF sensor end of the AEM inlet pipe to the MAF sensor with the supplied hose clamp. Reconnect MAF sensor.

k) Note for Diesel only: Insert the vacuum connector into the factory vacuum reference line disconnected in step 2g. Join both connecters with the supplied vacuum line.

j) Note for Diesel only. Gas vehicles proceed to l.): rt the vacuum connector into the cap. The connector should be snug.

Inse

m) Loosely secure the lower bracket to the rubber mount installed in step 3a using the last of the supplied washers and M6 nut.

l) Loosely secure the upper bracket to the stud from the previous step using another one of the supplied wa hers and M6 nut. s

Refer to this diagram for proper rubber mount ins

8

Rubber Mount

Fender Well

Inlet PSu

ipe pport Tab

Fender Washer

Lock Nut

tallation:

Plastic Clip

Machined Flat

o) 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. It may be helpful to lubricate the o-ring with a small

e

n) Install the AEM filter on to the end of the AEM inlet pipe with provided hose clamp. Adjust the inlet pipe and filter to ensure that it does not contact the vehicle at any point. Snug the M6 nuts and hose clamps. The Diesel installation stops here.

amount of soap. Use caution to avoid damaging tho-ring.

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isassembly. The large plastic cover behind the headlights not need to be reinstalled.

entire intake tube and filter can be readjusted 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

4) Fo the initial start up.

p) 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

q) Use the supplied plastic zip tie to secure the large breather tube to the smaller one just above it.

pipe to avoid kinks.

r) Re-assemble the vehicle in the reverse order of dthat was retained by the three plastic rivets does s) At this point the

plastic battery box and at the bend in the pipe just above the air filter. inal inspection of installed components

a) Verify that no items are left loose in the engine compartment before you d

Before After

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For technical inquiries e-mail us at

tech@aempower.com or

310.4 n #3

5.) Service and Maintenance a) is recommended that you service your AEM Dryflow filter every 20,000 miles for optimum performance. Use AEM Dryflow cleaning kit part # 21-110.

ur polished AEM intake pipe.

ish on a powder coated AEM intake pipe)

AEM Air Intake System Warranty Policy

4 n #3

5.) Service and Maintenance a) is recommended that you service your AEM Dryflow filter every 20,000 miles for optimum performance. Use AEM Dryflow cleaning kit part # 21-110.

ur polished AEM intake pipe.

ish on a powder coated AEM intake pipe)

AEM Air Intake System Warranty Policy

ItIt

b) Use aluminum polish to clean yo b) Use aluminum polish to clean yo c) Use window cleaner to clean your powder coated AEM intake pipe. (NOTE: DO NOT USE c) Use window cleaner to clean your powder coated AEM intake pipe. (NOTE: DO NOT USE Aluminum pol Aluminum pol

call us at

84.2322 Optio84.2322 Optio

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 isuse, accidents or flying debris. AEM will not warrant its

powdercoating if the finish has been oating should only be cleaned with a mild soap and water solution. P is required for redemption of a

Th

pu

m cleaned with a hydrocarbon-based solvent. The powderc

roof of purchase of both the vehicle and AEM intake systemwarranty claim.

is 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

rchase. This warranty applies only to the original purchaser of product and is non-transferable. Improper use or installation, alterations voids use for racing, accident, abuse, unauthorized repairs or 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 (310) 484-2322, extension 203 and our customer service department will assist you. A proof of purchase is required for all AEM warranty claims.