AEM 21-699 User manual

INSTALLATION INSTRUCTIONS
PART NUMBER: 21-699
* NOTE: Legal in California only for racing vehicles which may never be used upon a highway
AEM Induction Systems 1 [phone] WWW: http://www.aemintakes.com
2007-2010 MINI Cooper S L4-1.6L W/MAF SENSOR SEE * NOTE
Equipped with AEM® Dryow™ Filter
No Oil Required!

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Description Qty. Part Number
PARTS LIST
A Tube; Mini Cooper 1 2-1454
B Air Box Intake 1 9-0396
C Hood Scoop 1 9-0397-1
D Heat Shield, Lid 1 20-8517
E Air Filter 1 21-2027D-HK
F Gasket, Window 1 5-1060-1
G Coupler, Elbow, Turbo Inlet 1 5-1061
H Coupler, Elbow, Air Box Lower 1 5-1058
I Heat Shield 1 20-8524
J Hose, 5/32” I.D. X 18”L 1 5-3018
K Gasket, EPDM Trim-Seal 16” L 1 8-6016
L Hose; 2-3/4” Id X 1-1/2” L Reinforced 1 08179
M Grommet; 3/8”ID X 1-5/8”OD X 1-1/4” Panel Hole X 3/16” Gap 1 784643
N Rivet, Push-in, Nylon, Ribbed Shank, .281 Hole, .062-1.0” Mat 4 8-174
O Spacer, Alum 0.500” OD X 0.250” ID X 2-1/8”L 2 7-252
P Bolt; Hex M6-1 X 65mm 2 1-2095
Q Hose Clamp, 2.31-3.25” 3 9444
R Hose Clamp, 1.75 1 103-BLO-2820
S Bolt; Button Head M6-1.0 X 10mm 6 1-112
T Washer, #12 Nylon 6/6 4 1-3001
U Washer, M6 X 12mm OD Zinc 2 1-3018
V Washer, M6 Split Lock Zinc 7 1-3025
W Filter Minder, 10” 1 35-80311
X Bracket; Support Filter Minder 1 32-3017
Y Bolt; Hex M6-1 X 12mm 3 1-2065
Z Grommet,1/2” 1 784634
AA Elbow, Plastic 5/32” 90 Degree 1 8-152
AB Mount, Plastic Air box 3 8-186
AC Hose, 1/4” I.D., 1.0” Long 1 5-6001
AD 1/2” Bndhose Clamp, 2.56”-3.50” 1 9448

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Kit Illustration
A
B
C
D
E
AA
T
T
T
T
S
S
S
S
F
J
U
P
N
N
N
N
O
O
R
M
AB
AB
I
K
G
QH
W
Z
X
VS
V
YY
Y
L
Q
Q
AD
OEM
MAF Sensor
V
V
V
V
V
AC

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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 negative battery terminal.
e. Do not discard stock components after removal of the factory system.
2. Removal of stock system
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.
a. Disconnect the MAF sensor wiring harness at
the MAF sensor housing by pushing down the
small lock tab and pulling on the connector.
b. To remove the stock intake tube, disconnect the
turbo bypass tube from the stock intake and loosen
the 2 hose clamps retaining the intake tube.
c. To remove the stock MAF sensor housing,
remove the 2 screws retaining the MAF housing to
the upper air box lid, then remove the large o-ring
from the MAF sensor outlet.
d. Remove the lower Torx screw and plastic grom-
met insert at the passenger side foot of the stock
air box using a T20 Torx bit. Retain the Torx screw
for future use.
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 conguration. Failure to follow these
instructions will void your warranty.

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e. Pull up on the stock air box assembly carefully
until it pops free from the 3 rubber mounting grom-
mets on the intake manifold. Make sure all 3 rubber
grommets stay in the intake manifold.
f. Unclip the plastic vacuum line from the lower
intake elbow.
g. To completely remove the air box assembly,
disconnect the air box inlet elbow (left) from the
stock intake tube (right) by squeezing on the intake
tube and pulling it free from the 4 locking slots in
the intake elbow.

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d. Mount the lter minder support bracket onto the
brass inserts on the side of the air box using 2 of
the M6 buttonhead bolts (1-112) and 2 of the split
washers (1-3025). Fully tighten the bolts with a
4mm allen wrench.
e. Mount the AEM®Filter Minder Gauge (35-80311)
into the grommet of the support bracket and orient
as shown. Use glass cleaner or a silicone lubricant
to ease installation into the grommet. If necessary,
reset the gauge needle so it points to the green
section of the indicator.
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 3 black plastic airbox mounts (8-186)
onto the bottom of the air box (9-0396) as shown
using 3 of the M6 hex bolts (1-2065) and 3 of the
split washers (1-3025) inside the air box. Fully
tighten the 3 bolts and washers inside the air box.
c. Install the smaller grommet (784643) into the
black lter minder support bracket (32-3017) as
shown.

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j. Install the long 5/32” hose (5-3018) over the
elbow tting as shown.
k. Inside the air box, install the AEM® Dryow™
air lter onto the outlet of the MAF sensor housing
with a #44 hose clamp as shown. Fully tighten the
hose clamp.
h. Install the short reinforced hose (08179) over the
inlet ange of the MAF housing on the outside of
the air box with a #44 hose clamp as shown. Fully
tighten the hose clamp.
i. Install the small elbow tting (8-152) into the
small hole in the cap of the Dryow™ air lter
(21-2027D-HK) as shown.
f. Install the stock MAF sensor housing into the
large upper hole inside the air box (9-0396) as
shown. The 2-bolt ange should face left toward
the inside of the air box.
g. Rotate the MAF sensor housing in the hole until
the MAF sensor connector is aligned with the
access hole in the front of the air box as shown.

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q. Install the new air box assembly onto the 3 stock
mounting grommets on the intake manifold.
l. Push the long 5/32” hose attached to the air
lter’s cap through the 3/8” hole on the side of the
air box and connect it to the port of the AEM® lter
minder gauge as shown. Trim the hose as needed.
m. If your AEM®air box (9-0396-1) has a small 1/4-
inch hole in the mounting foot, install the stock Torx
screw (Removed in Step 2d) into the mounting foot
as shown. Proceed to Step 3q.
n. If your AEM®air box has a larger ½”-inch hole in
the mounting foot, cut the ½”-inch hose (5-6001) to
match the length of the hole in the mounting foot
(approximately 0.6” or 5/8”) as shown.
o. Insert the cut hose (5-6001) into the mounting
foot hole until it is ush with the bottom face as
shown.
p. Partially insert the stock Torx screw into the
rubber hose as shown. The hose will work as an
expansion grommet upon installation.

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v. Connect the MAF harness connector to the MAF
sensor housing inside the air box as shown.
w. Fully seat the split grommet (784643) into the
MAF sensor access hole in the front of the air box
to completely seal the hole as shown.
s. Install the oval end of the rubber elbow intake
coupler (5-1058) over the outlet of the stock plastic
intake tube. Fully seat the coupler until the 4 plastic
lock tabs t into the 4 slots in rubber elbow coupler.
t. Insert the round end of the elbow coupler
(5-1058) into the lower inlet hole of the air box.
Make sure it is fully seated.
u. Place the large split grommet (784634) over the
MAF wiring harness as shown. Note that that MAF
harness has been re-routed underneath the other
engine sensor harness to maximize slack.
r. Align the torx screw in the mounting foot to the
lower passenger side mounting pad on the intake
manifold. Fully tighten the screw with a T20 Torx
driver until it is fully seated in the intake manifold’s
mount.

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z. Mount the heat shield lid assembly onto the air
box using 4 M6 buttonhead bolts (1-112) and 4
plastic washers (1-3001); tighten using a 4mm
Allen wrench. Start all 4 bolts before fully tighting.
aa. Loosely install the turbo elbow coupler (5-1061)
onto the turbocharger inlet using the provided #28
hose clamp. Fully seat the turbo bypass connec-
tor into the bypass port of the coupler. Use glass
cleaner to ease installation of the interference-t
connector into the bypass port if necessary.
x. Remove the waxed paper backing from the sili-
cone foam window gasket (5-1060-1) by pinching
the gasket on its sides, then pealing up the edge of
exposed paper. DO NOT USE A KNIFE TO
REMOVE THE PAPER BACKING.
y. Place the powder coated air box heat shield lid
(20-8517) on a table with the part number stamp
facing DOWNWARD. Apply the adhesive side of
the silicone gasket (5-1060-1) on top of the heat
shield, aligning it with the window cutout as shown.
Press down on the foam gasket to ensure adhe-
sion to the heat shield lid.
NOTE: The adhesive must set for a full 24
hours before use for best results.

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ae. Fully tighten the 2 long hex bolts until the wash-
ers and spacer are seated. Pull up on the turbo
heat shield (20-8524) lightly to ensure there is
small air gap between it and the stock turbocharger
heat shield wrap. NOTE: The AEM®turbo heat
shield is required to protect your AEM®cold air
hood scoop from excess heat.
ad. Mount the 2 long hex bolts of the turbo heat
shield assembly into the 2 M6 mounting bosses at
the edge of the cylinder head as shown. If you are
installing an additional aftermarket valve cover heat
shield to these bosses, then do not install the split
washers between the AEM turbo heat shield and
the aluminum spacers in the last step (3-ac).
ab. Loosely install the intake tube (2-1454) into the
turbo coupler and then into the short hose (08179)
on the air box side using 2 #44 hose clamps. Ad-
just the tube until it is straight alongside the engine
and then fully tighten all 3 hose clamps.
ac. Assemble the 2 M6 x 65mm hex bolts (1-2095),
2 at washers (1-3018), 2 split washers (1-3025),
and 2 aluminum spacers (7-252) so the hex bolts
slide through the turbo heat shield (20-8524) holes
and into the aluminum spacers as shown. Assem-
ble the parts so that the at washers mount on top
of the heat shield and the split washers are sand-
wiched by the heat shield and aluminum spacers.
Ensure that the AEM®logo on the turbo heat shield
is facing up.

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b. Remove the 4 screws retaining the hood insula-
tion under the vehicle’s hood. Remove the insula-
tion pad. Note the 4 insulation pad mounting holes
on the under hood bracing.
c. Temporarily close the vehicle’s hood. Carefully
pull up at the rear center of the factory hood scoop
bezel using small ngertips or a athead screw-
driver covered in tape and a soft cloth until it pops
free from the hood. Carefully pull up on the remain-
ing mounting tabs to remove the bezel.
d. Place the hood scoop bezel face down onto a
clean cloth or towel to prevent scratching. Remove
the 4 small Phillips screws retaining the air
restrictor grill. Remove the grill.
e. Re-install the now fully open hood scoop bezel
onto the vehicle hood by popping the mounting
tabs back into position by hand. DO NOT use a
mallet to force them in.
4. Installation of the AEM®cold air hood scoop
a. When installing the intake system, do not completely tighten the hose clamps or mounting hardware until instructed
to do so.

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f. Install the edge trim (8-6016) onto the lower lip
and sides of the cold air hood scoop’s inlet. Ensure
the edge trim is even on both sides of the inlet and
is fully seated; use the heel of your hand or a light
rubber mallet to fully seat.
g. Open the vehicle’s hood. Mount the AEM®cold
air hood scoop onto the underside of the hood by
mounting the plastic push rivets (8-174) into the 4
insulator pad mounting holes by hand. Ensure the
4 push rivets are fully seated and properly secure
the AEM®hood scoop in place. Make sure the
edge trim of the AEM®hoop scoop inlet fully seals
around the cutout in the underside of the vehicle
hood.
h. In some vehicles, you may need to unclip the
windshield washer hose under the hood to prevent
the hose from being pinched. Re-route the hose
around the back of the new hood scoop and then
re-clip the hose.
AEM®intake system installed

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5. Reassemble Vehicle
a. Position the inlet pipes for the best tment. Be sure that the pipes or any other components do not contact any part
of the vehicle. Tighten the rubber mounts (if applicable), 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 the negative battery terminal and start the engine. Let the vehicle idle for 3 minutes. Perform a nal
inspection before driving the vehicle.
6. Service and Maintenance
a. AEM Induction Systems requires cleaning the intake system’s air lter element every 100,000 miles. When used in
dusty or off-road environments, our lters will require cleaning more often. We recommend that you visually inspect
your lter once every 25,000 miles to determine if the screen is still visible. When the screen is no longer visible
some place on the lter element, it is time to clean it. To clean, purchase our AEM Synthetic Air Filter Cleaner, part
number 1-1000 and follow the easy instructions.
b. 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
[email protected]
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 mechani-
cal damage (i.e. improper installation or tment), damage from misuse, accidents or ying debris. AEM will not warrant
its powder coating if the nish 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 [phone] and our customer service department will assist you. A proof of
purchase is required for all AEM warranty claims.
10-351C
04/15/13