AEM 21-8001 User manual

Equipped with AEM®Dryflow™ Filter
No Oil Required!
INSTALLATION INSTRUCTIONS
PART NUMBER: 21-8001
1995-1992 CHEVROLET C1500 Suburban V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1992 CHEVROLET C2500 Suburban V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1992 CHEVROLET K1500 Suburban V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1992 CHEVROLET K2500 Suburban V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET C1500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET C1500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET C2500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET C2500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET C3500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET K1500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET K1500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET K2500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET K2500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 CHEVROLET K3500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995 CHEVROLET C35 V8-5.7L C.A.R.B. E.O. # D-392-21
1995 CHEVROLET Tahoe V8-5.7L C.A.R.B. E.O. # D-392-21
1994-1992 CHEVROLET Blazer V8-5.7L C.A.R.B. E.O. # D-392-21
1991-1989 CHEVROLET R3500 V8-5.7L SEE * NOTE
1991-1989 CHEVROLET V3500 V8-5.7L SEE * NOTE
1988 CHEVROLET R20 V8-5.7L SEE * NOTE
1988 CHEVROLET R30 V8-5.7L SEE * NOTE
1995-1992 GMC C1500 Suburban V8-5.7L SEE * NOTE
1995-1992 GMC K1500 Suburban V8-5.7L SEE * NOTE
1995-1992 GMC K2500 Suburban V8-5.7L SEE * NOTE
1995-1988 GMC C1500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 GMC C1500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 GMC C2500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 GMC C2500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 GMC C3500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 GMC K1500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 GMC K1500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 GMC K2500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1988 GMC K2500 V8-5.0L C.A.R.B. E.O. # D-392-21
1995-1988 GMC K3500 V8-5.7L C.A.R.B. E.O. # D-392-21
1995-1992 GMC Yukon V8-5.7L C.A.R.B. E.O. # D-392-21
1991-1988 GMC R3500 V8-5.7L SEE *NOTE
1989-1988 GMC R2500 V8-5.7L SEE * NOTE
1991-1988 GMC V3500 V8-5.7L SEE * NOTE
1991-1988 GMC Jimmy V8-5.7L SEE * NOTE

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PARTS LIST
Description Qty. Part Number
Air Filter Assy. 4.00 X 9" Dry Ele. 1 21-2059DK
Heat Shield 1 20-8001
Inlet Pipe 1 2-80011
Hose, Silicone 4.00x3" Blk. 1 5-400
Edge Trim, 34" 1 8-4034
Plenum 1 9-8001
Mount, Rubber 1" X 6mm 1 1228599
Neoprene, 1/16" X 6" X 5" Adhes. 1 8-121-5
Rubber Edge Trim 14" 1 8-3014
Gskt., TB Spacer 2 2-9206
TB Spacer, Bl./An 1 2-9006
Bracket, Heat Shield 1 32-3029
Bolt, Hex M6 X 1.0 X 16mm 1 1-2030
Bolt, Hex 5/16-18 X 5/8 2 1-2090
Bolt, Hex 5/16-18 X 3.25 1 1-2091
Bolt, Intake Plenum 2 1-2093
Washer, 5/16 SAE Flat 12 1-3031
Washer, 6mm Soft Mount 4 08160
Nut, M6 Hex Serrated 3 444.460.04
Nut, 5/16-18 Nylock 6 1-2092
1/2" Bnd. Hose Clamp, 3.56"-4.50" 3 9464

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b. Remove the air cleaner housing and filter
element by removing the two wing nuts.
Remove the two mounting studs. Older models
may be equipped with only one wing nut. On
these models, remove the z-shaped rod from
the center of the throttle body. Keep the air
cleaner extension for use with the AEM®intake
system.
Air Cleaner
Lid
Air Filter
Air Cleaner
Housing
Air Cleaner
Extension
a. Remove the air intake duct, resonator, and
adapter form the engine bay. The adapter is
removed by gently squeezing the sides in to
release the lip from the inner fender.
Air Intake Duct
Resonator
Adapter
Resonator Hold
Down Strap
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.
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

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e. Remove the three bolts securing the throttle
body to the intake manifold. Make note of the
vacuum line connections at the front of the
throttle body. Lift the throttle body and remove
the old gasket.
c. From inside the passenger side fender well,
remove the two bolts holding the resonator hold
down strap bracket. Remove the bracket.
d. Follow the two fuel hard lines from the back of
the throttle body down to the bracket on the
transmission. Remove the nut securing the
bracket to the transmission.

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e. Reconnect any vacuum lines on the front of
the throttle body that may have become
dislodged. Secure the hard fuel line bracket
removed in step 2d.
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. Place the AEM
®
throttle body spacer between
the throttle body and intake manifold, using one
of the supplied gaskets on each side.
TB Spacer
c. Thread the two hex-standoffs into the two rear
throttle body mounting holes. Use one 5/16
washer under the hex portion of each standoff.
The longer threaded end of the standoff is the
end that threads into the intake manifold.
d. Place a 5/16 washer under the head of the
supplied 5/16-18 bolt and install into the front
throttle body mounting hole. Torque the hex-
standoffs and bolt to 12 ft-lb.

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Heat Shield
Bracket
h. Loosely secure the heat shield in the engine
bay using the supplied 5/16-18 bolts, washers
and lock nuts. Insert the bolts up from the wheel
well through the holes exposed in step 2c.
g. Install the supplied rubber mount onto the
AEM®heat shield using one each of the
supplied M6 washers and lock nuts.
Rubber
Mount
Washer and
Lock Nut
f. Remove the factory battery hold down bolt.
Place the AEM®heat shield bracket under the
head of the bolt and reinstall.
i. Align the hole in the heat shield with the heat
shield bracket installed in step 3f. Secure using
the supplied M6 bolt, fender washers and lock
nut. Once the heat shield is in place, all three
mounting bolts may be tightened.

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j. Install the rubber edge trim on to the heat
shield where the intake pipe passes through. k. Install the foam rubber edge trim on to the top
edge of the heat shield. Trim excess as
necessary.
m. Install the air cleaner extension removed in
step 2b. Reconnect the breather line on the
back side. Test fit the AEM®intake plenum. The
plenum should not rest on the washers installed
in the previous step. Adjust the lock nuts until
the top of the plenum compresses
approximately ¼” for gasket sealing. Use the
remaining washers and lock nuts to tighten
down the plenum.
l. Thread two of the supplied 5/16-18 lock nuts
on to the standoffs installed in step 3c. Leave
approximately ¾” of thread exposed above the
top of the nut. Place one 5/16” washer on top of
each nut.

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o. Install the AEM
®
inlet pipe into the coupler
installed in the previous step. The bracket will
line up with the rubber mount on the heat shield.
Loosely secure the bracket with an M6 washer
and lock nut. Refer to the following diagram for
proper rubber mount installation.
p. Install the AEM
®
air filter on to the end of the
inlet pipe. Secure with the supplied hose clamp. q. Apply the adhesive backed neoprene rubber to the heat shield directly opposite from the
positive battery terminal.
Proper installation of rubber mount assembly.
n. Loosely install the silicone coupler and two
hose clamps onto the intake plenum.

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4. Reassemble Vehicle
a. Position the inlet 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.
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 states 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)
Factory air box system installed AEM
®
intake system installed

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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.
AIR INTAKE CAR ACCESSORIES