Phil's Install of a AEM 240sx Intake System
On a 97 240sx
Notes: Click the
pictures to enlarge, and yellow * is to denote something
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The Car:
The Intake: |
97 240sx
Aem Short Ram Intake System |
Removing
old intake |
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1)
First disconnect negative battery terminal and let your car cool down |
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2) Unplug the MAS and the IAT sensor connectors |
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3) Disconnect and remove the large lower breather tube and
the small breather hose from the rubber connector on the intake tube |
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4) Release the four clips holding down the air box cover
then loosen the hose clamp on the throttle body. Remove the bolt from the
radiator fan shroud and the mounting tab nut from the radiator support. |
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5) Remove the air intake tube, intake tube mounting tab,
MAS and air box cover from the vehicle |
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6) Loosen the two nuts and one bolt that secure the lower
air box. Remove the stock lower air box form the vehicle |
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7) Remove the IAT sensor from the stock air box. On the
95-96, the IAT sensor is mounted with two bolts that thread through the
air box into a threaded backing plate on the inside of the air box, on the
97-98, it is a sensor that is held in with a rubber grommet. For the
95-96, keep the mounting plate and the two mounting screws for use with
the AEM MAS adaptor.
Note:
"AEM is now aware of the difference between the intake air temperature
sensors on the 95-96 240SX models and 97-98 Nissan 240SX models, and is in
the process of modifying the supplied bracket to accomodate later model
240SX owners. AEM does not recommend that customers modify their intake
systems and that 97-98 240SX owners wait until the design change is
completed before purchasing the system. The updated kit will be available
shortly. If you have any questions, AEM recommends that you contact them
directly at (310) 484-2322."
The kit is perfect for 95-96 models and if you have later model guys
give Aem a call for availability |
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8) Loosen the four mounting
bolts and remove the MAS form the stock air box cover. Remove the stock
air inlet tube from the MAS. The picture is your finished product
ready for the new install |
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9) This is a
shot of the AEM intake parts ready to be installed
Installation: |
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1) Install the 2.75" side of a reducer coupler onto the
throttle body using a 2.75” hose clamp and install one 2.5” hose clamp
onto the other end of the reducer coupler. |
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2) Slide the throttle body end
of the AEM inlet pipe into the coupler on the throttle body. The throttle
body end is the end nearest to the breather hose nipples on the AEM inlet
pipe. |
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3) For the 95-96, install the IAT sensor into the AEM MAS
adaptor using the original screws and backing plate, for the 97-98, I did
a little modification. 1st picture is the IAT sensor on the 97-98 with the
rubber grommet taken off. The 2nd pic is the AEM MAS adaptor.
The 3rd pic is how the IAT sensor needed to fit so to ensure a nice fit, I
trimmed the sides of it with my dremel to 2 flat edges (pic4). Then
I wrapped electrical tape around the adaptor to ensure that the 2 mounting
holes would be covered so no unfiltered air can get in there. Then I
poked a hole in the tape in the center hole (biggest one) and pushed the
sensor through and put a little epoxy glue (from a model airplane) on it
to seal it up perfectly. (This sensor just measures Intake Air
Temperature, so if you didn't want to go through these steps, just tape up
the holes and tie strap the sensor somewhere under the hood so it is still
connected but out of the way of moving components). The last picture
shows the finished product. |
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4) Remove the rubber bushing assembly from the factory air
box mounting tab. Remove the metal sleeve first, then the rubber piece
will pull out. |
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5) Install the bushing and metal
sleeve into the larger hole of the lower MAS mounting bracket. |
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6) Mount the AEM MAS adaptor to the MAS using the four
supplied m6 socket head bolts and washers. position the adaptor so that
the MAS and IAT sensor are oriented as they were originally, and mount the
IAT sensor connector bracket to the MAS mounting hole that it was
originally bolted to |
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7) Install the reducer coupler
onto the end of the AEM inlet pipe with a 2.5” hose clamp and
install the MAS into the reducer
coupler using a 2.75” hose clamp. The
lower MAS bracket should line up with one of the lower air box mounting
studs install a larger fender washer |
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8) Install the AEM air filter
onto the MAS adaptor using a 2.75” hose clamp. |
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9) Connect the small breather hose to the small nipple on
the AEM inlet pipe. Connect the lower larger breather hose to the lower
nipple on the AEM inlet pipe. Use the original hose clamp.
the lower larger breather hose
will need to be cut for proper fitment. When cut just after the first
bend in the hose the lower larger breather hose should line up with the
lower nipple on the AEM inlet pipe.
Replace the upper larger
breather hose with the supplied 5/8” hose and the two 1” hose clamps |
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10) Hook
back up the battery and then go feel that power increase! |
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All I need to say is
WOW! It looks great and when you have your foot down on the floor it
sounds like I have some other crazy motor.... There comes a nice sounding
'roar' from under the hood! I definitly recommend this intake... You
can feel the power increase and hear it. It also looks super under
the hood!
Some finished views
(looking great!) (also scroll down to see dyno sheets of the aem intake)
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