AEM Cold Air Intake Systems that are pending an Executive Order number (EO#) relating to exemptions under Section 27156 of the VehicleCode from the California Air Respource Board (CARB) are for off-road use only in California, which may never be used on public highways.© 2009, Advanced Engine Management, Inc. AEM is a registered trademark of Advanced Engine Management, Inc. All rights reserved.

Advanced Engine Management Inc.2205 126th Street, Unit A

Hawthorne, CA 90250Phone: 310.484.2322

http://www.aempower.com

2004 Saturn Ion CARB EO #: D-392-24

Equipped with AEM DRYFLOW FilterNo Oil Required!

Kit Part Number: 21-632

21-632

Instructions 10-7018 02.24.09 Rev 22

Quantity Part Number1 5-3051 94441 94481 94401 2-5472 99024.032

7.5 651161 7846341 12285991 12285983 5599993 444.460.041 21-201D1 10-70182 10-922S

Bill of Materials

Part DescriptionHose, elbow 3.00" X 2.50" 90

#44 Hose clamp#48 Hose clamp#40 Hose clamp

Aluminum Inlet PipeHose clamp,1"

Hose, 1/2IDGrommet, 1/2"

Mount,Rubber 1" X 6MMMount,rubber 5/8" X 6MM

Washer,fender 1/4-9/32 X 1Nut, Serrated 6MM

A/F Assy 2.50 X 5" DryflowInstructionsAEM Decal

21-632

Instructions 10-7018 02.24.09 Rev 13

1. Preparing Vehicle

a) Make sure vehicle is parked on a 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.f) Jack up front of the vehicle, place on properly rated jack stands, and remove front right wheel

2. Removal of Stock System

a) Stock intakesystem.

c) Loosen hoseclamp at the throttlebody.

d) Release the springclamp on the breatherhose and pull hose offof the valve cover.

b) Remove plasticretainer.

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Instructions 10-7018 02.24.09 Rev 24

i) Release allretainers and removethe liner from thefender well.

j) Release the upperretainer of the lowerair box.

e) Gently pull inlet airtemp (IAT) sensorfrom the rubbergrommet.

f) Remove the nutlocated behindheadlight.

h) Remove fenderliner by first releasingplastic retainers andscrews.

g) Remove upper airbox from vehicle.

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Instructions 10-7018 02.24.09 Rev 15

k) Remove the lowerretainer of the lowerair box.

l) Loosen andremove the boltsecuring the lower airbox to the vehicle.

m) Remove the lowerair box from thevehicle.

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Instructions 10-7018 02.24.09 Rev 26

d) Remove theparking light bulb byfirst rotating it aquarter of a turn.

e) Release the blueconnector on the rearof the headlight.Remove headlightfrom the vehicle.

3. Installation of Cold Air Intake System.

a) When installing the intake system , DO NOT completely tighten the hose clamps or mounting tab hardware until instructed to do so.

b) Install the 5/8"rubber mount to thelower mounting tab asshown. Secure it witha supplied washerand lock nut.

c) Release headlightby removing the twopins shown.

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Instructions 10-7018 02.24.09 Rev 17

f) Loosen andremove the lower bolton the plasticmember shown.

j) Install pipe inengine bay as shownby routing it upwardsfrom the fender well.

g) Install the 1"rubber mount frominside the engine bay,as shown.

k) Place inlet pipesupport tab underwasher as shown.Refer to step ‘l’ forproper installation.

h) Install the rubberelbow onto thethrottle body. Use thesize 48 clamp at thethrottle body. Do nottighten the clamp!

i) Insert suppliedgrommet into inletpipe.

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Instructions 10-7018 02.24.09 Rev 28

p) Install the air filteronto the end of thepipe. AEM Cold AirIntake Systeminstalled.

p) If you anticipatetraveling through water deepenough to completelysubmerge the filter, an airbypass valve may beinstalled on this intakesystem. Install the valveaccording to the suppliedinstructions and in thelocation as shown.

l) Place the lowersupport tab under thefender washer. Referto step ‘l’ for properinstallation.

m) Proper rubbermount installation.

n) Install the suppliedbreather hosebetween the inlet pipeand valve cover.Secure it with thesupplied 1" hoseclamps.

o) Insert IAT sensorthrough the grommetin the inlet pipe. Becareful not to pushthe grommet into thepipe.

Lock NutFender Washer

Inlet Pipe Support Tab

Rubber MountChassis

Cut

Cut

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Instructions 10-7018 02.24.09 Rev 19

Stock Intake Installed AEM Cold Air Intake System Installed

4. Re-assemble Vehicle

a) Position the inlet pipes for best fittment. Be sure that the pipes or any other components do not contact any part ofthe 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

tight.d) Re-connect the negative battery cable to the terminal.e) Start engine. Let car idle for 3 minutes. Perform a final ispection before driving vehicle.

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Instructions 10-7018 02.24.09 Rev 210

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 powdercoating if the finish has been cleaned with a hydrocarbon-based solvent. The powdercoating 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 forspecial, 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 proofof purchase. This warranty applies only to the original purchaser of product and is non-transferable. Improper use or installation, use for racing, accident, abuse, unauthorized repairs oralterations 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. Warrantyreturns 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.

5. Service and Maintenence

a) It is recommended that you service you AEM dryflow filter every 20,000 miles for optimum performance. UseAEM Dryflow cleaning kit part #21-110.

b) Use aluminum polish to clean your polished AEM Cold Air intake pipe.c) Use window cleaner to clean your powder coated AEM Cold Air intake pipe.

(NOTE: DO NOT USE ALUMINUM POLISH ON A POWDER COATED AEM COLD AIR INTAKE PIPE)

For technical inquiriese-mail us at

tech@aempower.comor

call us at310.484.2322 Option # 3