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AEM 21-696C & 21-696P air intake systems are engineered to add horsepower and reduce restriction
compared to OEM air intakes and they come with a lifetime limited warranty. These AEM
air intakes utilize a large reusable DryFlow air filter. This oil-free filter is durable
and very easy to clean.
AEM 21-696C & 21-696P air intakes fit 2009 and 2010 Dodge Challenger and Dodge Charger
models with 3.5 liter engines. These air intake systems are 50 state street legal for the
previously mentioned vehicles. See the AEM catalog or AEMintakes.com for up to date model
details. Check AEMintakes.com for up-to-date information on emissions legality for specific
parts on specific vehicles.
AEM power testing showed an estimated power gain of 7.3 horsepower gain at 3800 RPM with
these air intake designs installed on a 2009 Dodge Challenger with a 3.5 liter engine.
Actual results will vary depending on the condition of the vehicle, mileage, weather
and other variables.
Here’s a comparison of the vehicle’s sound on the dyno with the stock OEM system verses
AEM’s air intake. AEM air intakes come with detailed instructions
with pictures and diagrams. AEM intakes are engineered for specific vehicles to product
a safe horsepower increase. Make sure vehicle is parked on level surface.
Set parking brake.
If engine has run in the past two hours, let it cool down.
Disconnect negative battery terminal.
Do not discard stock components after removal of the factory system.
Remove the bolt securing the OEM air box and loosen the hose clamp at the throttle body.
Pull to remove the crank case breather hose from the *** on the head cover.
Unplug the IAT sensor. To unplug the IAT sensor, slide the red tab back to unlock the latch
on the plug then press in on the latch and pull the plug off of the sensor. Grey tabbed
connector: Push the top of the gray tab in and simply pull off the connector.
Pull the rubber inlet hose off of the throttle body then lift and remove the OEM air box
assembly.
Carefully remove the IAT sensor from the OEM rubber inlet hose. Set the sensor aside for
future use.
Raise the front of the vehicle with a jack. In the wheel well area on each side, remove
the 3 clips securing the belly pan.
From underneath the vehicle, remove the following: 3 clips, 7 screws, and 2 bolts from the front
belly pan. Remove the front belly pan.
Locate and remove the 10mm bolt securing the lower intake resonator to the vehicle. Remove
the resonator.
Because the stock IAT connectors and wire colors may vary between vehicles of the same
model year, the AEM intake system includes a universal IAT extension harness kit.
Slit open the insulation cover at the end of the IAT connector cable to expose the 2
wires. Cut the wires 1-2 inches [5 cm] below the connector.
Strip the ends of the wires at the connector.
Crimp on two Perma-Seal connectors.
Crimp a Perma-Seal connector onto one end of the provided 20 gauge black extension wire.
Crimp another Perma-Seal connector onto one end of the provided 20gauage white extension
wire.
Strip the ends of the cut IAT wires near the throttle body.
Crimp the stripped stock wires into the new Perma-Seal connectors on the black and white
wires. Since the color of the stock wires may vary with each vehicle, pay close attention
and crimp the other ends of the new black and white wires to the correct color wires
on the IAT connector.
Using a heat gun or other safe heat source, heat shrink each of the Perma-Seal connectors
until clear sealant comes out of both ends of the connector.
Slip the protective convoluted split-loom wire cover over the newly extended IAT wire
harness. Trim as needed.
When installing the intake system, do not completely tighten the hose clamps or mounting
hardware until instructed to do so.
From underneath the vehicle, install the M8 rubber mount through the slotted hole in the
sheet metal using one M8 washer and M8 nut. In order to leave some room for adjustment,
do not fully tighten the M8 rubber mount.
Hold the rubber coupler and squeeze the hump end of the coupler to collapse it into itself.
From underneath the vehicle, hold the collapsed coupler firmly and insert it through the large
hole in the sheet metal.
Make sure that the hump is all the way through the hole then release the coupler and manipulate
it until the sheet metal “snaps” into the grove in the coupler.
Orient the coupler.
Install the grommet into the lower pipe. Attach the air filter with one #56 clamp.
Carefully install the IAT sensor into the grommet.
Install the lower pipe assembly using one M8 washer, one M8 nut, and one #56 clamp.
Adjust the lower pipe assembly so that there is equal space between the filter, bumper
support, fender liner, and marker lamp. When a good fit is achieved, tighten both nuts
on the rubber mount and the #56 clamp.
At the top end of the upper intake tube, install the reducer coupler, one #56 clamp and one
smaller #48 hose clamp. Loosely tighten the hose clamps.
Install 1 #56 hose clamp onto the lower elbow hump hose coupler.
Route the new IAT extension harness underneath the existing OEM factory harness. Use the
2 supplied zip ties to secure the extension harness and route the female connector down
below to the lower intake tube.
From underneath the vehicle, plug the IAT connector onto the IAT sensor in the lower
intake tube. Be sure to pull up the red lock tab to secure the connector (if applicable).
The lower end of the upper intake pipe should be inserted into the lower rubber coupler
to a depth of about 3/4 of an inch to 1 inch. Use glass cleaner as a lubricant if needed.
To allow fitment of the reducer coupler over the throttle body, slide the lower end further
into the elbow coupler, then adjust the top end of the intake tube to fit over the throttle
body. When a proper fit is achieved, pull up on the lower end of the tube to adjust
the fit then tighten the 3 hose clamps.
Install the supplied 1/2 inch inside diameter hose between the crank case vent on the head
cover and the *** on the upper intake pipe using the provided small hose clamps. Trim
the hose if needed.
Remove the protective clear film from the AEM intake system decal.
Reinstall the belly pan and hardware (3 clips, 7 screws, and 2 bolts) that were removed in
step 2g. Also install the 3 clips for each wheel well area that were removed in step
2f.
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.
Check for proper hood clearance. Re-adjust pipes if necessary and re-tighten them.
Inspect the engine bay for any loose tools and check that all fasteners that were moved
or removed are properly tightened.
Reconnect negative battery terminal and start engine. Let the vehicle idle for 3 minutes.
Perform a final inspection before driving the vehicle.
It will be necessary to check AEM air intakes periodically for realignment, clearance and
tightening of all connections. Failure to follow the above instructions or proper maintenance
may void warranty.
Go to AEMintakes.com to find products, download installation instructions, view dyno charts
showing estimated horsepower gains, and for other product details.