HOW TO: Installation walktrough for AEM's Intake on a 09 KK

[Diggerfreek]

Hello everyone!
first off, Id like to thank digger for getting me into this...the install of the intake was a little annoying (unconventional/non practical perhaps?) but in the end it was all worth it.
Im going to try and explain the install step by step and I really hope that digger will correct me if I did something wrong: In case I did, please tell me digger so that my KK will not explode.

PROBLEM
you have to install the sensor I circled in red on your new intake.... The wire harness for the 09 is different from the one on the 08 hence being shorter: here are some pics:

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The sensor's connector must go from point 1 to point 2 BUT the wire length is way short

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SOLUTION
Cut the wires from the sensor's connector like ziz:

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Solder a wire extension (I used color wires to identify one from the other) 6 inches should do the trick

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Use thermofit to seal the area that you soldered

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Solder the other end of the wires (be sure to match the corresponding wires)

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Use thermofit again

Plug in the sensor, turn your KK on and if no check engine light comes on then you are all set!

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Then use split wire loom to cover the newly soldered wire extension (thanks MtnLvr!)
This will give you a nice clean install

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So now that you got your wire extended, lets proceed to the intake installation!

INTAKE INSTALLATION

Disconnect this little hose from your AIRBOX

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Loosen the fastener that holds the OEM intake tube in place and then pull the tube towards you (open the two clips in front of the airbox to open the airbox also)
it will look like this:

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REMOVE your air filter and air box... just pull it up

In this pic you'll see a blue line and a red circle... ignore them (for now)

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Once the airbox is removed it should look like this

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Take a look at the airbox fasteners

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Remember the red circle from previous picture??? you have to remove this air duct by pulling it... its being held in place by this little bracket:

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This is what it looks when removed:

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REMEMBER THE BLUE LINE ABOVE? thats a tube and you have to pull it up from here

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rotate the tubes endings so that it will look like this

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and then reattach....
you should end with the tube located like this:

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NEXT
Remove this rubber grommet

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Install the corresponding nut, washer and bolt like this

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Install that little metal cone that came with your kit

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Use the corresponding nut to secure that metal cone:

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Reattach grommet

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Install your intake's heatsink like this

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(add the corresponding nuts and washers)

Tell your dog to bring you a soda:

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Install the rubber mount on your engine

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Remove your sensor from your old intake tube (you have to pull it and requires a little elbow grease)

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Attach the included rubber grommet on your new intake

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Use some lube (I used a few drops of WD-40) to install your sensor like this:

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Attach your new intake tube to the rubber mount and fasten with the included fasteners

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Dont forget to fasten "the blue hose" to your intake"

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your installation should look like this

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Plug in your sensor

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Install your Filter element and the rubber supports on your heat sink

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Be sure to tighten these fasteners:

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turn your kk on let the engine idle for 3 mins and while you do that install this:

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if you dont install it your intake will not activete
:lol: :lol:

Sorry if I made this post long, but I tried to make it simple for those who want to add an intake to their KKs... Digger used some self tapping screws to fix the heat sink to his kk... But in my opinion they were not necessary at all.


Let me tell you guys that IM AMAZED with this mod, your engine will now roar and youll feel the power!!! I just love it!
If you have a 08 just skip the soldering part... if you have a 09 then do it ... I know that youll love it!!!
best regards and now Im off to bed

*EDIT* Some have asked which wire gauge to use, as stated by Mike08 a 16-18 gauge wire will do the trick... just try to color match the wire.
I also need to note that the intake is for a 07 NITRO... there is no intake for the KK....
Look for it on amazon! =)
best regards

 

[kkdriver]

What model AEM did you use

There are none listed for the Liberty