Toyota Celica DIY

I installed the gen 2 AEM CAI today, with an Apexi Power Filter and a custom splash shield. The Apexi filter is meant for an intake pipe with a flange, so it doesn’t fit straight on the AEM pipe, so some custom work was needed.

The parts: the filter, a pipe flange with no holes from McMaster Carr (#1764K81) for $3, some “Amazing Goop” sealant, hose clamp from the AEM CAI kit, the bottom rubber cut from the AEM filter, gaskets that come with the Apexi filter.

Making the filter mount: the best way to do this would be to weld the pipe flange onto the CAI, use the supplied gasket and screw on the filter. Unfortunately, I don’t know how to weld, so I went a different route. First I cut off the flange with a hacksaw, and deburred it with a file.

Then use the Apexi gasket to mark holes on the flange. Note that the inside diameter matches perfectly.

After drilling the flange, jam the rubber from the AEM filter through it, and drill holes through the rubber as well.

Use the screws that come with the apexi filter to screw on the rubber. Don’t over-tighten or the inserts on the filter start to get pulled out!

After this the inside surface will match perfectly for a smooth transition from the filter diameter to the CAI pipe. Use the goo to seal around the gap of the rubber to plug any remaining possible leaks and set aside to dry.

Time to install the CAI (just follow the included instructions).

Install the filter just like instructed for the AEM style filter using the included hose clamp.

I live in Seattle, where we get a lot of rain, sometimes pretty good down poors and standing water. So I decided to plug the holes in the fender well with a splash guard. I used a zinc sheet from Home Depot ($4). Here my buddy is drilling holes into it.

The sheet is mounted through existing holes in the fender liner using 7mm hex bolts and 1/4″ fender washers. Just bent to shape and use tin snips to cut off the excess (and round the corners – this thing is sharp!).

I also wrapped some rubber sheet around the intake pipe where it goes through the hole in the fender liner to protect it from rubbing (fixed with zip ties).

Next time I take my bumper off (installing an oil cooler in 2 weeks), I will add stand offs between the bottom screws and the fender liner. That way the filter is still protected from water, but the gap will allow air to flow under the shield and to the holes behind it, providing cooling to the brakes (probably the reason the holes are in the fender to begin with).

First impressions: I didn’t have a CAI before so I don’t know how much is due to the CAI, or the apexi filter, but the sound of this thing is OFF-THE-HOOK . I was driving with the window open and couldn’t stop grinning every time I hit lift! As far as power gains, I’ll have to wait for the ECU to adjust to get a good feel for what gains I achieved.