I have had numerous requests for this info, and I think it is about time to post the instructions on how to get it done.
Insturctions for the custom Eaau 4090 amsoil filter intake system.
Purchase the Eaau 4090 amsoil filter from an amsoil dealer "plenty of
them on the forum here". Puchase an afe torque tube "many sponsors have
these as well". Then start with the instructions below.
Here are the added parts that you will need to buy from a hardware store, Home Depot, or Menards.
1) 4" ABS 45 degree street elbow (wider flanged opening on one side and not on the other)
2) 4" to 4" rubber coupling w/ clamps
3) 5" Hose clamp used to clamp the filter to the ABS street elbow. The stock clamp will not fit.
After you have purchased all the pieces, bring them home and start your project.
First step: you will need to cut the flange off the end of the street elbow. (I used a saws-all)
Second step: You will need to clean up the cut from the saws-all with
anything that you may have. (I used an angle grinder) File works well
to.
Then you are ready to start the constrution of your project for the truck.
Here are the steps that I took to build the custom intake.
1) Remove the stock air box, torque tube & sensor
2) Install the new torque tube to the turbo.
3) Install the filter to the end of the ABS elbow that you cut the
flange off. (this will take some minipulating, but it will go on.) best
if you had some one help you.
4) Slide the rubber coupling that came with the torque tube over the
tube, until the front side of the coupling is flush with the end of the
torque tube.
5) Slide the 4" to 4" coupling over the rubber coupling that you just
put on the torque tube, until the 2 couplings are flush on the backside.
6) Install the ABS elbow with the filter attached to the 4" to 4" coupling.
7) Get everything lined up the way you want. Don't tighten anything down yet, we are not done.
8) With everything lined up, mark where you want to put the sensor in the elbow.
9) Remove the elbow from the truck and drill a 1/2" hole into the ABS elbow where you made the mark.
(remove any material that falls into the filter)
10) Measure the distance from the center of the sensor to the center of the screw holes.
11) Drill your pilot holes for the screws that attach the filter to the elbow.
12) Install the elbow and the filter into the 4" to 4" coupling, tighten all clamps, install the sensor and you are ready to go.
(make sure when you tighten the sensor onto the elbow that you take
care that you do not over tighten the sensor. The sensor is made to
attach to a flat surface and if you overtighten you might break the
sides of the sensor off. You just need to get it snug so the sensor
stays in the elbow)
Pictures of the complete install are in my garage pics. There is step by step pics there.
If you need any thing else (pictures, more info) let me know.