orbalt08

iTrader: (4)

I am trying to get a list together of all the people who have purchased and used the AEM Intake for their turbo cobalts.

I myself am having issues with it, as well as a few others on here. I have taken the first step as to contacting AEM about the issues I am having. It would be beneficial if we could get all the information as to what issues others are having with the intake.

I myself when driving with the intake installed experience compressor surge/choke during cold start ups, as well as when driving at a constant speed down the highway. If I remove the metal tube and attach the stock box onto the AEM silicone tube I still experience these problems. If I return everything back to stock then all of my issues go away. Lets get some people listed here who are having problems with their AEM intakes as well.

1. orbalt08

HB_SS/TC

iTrader: (1)

That goes for every other intake manufacturer then for our cars

I bought the AEM intake but I'm just using the elbow for now

purplehaze03

thats your problem under the boost pressure it tends to collapse...causing compressor surge... i have a hahn.... so cant chime in but just to let you know this is not the first time this has been posted.

orbalt08

iTrader: (4)

I'm trying to get some company specific information so that this AEM tech can better chime in. I understand that other intakes are having issues as well, but this thread is for the AEM intake so that we can try to get something worked out to get it fixed. Trying to get documentation of others having problems with their intake.

Iam Broke

iTrader: (10)

I sold mine but the silicone sucking in under turbo boost and surging at cold start was an issue I had as well.

Under a 30 lb boost spike it collapsed once enough to choke the engine off. Scary ****!

orbalt08

iTrader: (4)

Ok, these are things that need to be documented in this thread. Please post in here if you have then intake and if you have problems or not. This problem needs to be fixed and resolved.

ninja44

iTrader: (1)

I'm having similar issues as well but good luck with getting them to do anything about it. I've tried to tune out the on/off low rpm studdering but I've done all I can. The bypass valve flutters like crazy at low rpm also. The elbow did not collapse on my dyno runs with 22 psi though.

Terminator2

Here are my findings on the AEM intake for the 2008 and up Chevrolet Cobalt SS Turbo. I have tuned every intake avaliable for the 08 and up Cobalt SS Turbo. I have also own AEM's intake and I can say without a shadow of a doubt that it causes issues that cannot be resolved even through careful tuning. It like all other intakes causes MAF skew which throws off the fuel trims. The MAF skew can be tuned out albeit not that easily because of laminar flow issues at the MAF sensor which cause inconsistancies in airflow seen by the sensor. The compressor choke on cold start and compressor surge at higher boost levels and loads cannot be tuned out. Even when one uses the stock airbox with the AEM elbow attached to it these problems with compressor choke and surge continue. It is only upon removing the silicone elbow that the problems disappear. It appears that the elbow is not rigid enough and it seems to get very restrictive as it necks down from 3.5" OD to 2.5" right near the 90* bend. To fix these issues I believe several design aspects need to be addressed. First of all, the silicone elbow needs to be removed and a small section of 3.25 to 3" tapered aluminum tubing should be put there with two much smaller and more rigid silicone couplers to connect everything together. Secondly the MAF being position leads to laminar flow issues over the sensor as there is no screen to straighten airflow on the stock MAF sensor. Also, because the MAF is positioned right near a slight bend and right near the filter the airflow is very turbulant at the sensor which contributes to said laminar flow issues as well even if one retunes the MAF sensor for the AEM intake.

To sum everything up there was clearly not enough R&D done before releasing this intake as it is clear to me that there are several inherent design flaws which cause very poor driveability and poor overall performance of this intake. These issues happen to bone stock cars as well as tuned cars so even at stock performance levels this intake fails to deliver satisfactory performace. The compressor surge and choke are very harmful to the turbo over time because each time it surges it creates a huge torque spike that will cause accelerated wear on the beaings in the turbo and the surging also weakens the blades of the turbine which will cause premature failure of said part. The is no evidence of any kind that ANY of the cars that have this AEM intake installed have been free from these issues (as long as the consumer knows how to recognize these issues) and something needs to be done to rectify this matter at hand. AEM should give everyone who purchased this intake their money back and they need to put out a full recall on this faulty product.

importkiller

iTrader: (1)

I had these exact problems with the AEM.

orbalt08

iTrader: (4)

Great post David, now lets grab everyone who has an AEM Intake and get their names on a list so that this issue can get taken care of.

ninja44

iTrader: (1)

As I said Term, good luck with AEM doing anything about this. I was thinking of moving the MAF flange higher up towards the coupler to reduce the turbulence as I'm sure that would help quite a bit but the money spent for a custom flange, welding etc does not warrant me going out of my way to fix a design they clearly didn't test. I might even try to get a buddy to use the silicone elbow as a template to make an elbow made of plastic or fiberglass, we'll see over the winter.

Terminator2

We will see if they do anything. If enough of us complain they will listen. The old adage "The squeaky wheel gets the grease" really applies here so the lounder we squeak the more likely they are to do something about it.

Here is the list. Anyone who would like to make a complaint about the above issues or any other issues concerning AEM's intake for the 08 and up Cobalt SS Turbo please put your name on this list. The more people we get the more likely they are to listen to us so if you owned or still own this intake put your name on the list.
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orbalt08

iTrader: (4)

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HB_SS/TC

iTrader: (1)

why not

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Schullz51

I have the AEM cai, and have only noticed the strange noise on startup, this is my first turbocharged car so i thought it was just the BPV fluttering, but if that noise is it actually choking the compressor apparently im having this problem too.

importkiller

iTrader: (1)

I still have mine but I took it off, I had too many issues with it, and then while taking it off I broke the bracket

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orbalt08

iTrader: (4)

I'll add you to the list then. Believe it or not, some people actually think this is normal and NOT harmful for the turbo. Trying to educate people about the problem now so it doesn't turn into a huge mess later on. AEM NEEDS to address this issue!

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Iam Broke

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Schullz51

I'm really disappointed the AEM is causing issues, i had no drivability problems with it, just the weird noise i even thought it was kinda cool sounding and started calling my SS the space ship

ninja44

iTrader: (1)

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Stamina

I don't have an AEM, but I've got an idea to throw in the bucket. Depending on how the elbow is collapsing, how about reinforcing it with plastic rings or (preferably) metal rings fastened/gorilla-glued every inch or so around the outside. It might give the elbow enough extra rigidity to keep it from imploding on you all.

ninja44

iTrader: (1)

Part or all of the reason causing the elbow to collapse is due to the fact that the intake is bolted solid to the car. When the motor rocks it flexes at it's weakest point which is the elbow so when the motor rocks it twists the elbow. On my 10+ dyno pulls I watched the elbow and it didn't collapse once so not sure what to say there.

Iam Broke

iTrader: (10)

My biggest complaint was the cold start surging and DFCO lurch that I could not tune out. Other tuners much better than I had the same issues. THe collapsing at a 30 psi boost spike happened during other 'experiments' and I wouldn't run that much midrange boost through it normally. I'm sure the vacuum created at the elbow during that event had a lot to do with it sucking in. No issues with it collapsing at 22 psi boost on mine.

Terminator2

Mine collapsed one time at 28psi but even at vac it is acting as a restriction it seems because once you remove the silicone elbow the compressor choke and surge disappears. I might try running my stock intake tube to the turbo with the AEM intake on the car and see how it runs. Then I might try putting a screen in the intake right before the MAF if the intake works better with the stock intake tube.