Cold Air Intake Installation Instructions

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Norman Atkinson
6 years ago
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BAVARIAN AUTOSPORT Cold Air Intake Installation Instructions Page 1/5 3.06 INS264 NOTE: The vehicle shown for this installation is equipped with ASC+T.

It refers to the Air Flow Meter which is located between the engine and the factory airbox. NOTE: Before attempting this install make sure you fully read and understand these instructions.

NOTE ON FILTER MAINTENANCE: The filter on your new intake is washable and will last for many years if cleaned periodically.

These kits are available from Bavarian Autosport and require that you wash the filter and oil it after it has had the opportunity to dry. DO NOT OVER-OIL THE FILTER.

1 BAVARIAN AUTOSPORT Cold Air Intake Installation Instructions Page 1/ INS264 NOTE: The vehicle shown for this installation is equipped with ASC+T. If your vehicle dos not have this feature, installation is exactly the same. Throughout the instructions the term AFM is used. It refers to the Air Flow Meter which is located between the engine and the factory airbox. NOTE: Before attempting this install make sure you fully read and understand these instructions. Also, ensure that the install is performed on a car that has had the opportunity to cool off after driving. Failure to do so could result in burns from touching hot engine components. NOTE ON FILTER MAINTENANCE: The filter on your new intake is washable and will last for many years if cleaned periodically. The best way to clean the filter is to remove it and service it with a filter cleaning kit. These kits are available from Bavarian Autosport and require that you wash the filter and oil it after it has had the opportunity to dry. DO NOT OVER-OIL THE FILTER. BE SPARING WITH THE OIL AS EXCESSIVE OILING CAN LEAD TO DAMAGE TO THE AFM. 3 Series 6 Cylinder 92 thru 98 PART NUMBER: PF BMWE36-6 PROCEDURE: 1. Using a flat-head screwdriver, loosen the 2 steel clips that connect the airbox to the AFM. Placing the tip of the screwdriver between the clip and AFM and twisting is all that is required to loosen these clips (Figure 1). rotate screwdriver AFM Figure 1 2. Using a 10mm wrench, loosen the 2 bolts that fix the airbox to the body (Figure 2). The unit with the cables coming out of it is for the cruise control. If you do not have this option, the installation is exactly the same. 3. Separate the AFM from the airbox by pulling apart and lifting the airbox out of the car (Figure 3). NOTE: There is a rubber ring that goes between the airbox and the AFM. If this ring remains on the AFM, remove it and set it aside; it will not be needed. Figure 2 NOTE: Some models will have a sensor (with 1 or 2 hoses leading to it) attached to the airbox. If your vehicle is equipped with this part, unbolt the sensor from the airbox and using the included plastic zip ties, secure the sensor to a point that is neat and out of the way in the engine compartment. Figure 3

Page 2/5 3.06 INS264 4. When the airbox is removed, a plastic duct remains behind that needs to be removed.

If the duct is difficult to remove, this plastic clip can be accessed from just behind the headlight and unhooked from the body of the car with a thin flat-head

This is done by pressing the two tabs on either side of the horn s wire connector and pulling apart. Set the cable aside for later (Figure 5).

NOTE: In the photo, the horn was removed to better show the area to be cut. 7.

2 Page 2/ INS When the airbox is removed, a plastic duct remains behind that needs to be removed. Many times the duct can just be pulled out, however take note that the duct is held to the body of the car with a plastic clip (Figure 4). If the duct is difficult to remove, this plastic clip can be accessed from just behind the headlight and unhooked from the body of the car with a thin flat-head screwdriver. This duct will no longer be needed. plastic clip Figure 4 5. Disconnect the wire leading to the horn. This is done by pressing the two tabs on either side of the horn s wire connector and pulling apart. Set the cable aside for later (Figure 5). press tabs and pull out Figure 5 6. Using a pair of aviation snips or sheet metal shears, cut the horn bracket off of the car (Figure 6). NOTE: In the photo, the horn was removed to better show the area to be cut. 7. Using a 13mm wrench or socket, remove the nut that held the horn bracket to the horn assembly. Set the horn aside for later. cut off horn bracket Figure 6 8. To prevent the old horn bracket mounting point from rusting, touch up the exposed metal areas with touch up paint. If you do not have matching paint, you can brush on some nail polish instead. This area becomes totally hidden later on (Figure 7). touch up bare metal Figure 7

Page 3/5 3.06 INS264 9. Once the horn bracket is removed, lower the air filter into the triangular shaped hole that is left behind.

Make sure the filter lowers until it touches the top of the plastic brake duct. You will know when this occurs because the filter will bottom out and not lower any further into the opening (Figure 8).

3 Page 3/ INS Once the horn bracket is removed, lower the air filter into the triangular shaped hole that is left behind. If your car is equipped with headlight sprayers the fit will be very tight. This is ok and a firm push will get the filter in. Make sure the filter lowers until it touches the top of the plastic brake duct. You will know when this occurs because the filter will bottom out and not lower any further into the opening (Figure 8). push filter in Figure 8 If your vehicle is equipped with ellipsoid headlights (i.e. Glass lens Bosch, ZKW, or I-Pro units), see Steps For non-ellipsoid headlights, see Steps Included with your kit is a small bracket that takes the place of the large black filter bracket (the one with a large hole in it). The large bracket will not be needed for an ellipsoid install. Figure 9 shows how this small bracket is fitted. Test fit the whole assembly but do not tighten the hose clamp at this time. 11. Drill a 7 64" hole in the center of the hole on the filter mounting bracket and install one of the self tapping hex screws (Figure 9). DO NOT fully tighten this screw at this time. hose clamp location of 7/64" hole filter mounting bracket ear is between filter flange and hose clamp NOTE:DO NOT tighten both the hose clamp around the filter or filter mounting bolt until the entire system is fitted and ready for a final tightening. This will allow you a little bit of movement to ensure the intake does not interfere with any of its surrounding components. Front of Car Figure 9 Filter

Page 4/5 3.06 INS264 Arrows indicate mounting holes 1. Mark location 2. Drill holes 3. Mount screws Figure 10 12. Fit the large metal filter bracket to the air filter.

Using an awl or punch, mark the position of the two mounting holes (Figure 10). 14. Using a 7 64" drill bit, drill holes through the marks made in Step 13. Space may be a little tight here.

4 Page 4/ INS264 Arrows indicate mounting holes 1. Mark location 2. Drill holes 3. Mount screws Figure Fit the large metal filter bracket to the air filter. Make sure that the hose clamp is off the filter and the rubber neck of the filter is fully through the hole on the bracket (Figure 10). 13. Using an awl or punch, mark the position of the two mounting holes (Figure 10). 14. Using a 7 64" drill bit, drill holes through the marks made in Step 13. Space may be a little tight here. However, it is possible to get in with a drill to make the holes. 15. Using a 7mm socket, fix the filter bracket to the car by installing the two hex head screws included. Be careful not to over-tighten these bolts as it will strip the thread in the sheet metal below. 16. Slip the 3" hose clamp removed in Step 12, over the filter. Position the tightening screw at a place where you can reach it with a screwdriver later. Make sure that the hose clamp rests loosely around the neck of the filter (Figure 11). Figure 11

Page 5/5 3.06 INS264 17. Slip a 3" hose clamp over the end of the ribbed rubber adapter included in the kit and slide the end over the open end of the AFM.

Slide the short end of the carbon fiber pipe into the air filter and the long end into the ribbed rubber adapter.

Tighten the hose clamp on the air filter and the hose clamp that fixes the ribbed coupling to the carbon fiber pipe. Figure 12 21. Included in the kit is a black metal bracket.

Make sure that the bracket slides into the point where the edge of the hose clamp touches the inside edge of where the bracket bends. Once this is done, tighten the hose clamp.

5 Page 5/ INS Slip a 3" hose clamp over the end of the ribbed rubber adapter included in the kit and slide the end over the open end of the AFM. DO NOT TIGHTEN THE HOSE CLAMP AT THIS TIME (Figure 12). slide adapter over AFM 18. Slip a 3" hose clamp over the other end of the ribbed rubber adapter. Make sure the clamp is loose. 19. Slide the short end of the carbon fiber pipe into the air filter and the long end into the ribbed rubber adapter. Make sure that at least 1" of the carbon pipe goes into the filter and that the pipe bottoms out into the ribbed rubber adapter. 20. Tighten the hose clamp on the air filter and the hose clamp that fixes the ribbed coupling to the carbon fiber pipe. Figure Included in the kit is a black metal bracket. Slide the side of the bracket without the hole under the hose clamp on the AFM and through the rectangular shaped hole on the AFM. Make sure that the bracket slides into the point where the edge of the hose clamp touches the inside edge of where the bracket bends. Once this is done, tighten the hose clamp. Be careful not to overtighten these clamps (Figure 13). rectangular hole 22. Use the included 6mm bolt and nut along with two 6mm washers to fix the bracket installed in Step 21 to the rear-most original airbox mounting bracket on the body of the car. If the vehicle is equipped with cruise control (as is the vehicle in the picture) be sure to also tighten down the cruise control using this same bolt (Figure 14). Figure Re-position the horn, removed in Step 7, by mounting it to the forward-most support bracket used by the original airbox (when viewed from above, the bolt on the bottom of the horn should face the carbon pipe). Use the included 6mm bolt, nut, and washers to tightly hold this assembly together (Figure 15). Once again, if the vehicle is equipped with cruise control (as is the vehicle in the picture) be sure to also tighten down the cruise control using this same bolt. 24. Reconnect the horn wire set aside in Step 5. If the wire does not reach, you can cut some of the black electrical tape that holds it to the other wires running behind the headlight. This will give you a little more free cable to reach the horn with. Figure Start the car and let it idle for 5-10 minutes. During this time DO NOT ACCELERATE THE ENGINE AT ALL. This will allow the computer a chance to re-calibrate itself to the increased airflow offered by the intake. The install is now complete. Be sure to double check the tightness of all connections, bolts, and clamps before driving the vehicle. horn Figure 15

Cold Air Intake Installation Instructions

BAVARIAN AUTOSPORT Cold Air Intake Installation Instructions PARTS LIST: PF BMWE36-4 PROCEDURE: 1. Using a flat-head screwdriver, loosen the hose clamp between the AFM and rubber boot leading to engine