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 (Figure 1). 96 thru 98 Figure 1 2. Disconnect the wire that leads to the AFM. This is done by unscrewing the round plastic fitting that leads to the AFM and pulling the connector apart (Figure 2). Page 1/7 3.04 INS263 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. 318i 96 thru 98 318is 96 thru 98 318ic 96 thru 98 318ti AFM 3. 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 3). Figure 2 Rotate Screwdriver Figure 3
Page 2/7 3.04 INS263 4. On the airbox lid there is a wire leading to a sensor. Disconnect this cable by pressing on its steel spring clip and by pulling apart (Figure 4). pull apart 5. Loosen the 4 latches on the airbox lid (Figure 5). Figure 4 pull up and unhook Figure 5 6. Using a 10mm wrench, loosen the 2 bolts that fix the airbox to the inner fender brackets (Figure 6). 7. Remove the airbox lid. Pay attention to remove the lid with the rubber hose that leads to the air pump. At this time separate the AFM from the airbox lid (Figure 7). Figure 6 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. Air Pump Hose Figure 7
Page 3/7 3.04 INS263 8. Remove the AFM from the rubber boot discussed in Step 1 and set it aside (Figure 8). pull apart 9. Lift the airbox, with original air filter, out of the car. Take care, as the factory intake snorkel may get stuck when lifting the box out (Figure 9). factory intake snorkel Figure 8 Figure 9 10. 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 10). press tabs and pull apart 11. Using a pair of aviation snips or metal shears, cut the horn bracket off of the car (Figure 11). cut off horn bracket Figure 10 NOTE: In the photo, the horn was removed to better show the area to be cut. 12. Using a 13mm wrench, remove the nut that held the horn bracket to the horn assembly. Figure 11
Page 4/7 3.04 INS263 13. 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 12). touch up bare metal Figure 12 14. 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 brake duct. You will know when this occurs because the filter will bottom out and not lower any further into the opening (Figure 13). push filter in Figure 13 If your vehicle is equipped with ellipsoid headlights (i.e. Glass lens Bosch, ZKW, or In-Pro units), see Steps 15-16. For non-ellipsoid headlights, see Steps 17-21. 15. Included with your kit is a small bracket that takes the place of the large black filter bracket (the one with the large hole in it). The large bracket will not be needed for an ellipsoid install. Figure 14 shows how this small bracket is fitted. Test fit the whole assembly but do not tighten the hose clamp at this time. 16. 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. 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 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 14 Filter
Page 5/7 3.04 INS263 Arrows indicate mounting holes 1. Mark location 2. Drill holes 3. Mount screws Figure 15 17. 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 15). 18. Using an awl or punch, mark the position of the two mounting holes (Figure 16). 19. Using a 7 64" drill bit, drill holes through the marks made in Step 15. Space may be a little tight here. However, it is possible to get in with a drill to make the holes. 20. 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. 21. Slip the 3" hose clamp removed in Step 17 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 16). Figure 16
Page 6/7 3.04 INS263 22. Return to the airbox lid and remove the sensor whose wire was removed in Step 4. This is done by pressing on the plastic tab on the top of the sensor and simultaneously pulling apart. The sensor will have a rubber ring on it; do not remove this ring (Figure 17). 23. Press the sensor into the hole in the carbon pipe that has the rubber grommet. Make sure that the sensor goes all the way until it bottoms out. DO NOT use any lubricant to make this install go any easier. Both the grommet and the sensor need to be clean and dry for this install. At this time you can set the carbon pipe aside. 24. Remove the rubber air pump hose from the airbox lid. This is done by loosening the clamp that goes to the lid and pulling the hose off the lid. 25. Attach the included breather filter to the air pump hose. Make sure it is fitted to the end of the hose that formerly went to the airbox lid. Secure the filter using the small clamp that was removed in the previous step (Figure 18). Press down on plastic tab Ensure that rubber ring stays on sensor Figure 17 Push breather filter onto air pump hose Figure 18 26. Slide the loose end of the air pump hose over the spout on the air pump and affix using the included small hose clamp (Figure 19). 27. Connect the wire removed in Step 4 to the sensor installed in the carbon pipe in Step 23. 28. Insert the carbon pipe into the air filter (ensure that it is the end with the sensor on it). DO NOT TIGHTEN THE HOSE CLAMP AT THIS TIME. Visually line up the opposite end of the carbon pipe with the rubber boot that leads to the engine (Figure 20). Figure 19 Figure 20
29. Slide the included rubber reducing adapter over the AFM. The narrow side slips over the end of the AFM that came off of the airbox lid. BE SURE TO INSTALL THE ADAPTER TO THE CORRECT SIDE OF THE AFM. There is an arrow on the body of the AFM; make sure it points towards the engine once installed. Fix the adapter to the AFM with the 2.5" hose clamp included (Figure 21). Page 7/7 3.04 INS263 30. Fit the supplied 3" hose clamp loosely over the open end of the silicone adapter installed in the previous step. Install the AFM by sliding the rubber adapter over the carbon pipe and the loose end of the AFM into the rubber boot that leads to the engine. Line up all of the hoses so that there is no stress on any of the joints and tighten all of the hose clamps including the clamp around the air filter. Be careful not to over-tighten these clamps (Figure 22). Figure 21 Tighten all clamps marked with arrows 31. Re-install the cable to the AFM (the reverse of Step 2). 32. Re-position the horn removed in Step 11 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 M6 bolt, nut, and washers to tightly hold this assembly together. 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 23). Slip carbon pipe into adapter and tighten hose clamp Figure 22 Horn Figure 23 33. The rear-most original airbox bracket may still be used to affix cruise control or ASC+T actuators. If your vehicle is equipped with these options, you must use the other included M6 bolt, nut, and washers to affix the actuators to this bracket. 34. Reconnect the horn wire set which was aside in Step 10. If the wire does not reach, you can cut some of the black electrical tape that holds it to the other wires that run behind the headlight. This will give you a little more free cable to reach the horn with. 35. 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.