So here we have our E-46 M3 project car. We've already installed a complete Super Sprint Exhaust from head to tail pipe on this vehicle with stepped headers. The next project we are doing to the car is going to be the AFE Magnum Force Stage 2 Air Intake System. The final piece, we are going to install is the shark injector.
So here's all the pieces for that AFE intake kit. What we've got is an AFE dry filter, we've got the clamps that'll attach the connecting boot to the intake piece that goes on the plenum on the vehicle, you've got the heat shield that protects it and mounts the piece to the fender of the vehicle. And you have got a seal that protects it from any contact under the hood. The instructions are really simple. It's all pictures, you've got 15 steps, it walks you right from the beginning of what's included in the kit throughout what to remove, goes into what to install and then the final tightening of all the fasteners.
Here we are under the hood and this is going to be a summary of what we are going to remove. We are going to obviously have to remove this snorkel from the front end of the vehicle, this piece will come out. We have got the air filter cover. We've got the air intake boot that goes to the plenum. We are also going to disconnect the mass air sensor connected right here. The head light controller, we've to got take the cover off a bit because we have got two fasteners one right here and one that's slightly hidden underneath the cover right there. So what we need to do is, we'll get the cover off, disconnect this it'll take a screw driver, it'll take 10 millimeter ratchet. It includes a T20 Torx with the kit. The whole system should come off in just a few minutes.
Okay, we are going to put the boot in position, reach inside, make sure it slips completely over the flange. This'd be the last chance to get really get to this area here to make sure it's on. Here is the clamp, we are going to install, kind of pinch it little bit into an oval because the plenum has a slight oval shape to it.
Okay now we're going to install the bracket that holds the intake system. What you want to do is you got two fasteners down here on the factory air filter mount. You've got the front one which -- this is one we're going to use -- the rear one you don't use that anymore. So I am going to make sure this slides over the first stud, aligns with this, leave it position, you are going to put a flat washer and a 6 millimeter nut on top of this existing mount from the old system, and right now I am just going to tighten every thing barely tight. I just want to keep it a little loose, so I can move it later on.
Now what I want to do is that I want to align this hole, so I can have this piece tightened down and what this is -- I am just using the factory -- you are required to use the factory fasteners there for that. We'll get this in position. I've installed the other factory bolt from the air filter assembly, the original one to reattach the head light control unit.
Now, I am going to tighten this all the way down because we are finished in this area right here. Now we are ready to install the intake tube. What I have done here is, I've installed the clamp that I am going need to attach to my coupler on to the tube first loosely. I've also put my screw to the clamp in the position it's going need to be in so I can tighten it down. I am going to feed it through opening and what I am going to do is turn it up, get it into the boot slightly, and then rotate it towards the engine. Once I have rotated it towards the engine, I know that the bottom part is attached and I am just going to slip it over, there we go. Now we are in position, you might want to feel it all the way around, we can't have any vacuum leaks here this is a pretty critical spot right here.
Then I am going to feed my clamp all the way the through, put it into position and then tighten it down. Next step, we are going to tighten the tube, the intake up to the housing. Now I have already installed the lower bolt but I left it loose. I always install the most difficult bolt first. Then you go to the top, bolt washer, line up your hole and you are going to go through the connector, put a nut on the back side. They are both 10 millimeters, so you'll need a 10 millimeter socket a 10 millimeter ring.
The next step we are going to tighten the heat shield bracket assembly. Now, there is a wire right behind the bracket that you don't want to pinch underneath the bracket, so what we're going to do is pull it all the way, we're going to push the bracket down and we are going to tighten every thing down now.
Now, we are going to install the heat shield for over this water hose right here. We'll do the lower bolt first, get it started and don't tighten any thing until you get both pieces started because that'll allow you to move in and align it.
Now what we are going to do is install the filter unit, and what we are going to first is put the clamp over. I always make sure that I can get to the screw really easily. Open the clamp up, as large as you can so it doesn't -- before it disconnects, just so that you have plenty of room to slip it over the filter and then make sure it's on the filter all the way around the bottom and tighten the screw.
The next step is we are going to take the mass air sensor and we are going to remove it from the factory air filter cover and we are going install it into the intake of the AFE. You have got two Torx head screws right here, and you get the bit, included with the kit. You should have a nut driver to do that and what we are going to do is remove this, it goes in a certain direction you won't be able to mix it up basically the arrow part points towards the intake. What we're going to do right now is remove the piece from the factory filter housing and then reinstall it into the AFE unit.
Now what we are going to do install the seal that comes with the AFE kit over the mass air sensor. Go all the way to the bottom. It's a different type of seal, it's a surface seal rather than the 'O' ring the factory puts on it. You want to make sure, it gets a good seal. It's like a foam seal. Place, now I am going to snug him down.
Now you don't need to over torque these, all we're a trying to do is just compress the seal slightly, apply a little bit of pressure to keep it tight. Then you are going to take your mass air sensor wire and we are going to snaff it right into position.
Next we are going to install the headlight control unit cover. That'll go back into position there is a tab slot in each corner over here, that we got to make sure that we get position on. In position, we'll take our wire harness, pretty self explanatory, a large one and small one. Put your boot over it because we don't want any moisture inside, same thing with this. It will fit in, and you'll feel it snapped in, put the boot over it and it will fit inside.
Now the only thing left is our cover seal. Okay the upper seal has a break point right here. What you want do at that break point, that's what's going to go around the corner smoothly here, so what we are going to do is you're going to tuck that all the way down over the sharp edge of the sheet metal, more of a protection than for you and for the vehicle's hood pad.
If you are interested in an AFE intake system for you vehicle go to bmpdesign.com.
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