E90Post
 


 
BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > NA Engine (non-turbo) / Drivetrain / Exhaust Modifications > 08 e92 328i 3 Stage Air Intake Conversion!



Reply
 
Thread Tools Search this Thread
      01-27-2013, 07:45 PM   #1
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

08 e92 328i 3 Stage Air Intake Conversion! Complete!

So I have been doing my research for a while and I am going for it. I am going to do the 3 Stage Air Intake Conversion on my 328i. I already have the intake manifold and one of the DISA adjusters on the way to me, I just need to find the other adjuster for a good price and I will be able to start the conversion.

On top of the 3 stage intake conversion, I also have a Injen Short Ram Air, cyba air scoops and the AA Signature exhaust, all on their way to me.

Once I get everything installed I will also be doing the AA tune.

I'll take plenty of pictures during the installation of all the mods and post them when im done.

Update 3
Modifications are complete and I have loaded the aa tune! I can say I am very happy with the results and I cant wait till the tune fully adapts and I feel the full effects!

The three stage conversion was not very difficult, you just need the right tools. I recommend that you have torx bits. All in all the conversion, including installing the new afe intake and doing the tune, it took me about 6 to 7 hours. Just be patient and take you time, you dont want to mess anything up.



These are the two wires that will plug into the DISA Adjusters on the new intake manifold. The longer one of the two is that one that will wrap around the manifold and plug into the adjuster facing the engine block.



First things first you need to remove the Air Box



and take the two nuts off to looses the power steering fluid reservoir.



Once you get the air box out, move the steering fluid reservoir over to the side and it should look somewhat like this.



Now remove all of the plastic pieces from around the engine. Just be careful not to break any of the plastic clips, everything came off pretty easily and was pretty self explanatory.



The engine bay should look somewhat like this now.



Now i didnt get any pictures of it because i got so caught up in working that i kind of forgot, but you need to remove the throttle body from the manifold, there are 4 10mm bolts holding it on. also remove the vacuum hose that is right behing the throttle body on the air intake manifold. Just squeeze the connection and it pulls right out.

Now you need to disconnect a few wire before you take off the manifold.



Once you get those disconnected, just go around the manifold and look for any wires that many still be attached.

Now you can take off the bolts and nuts that are holding the manifold onto the engine. lift up on the manifold so you can reach behind and disconnect the two hoses and one wire that you will see. Also there is a bracket that is connect to the manifold, under where the throttle body was, you need to use a torx bit to remove the two screws that are holding it to the manifold. Once you are sure that you have everything disconnected from the manifold you can slowly pull it out making sure you did not forget to disconnect anything.





Now that you have out the manifold, move any brackets that may still be attached to it, to the new manifold. Also be sure to put the new gaskets one the new manifold and screw in the DISA Adjusters.

Old manifold.



New Manifold.



Old Vs. New



Now just revers all the steps and be sure to plug in the DISA Adjusters, double check that you are plugging everything back in.

Once you are done it should look like this



Let me know if anyone has any questions and i will try to answer it.

Update 2

Out with the old



And in with the new



More pictures and a full write up once I get everything else done. Im going to start the 3 stage intake conversion tomorrow night assuming I can make some time.

Update 1

Ended up selling the injen and got an aFe Stage-2 Si, will be starting the conversion tomorrow night!
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs

Last edited by BradZditosky; 02-07-2013 at 06:35 PM.
BradZditosky is offline   United_States
0
Reply With Quote
      01-27-2013, 08:34 PM   #2
andrey_gta
Brigadier General
 
andrey_gta's Avatar
 
Drives: 130i coupé ;)
Join Date: Nov 2011
Location: Bimmerpost

Posts: 3,096
iTrader: (1)

Garage List
2008 BMW 128i  [0.00]
Awesome!

in the meantime consult the zpost user -c- diy. Its quite good, but more Diy are welcome.
Thewire loom box attached to the oem manifold needs torx 37 I believe to unscrew, i had alot of trouble here with wrong torx size...
__________________
128i Sport 6MT converted to Euro 130i spec, tuned by evolve ~220 whp 207 wtq(ft-lb) SAE
In-progress: e46 m3 trans mnt, e36M lip Wishlist: m3 susp, n55 eng mnt, headers, LSD, finn dif e60


"The 1-series is the last car that BMW engineered before the Germans, as a car-making culture, fell out of love with driving." - R&T 2013 135is
andrey_gta is offline   Canada
0
Reply With Quote
      01-27-2013, 08:43 PM   #3
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

I just found that DIY a little bit ago. Definitely going to help.
Thanks for the info!

Quote:
Originally Posted by andrey_gta View Post
Awesome!

in the meantime consult the zpost user -c- diy. Its quite good, but more Diy are welcome.
Thewire loom box attached to the oem manifold needs torx 37 I believe to unscrew, i had alot of trouble here with wrong torx size...
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-28-2013, 01:16 PM   #4
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

If anyone can help me I need the other DISA Adjuster, part number 11617560538, i was able to get the other one for $78 so i really dont want to pay over $100 for the other one. Let me know if you know of any where i can get one relatively cheap, thanks in advance.
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-28-2013, 01:42 PM   #5
andrey_gta
Brigadier General
 
andrey_gta's Avatar
 
Drives: 130i coupé ;)
Join Date: Nov 2011
Location: Bimmerpost

Posts: 3,096
iTrader: (1)

Garage List
2008 BMW 128i  [0.00]
Quote:
Originally Posted by BradZditosky View Post
If anyone can help me I need the other DISA Adjuster, part number 11617560538
ebay seems to have lowest prices:
http://www.ebay.ca/itm/BMW-DISA-Valv...#ht_1359wt_952

http://www.ebay.com/itm/BMW-E83-F25E...-/321006082534

Otherwise ECS and Turner motorsport has the cheapest retail price
http://www.ecstuning.com/Search/1161...Fe9cMgodOFEAbA

Try this too:
http://data.bmrparts.com/bmwparts/BM..._throttle.html

http://www.automotix.net/partshotlin...-requests.html

http://www.circlebmwparts.com/cgi/pa...rds&mh=1&nh=27
__________________
128i Sport 6MT converted to Euro 130i spec, tuned by evolve ~220 whp 207 wtq(ft-lb) SAE
In-progress: e46 m3 trans mnt, e36M lip Wishlist: m3 susp, n55 eng mnt, headers, LSD, finn dif e60


"The 1-series is the last car that BMW engineered before the Germans, as a car-making culture, fell out of love with driving." - R&T 2013 135is

Last edited by andrey_gta; 01-28-2013 at 01:48 PM.
andrey_gta is offline   Canada
0
Reply With Quote
      01-28-2013, 01:58 PM   #6
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

Thanks for the links!
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-28-2013, 03:30 PM   #7
SDemetris
FSAE Dude
 
Drives: E90 328xi
Join Date: Jul 2012
Location: Pittsburgh, PA

Posts: 464
iTrader: (0)

yeah... give yourself enough time. I didnt do mine at home so it was stressful getting it done in time before I had to move my car, but its not too complicated. More of just a pain in the ass disconnecting some things. Like the hose ends and the one wire harness especially. And make sure you have torx tools. I almost didnt and that would have been really bad for me
__________________
2007 Titanium Silver 328xi: FBO - headers. Upgraded suspension and brakes.

1985 Gazelle Beige 325e: Nursing it back to health from PO negligence.. Soon to be track car.
SDemetris is offline  
0
Reply With Quote
      01-28-2013, 03:40 PM   #8
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

Thanks for the info! I'v got a bunch of torx tools and I have access to an extra vehicle and my work vehicle so I can keep it in the garage as long as i need
Quote:
Originally Posted by SDemetris View Post
yeah... give yourself enough time. I didnt do mine at home so it was stressful getting it done in time before I had to move my car, but its not too complicated. More of just a pain in the ass disconnecting some things. Like the hose ends and the one wire harness especially. And make sure you have torx tools. I almost didnt and that would have been really bad for me
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-28-2013, 10:21 PM   #9
Zajac1
Second Lieutenant
 
Zajac1's Avatar
 
Drives: 2007 E92 328i
Join Date: May 2011
Location: New Jersey

Posts: 287
iTrader: (1)

Good Luck Buddy : ))) I want to do 3 stage in summer.
Zajac1 is offline   Poland
0
Reply With Quote
      01-29-2013, 10:55 AM   #10
ska///235i
***** noob
 
ska///235i's Avatar
 
Drives: M235i
Join Date: Sep 2005
Location: Boston

Posts: 9,018
iTrader: (31)

Garage List
2006 325xi  [0.00]
I have some bolts...etc from my conversion that i didnt need. Can sell to you cheap, let me know
ska///235i is offline   United_States
0
Reply With Quote
      01-29-2013, 02:48 PM   #11
SuckMy_Nick
Red Liner
 
SuckMy_Nick's Avatar
 
Drives: E92 335i XDrive
Join Date: Dec 2012
Location: Boston

Posts: 181
iTrader: (0)

Congrats man, definitely show some pics!
__________________
07' E92 328xi (First BMW)
09' E92 335xi (Current Car)
SuckMy_Nick is offline   United_States
0
Reply With Quote
      01-29-2013, 03:05 PM   #12
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

Quote:
Originally Posted by ska325xi
I have some bolts...etc from my conversion that i didnt need. Can sell to you cheap, let me know
What all do you have? Because as far as bolts and the gaskets, I checked and I get get everything from my local dealer for like 20 bucks lol
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-29-2013, 04:17 PM   #13
e90pilot
Freight Dawg
 
e90pilot's Avatar
 
Drives: E90 325i
Join Date: Jul 2005
Location: Oakland, CA

Posts: 2,105
iTrader: (3)

Be careful with the PCV hoses in the back. They break very easily.
__________________
--Marcelo
'06 Arctic Metallic 325i | Sport Package | 6MT | Dinan Stage III suspension | Dinan exhaust | 330i manifold swap! Click here! | Active Autowerke tune | 135i Brake Calipers | Deiselboost caliper brackets | E46 M3 front rotors
e90pilot is offline   United_States
0
Reply With Quote
      01-29-2013, 04:18 PM   #14
andrey_gta
Brigadier General
 
andrey_gta's Avatar
 
Drives: 130i coupé ;)
Join Date: Nov 2011
Location: Bimmerpost

Posts: 3,096
iTrader: (1)

Garage List
2008 BMW 128i  [0.00]
Quote:
Originally Posted by e90pilot View Post
Be careful with the PCV hoses in the back. They break very easily.
i do agree with you.

be very gentle and use the torqe power of your wrist & finger & not the whole arm
__________________
128i Sport 6MT converted to Euro 130i spec, tuned by evolve ~220 whp 207 wtq(ft-lb) SAE
In-progress: e46 m3 trans mnt, e36M lip Wishlist: m3 susp, n55 eng mnt, headers, LSD, finn dif e60


"The 1-series is the last car that BMW engineered before the Germans, as a car-making culture, fell out of love with driving." - R&T 2013 135is

Last edited by andrey_gta; 01-29-2013 at 05:05 PM.
andrey_gta is offline   Canada
0
Reply With Quote
      01-29-2013, 05:20 PM   #15
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

Quote:
Originally Posted by e90pilot View Post
Be careful with the PCV hoses in the back. They break very easily.
Quote:
Originally Posted by andrey_gta View Post
i do agree with you.

be very gentle and use the torqe power of your wrist & finger & not the whole arm
Thanks for the tip guys, will do!
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-29-2013, 06:59 PM   #16
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

So I have been reading and I am wondering if I made the right choice to go with the injen ram air or if I should have gone with the aFe intake. Is there really a difference? What do you all think?
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-29-2013, 08:10 PM   #17
Delta0311
Brigadier General
 
Delta0311's Avatar
 
Drives: 2011 BMW 335xi E92
Join Date: Apr 2009
Location: NJ

Posts: 3,674
iTrader: (1)

Quote:
Originally Posted by BradZditosky View Post
So I have been reading and I am wondering if I made the right choice to go with the injen ram air or if I should have gone with the aFe intake. Is there really a difference? What do you all think?
Doesn't matter which one you go with, your cars performance will suffer. I had the original AFE CAI and the only thing good about it was the sound. On hot days the car felt like a tank on take off. There might be a slight performance increase at high speeds since you will be pulling in plenty of cold air but on take off your car will be pulling in a lot of hot air from the engine bay.

You will be better off with a stock intake with a K&N drop in and the carbon filter cut out. The next options would be either a BWM performance intake or a Euro intake with a K&N cone. All 3 options are far better than an open CAI, which in reality is nothing more than a heat sponge.
__________________
Space Gray 2011 335xi E92
Delta0311 is offline  
0
Reply With Quote
      01-29-2013, 08:51 PM   #18
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

Well thats good information to have, I will have to looking into get something sealed, the aFe intake i was referring to was the Stage-2 Si, which I have been reading a lot of good things about.

http://afepower.com/shop/details_new...0L&&brandID=56
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      01-30-2013, 01:19 AM   #19
andrey_gta
Brigadier General
 
andrey_gta's Avatar
 
Drives: 130i coupé ;)
Join Date: Nov 2011
Location: Bimmerpost

Posts: 3,096
iTrader: (1)

Garage List
2008 BMW 128i  [0.00]
Quote:
Originally Posted by BradZditosky View Post
So I have been reading and I am wondering if I made the right choice to go with the injen ram air or if I should have gone with the aFe intake. Is there really a difference? What do you all think?
Look up user Pushkin, he had a dyno of his injen. Some gains up top

If you are concerned, I think you can modify the Injen heat sheild to be more closed or have more air funneled to it with a flexible hose from the lower bumper grilles


Myself, I sourced a used eurobox from sweeden for a price around 250 shipped plus the cost of Afe Dry euro filter. If you are interested in the source, look up my recent posts in the "No 128i love thread"
__________________
128i Sport 6MT converted to Euro 130i spec, tuned by evolve ~220 whp 207 wtq(ft-lb) SAE
In-progress: e46 m3 trans mnt, e36M lip Wishlist: m3 susp, n55 eng mnt, headers, LSD, finn dif e60


"The 1-series is the last car that BMW engineered before the Germans, as a car-making culture, fell out of love with driving." - R&T 2013 135is
andrey_gta is offline   Canada
0
Reply With Quote
      01-30-2013, 07:26 AM   #20
Delta0311
Brigadier General
 
Delta0311's Avatar
 
Drives: 2011 BMW 335xi E92
Join Date: Apr 2009
Location: NJ

Posts: 3,674
iTrader: (1)

Quote:
Originally Posted by andrey_gta View Post
Look up user Pushkin, he had a dyno of his injen. Some gains up top

If you are concerned, I think you can modify the Injen heat sheild to be more closed or have more air funneled to it with a flexible hose from the lower bumper grilles


Myself, I sourced a used eurobox from sweeden for a price around 250 shipped plus the cost of Afe Dry euro filter. If you are interested in the source, look up my recent posts in the "No 128i love thread"
And how was the car dynoed, open hood, and fans blowing? Yes you might see a slight performance increase since you will be getting plenty of cool air into the engine bay, sort of like if you where driving at high speeds. Now run the car for a while on a hot day and try to take off at the light and watch how sluggishly the car will run with the CAI.
__________________
Space Gray 2011 335xi E92
Delta0311 is offline  
0
Reply With Quote
      01-30-2013, 07:14 PM   #21
BradZditosky
Second Lieutenant
 
BradZditosky's Avatar
 
Drives: Crimsion Red 2007 335i Sedan
Join Date: Mar 2012
Location: Indiana

Posts: 266
iTrader: (1)

i'll probably end up going with the aFe Stage-2 Sealed Intake, after what delta0311 said and doing some more research i feel like a sealed intake is the only way to go.
__________________

18" Style 197 Rims - M3 Spoiler - Aero Lip - Shadowline Trim - Black Kidney grills - 30% Tint - Tinted Taillights - White LED Front Turn Signals & Side Makers & Fog Lights - 20W CREE Angle Eye Bulbs - Active Autowerke Signature Exhaust - 3-stage Conversion - Air Scoops - aFe Stage-2 Si Intake - AA Tune - H&R Wheel Spacers - Eibach Springs
BradZditosky is offline   United_States
0
Reply With Quote
      02-01-2013, 04:49 PM   #22
ska///235i
***** noob
 
ska///235i's Avatar
 
Drives: M235i
Join Date: Sep 2005
Location: Boston

Posts: 9,018
iTrader: (31)

Garage List
2006 325xi  [0.00]
Quote:
Originally Posted by BradZditosky
Quote:
Originally Posted by ska325xi
I have some bolts...etc from my conversion that i didnt need. Can sell to you cheap, let me know
What all do you have? Because as far as bolts and the gaskets, I checked and I get get everything from my local dealer for like 20 bucks lol
I can do cheaper...let me see what i have tonight
ska///235i is offline   United_States
0
Reply With Quote
Reply

Bookmarks

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump


All times are GMT -5. The time now is 03:55 AM.




e90post
Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
1Addicts.com, BIMMERPOST.com, E90Post.com, F30Post.com, M3Post.com, ZPost.com, 5Post.com, 6Post.com, 7Post.com, XBimmers.com logo and trademark are properties of BIMMERPOST