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      01-27-2013, 07:45 PM   #1
BradZditosky
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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!
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      01-27-2013, 08:34 PM   #2
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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...
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      01-27-2013, 08:43 PM   #3
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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...
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      01-28-2013, 01:16 PM   #4
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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.
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      01-28-2013, 01:42 PM   #5
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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
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"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

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      01-28-2013, 01:58 PM   #6
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Thanks for the links!
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      01-28-2013, 03:30 PM   #7
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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
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      01-28-2013, 03:40 PM   #8
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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
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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
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      01-28-2013, 10:21 PM   #9
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Good Luck Buddy : ))) I want to do 3 stage in summer.
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      01-29-2013, 10:55 AM   #10
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I have some bolts...etc from my conversion that i didnt need. Can sell to you cheap, let me know
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      01-29-2013, 02:48 PM   #11
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Congrats man, definitely show some pics!
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      01-29-2013, 03:05 PM   #12
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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
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      01-29-2013, 04:17 PM   #13
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Be careful with the PCV hoses in the back. They break very easily.
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      01-29-2013, 04:18 PM   #14
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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
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      01-29-2013, 05:20 PM   #15
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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!
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      01-29-2013, 06:59 PM   #16
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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?
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      01-29-2013, 08:10 PM   #17
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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.
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      01-29-2013, 08:51 PM   #18
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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
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      01-30-2013, 01:19 AM   #19
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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"
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In-progress: e36M lip Wishlist: //M front arm, coils, n55 eng mnt, headers, LSD, e60 finn diff


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      01-30-2013, 07:26 AM   #20
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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.
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      01-30-2013, 07:14 PM   #21
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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.
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      02-01-2013, 04:49 PM   #22
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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
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