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DIY: 328i 3-stage intake manifold conversion
Published by BradZditosky
02-07-2013
DIY: 328i 3-stage intake manifold conversion

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 aa tune, it took me about 6 to 7 hours. Just be patient and take you time, you dont want to mess anything up.

obviously the intake and the tune are not needed to do the conversion, but to take full advantage of the new intake with the disa's you will need a tune.

here is a list of parts you will need. Search around for everything, you should be able to get everything for around 300-350.

11617559523 Intake Manifold
11617579114 Adjustor Unit
11617560538 Adjustor Unit 2
11617547242 Gasket set
11617535850 x2 Screw 50x35
11617535849 x4 Screw 50x20
11617535851 x1 Screw 50x66
some other lists say you need 5 of the 50X20 screws so thats what i had bought but i only used 4, i could not find anywhere that the 5th screw would go so i have an extra one now lol

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.
__________________

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
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  #1  
By blingman on 02-08-2013, 01:13 AM
Awesome job! How you liking it?
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  #2  
By BradZditosky on 02-08-2013, 09:30 AM
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i really like it, you can definitely tell there is more power there.
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  #3  
By DUI Elite on 02-08-2013, 09:33 AM
awesome write up! thanks for taking the time.
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  #4  
By OrangeInOhio on 02-23-2013, 09:35 PM
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Dude, awesome write up. I've thought about doing this to my 328i but I might wait until my CPO is over. Don't want to void that. Have you had it on a Dyno since doing this?
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  #5  
By BradZditosky on 02-24-2013, 01:29 PM
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Quote:
Originally Posted by OrangeInOhio View Post
Dude, awesome write up. I've thought about doing this to my 328i but I might wait until my CPO is over. Don't want to void that. Have you had it on a Dyno since doing this?
Thanks! but no i have not, but i can definitely tell there is more power there then before.
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  #6  
By andrey_gta on 02-24-2013, 10:36 PM
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Great Post. best mod for the n52 hands down.

I would stress that before you go on pulling out the manifold, make sure you undo what is connected to it on the bottom, It is a cable loom box attached with torx 35 or 37 bolts. It was my most challenging struggle, followed by the gentle removing of air/oil catch hoses.
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  #7  
By intensee92 on 03-11-2013, 02:54 PM
thanks for the diy!
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  #8  
By Tony v on 03-26-2013, 01:28 AM
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great diy so is this what turns the 230hp to the exact 255? or around there
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  #9  
By BradZditosky on 03-26-2013, 09:06 PM
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Quote:
Originally Posted by Tony v View Post
great diy so is this what turns the 230hp to the exact 255? or around there
you need to get a tune to get the full effects of this mod and depending on what other mods you have, you could possibly get an extra 50hp at the crank based on the research i have done. but with the mod alone and a tune you should be getting an extra 30-35hp at the crank, so yes around the 255hp like the 330 has.
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  #10  
By Tony v on 03-26-2013, 10:11 PM
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Quote:
Originally Posted by BradZditosky View Post
you need to get a tune to get the full effects of this mod and depending on what other mods you have, you could possibly get an extra 50hp at the crank based on the research i have done. but with the mod alone and a tune you should be getting an extra 30-35hp at the crank, so yes around the 255hp like the 330 has.
cool wish they would have continued with 330i for the newer models after 06 would be great in e92 seems like its a little of everything power mpg reliability
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  #11  
By E90X on 04-02-2013, 11:52 AM
You mentioned you recommended having torx bits. What sizes did you use and what portions of the install required them?

Thanks!
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  #12  
By BradZditosky on 04-02-2013, 05:16 PM
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i believe it was t27 that i used mostly and it was quite a bit that i used it, but there were a few others i would get a torx bit set and a torx socket set. just incase you run into anything you are prepared
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  #13  
By OrangeInOhio on 04-05-2013, 06:39 PM
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Quote:
Originally Posted by BradZditosky View Post
you need to get a tune to get the full effects of this mod and depending on what other mods you have, you could possibly get an extra 50hp at the crank based on the research i have done. but with the mod alone and a tune you should be getting an extra 30-35hp at the crank, so yes around the 255hp like the 330 has.
I forgot to ask you in my original post... what tune did you get? AA Stage 2?
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  #14  
By BradZditosky on 04-05-2013, 08:53 PM
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Quote:
Originally Posted by OrangeInOhio View Post
I forgot to ask you in my original post... what tune did you get? AA Stage 2?
You are correct, the AA Stage 2.
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  #15  
By Clammy on 04-05-2013, 09:10 PM
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Quote:
Originally Posted by BradZditosky View Post
You are correct, the AA Stage 2.
Sweet! I'm getting the AA Stage 2 Tune next week, and will do the IM swap late spring/early summer. Looking forward to the power gains!

BTW, did you do the charcoal filter delete as well?

Cheers!
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  #16  
By BradZditosky on 04-05-2013, 09:21 PM
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Originally Posted by Clammy View Post
Sweet! I'm getting the AA Stage 2 Tune next week, and will do the IM swap late spring/early summer. Looking forward to the power gains!

BTW, did you do the charcoal filter delete as well?

Cheers!
nice man! im sure you will enjoy it as much as i do! but no i got a aFe Stage 2 Seal Intake.
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  #17  
By Clammy on 04-05-2013, 09:25 PM
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Originally Posted by BradZditosky View Post
nice man! im sure you will enjoy it as much as i do! but no i got a aFe Stage 2 Seal Intake.
I know it!! Heheh... I'm planning on keeping the stock airbox, and doing the charcoal filter delete.

Cheers!
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  #18  
By BradZditosky on 04-05-2013, 09:38 PM
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Originally Posted by Clammy View Post
I know it!! Heheh... I'm planning on keeping the stock airbox, and doing the charcoal filter delete.

Cheers!
Very nice!
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  #19  
By saeng on 05-05-2013, 02:01 AM
Do it have to be aa tune?? Will this mod work with bms powerboxs??
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  #20  
By optimaxed on 05-05-2013, 12:29 PM
AA have probably most experience at tuning these conversions, powerbox doesn't retune the ECU for new manifold I believe
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  #21  
By ObiwanChen on 05-16-2013, 12:55 AM
Pics are dead, OP can you edit the thread to show the pics? PLEASE!!!
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