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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Powertrain and Drivetrain Discussions > NA Engine (non-turbo) / Drivetrain / Exhaust Modifications > E91 328i 3 Stage Manifold Conversion + Active Performance Software Build w/Dyno



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      03-15-2013, 10:16 AM   #1
Viral@ActiveAutowerke
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Lightbulb E91 328i 3 Stage Manifold Conversion + Active Performance Software Build w/Dyno

Hello Fellow Members,

I am glad to share with you all a recent project we have completed involving installation of a 3 Stage Intake Manifold and Version 2 Software on a E91 328i. To give you some background history on this vehicle it is an 2007 328i Automatic with close to 89,000 Miles on the clock also the vehicle has a BMW Performance Exhaust and European Airbox & K&N Filter w/ Carbon Filter Delete. Below are documented pictures of the installation and dyno of the vehicle. Please feel free to reply or contact us directly for more information on this project.


Here are the Pics of this Transformation

We began by strapping down this beast and getting the base Dyno on this Vehicle. Which put down a Solid 175 WHP & 168 Ft. Lbs. of Torque to the wheel on a Mustang Dyno.



Proof that even Automatics can get down and dirty.



From there we quickly began the tear down of the motor and made way for the 3 Stage Manifold.







Stock 328i Intake Manifold





3 Stage Intake Manifold





Finally time to strap down this beast on the dyno and tune it for more power.







Dyno Sheet Before & After

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      03-15-2013, 11:08 AM   #2
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Noticeable gains in both tq and hp. What's the cost for this conversion? Depending on cost, I may consider it for my '08 328i.

Thanks.

Cheers!
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      03-15-2013, 11:12 AM   #3
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nice work guys.
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      03-15-2013, 12:28 PM   #4
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Quote:
Originally Posted by Clammy View Post
Noticeable gains in both tq and hp. What's the cost for this conversion? Depending on cost, I may consider it for my '08 328i.

Thanks.

Cheers!
Yes, it is a noticable difference but driving it is a complete night and day experience. I will PM you information on pricing for this conversion kit.

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nice work guys.
Thank you for the support.
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      03-15-2013, 12:44 PM   #5
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Nice! stage 3 manifold can be notice by dealership? mine is a CPO.
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      03-15-2013, 01:46 PM   #6
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Do you guys sell the 3 Stage intake manifold? Also how hard of an install is it?
Could I do it myself?
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      03-15-2013, 02:07 PM   #7
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Quote:
Originally Posted by Viral@ActiveAutowerke View Post
Yes, it is a noticable difference but driving it is a complete night and day experience. I will PM you information on pricing for this conversion kit.
Great! Look forward to exploring this option.

Cheers!
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      03-15-2013, 02:25 PM   #8
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Quote:
Originally Posted by jan31 View Post
Nice! stage 3 manifold can be notice by dealership? mine is a CPO.
Since the 3 Stage Manifold uses OEM Parts it can slide through undectable.

Quote:
Originally Posted by Dylanize View Post
Do you guys sell the 3 Stage intake manifold? Also how hard of an install is it?
Could I do it myself?
We unfortunately do not sell the 3 Stage Intake Manifold, you would have to contact your local BMW Dealership or Tischer for the parts. It is possible to DIY but I would personally take it to a shop just to be on the safe side.

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Great! Look forward to exploring this option.

Cheers!
Awesome let me know which route you end up going with buddy.
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      03-15-2013, 02:55 PM   #9
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I really should send my 325 down to you guys. You're getting way more power than I did.
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      03-15-2013, 03:02 PM   #10
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Quote:
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I really should send my 325 down to you guys. You're getting way more power than I did.
We would be more than glad to get your car on our Dyno and custom tune.
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      03-15-2013, 03:39 PM   #11
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just got my tune from you guys and have a complete 3 stage w/parts sitting in my garage. can't wait to install given this is what i can expect out of my 2007 E91!
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      03-15-2013, 03:39 PM   #12
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minus the custom tune, of course.
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      03-15-2013, 09:32 PM   #13
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nice work.
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      03-15-2013, 09:38 PM   #14
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Very nice,

Why dont we see the waves at DISA points?? ( JUST NOTICED THE RPM starts at 2500)



Edit: Quick search has this car at USA e90 330i levels maybe even tuned 330i levels

Link to No Disa, 328 XI & AA revision tune http://activeautowerkeblog.wordpress...s-no-problems/
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      03-16-2013, 08:47 PM   #15
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Large gains in mid range and onwards great work !
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      03-16-2013, 09:11 PM   #16
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Quote:
Originally Posted by Viral@ActiveAutowerke View Post

Awesome let me know which route you end up going with buddy.
I just finished reading the entire "Official" flash thread, and have decided that I'll do the tune first, when the weather gets nicer here, and then see about sourcing the parts for the 3-stage manifold. Based on the other thread, I am expecting significant gains with the tune alone.

Cheers!
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      03-18-2013, 09:21 AM   #17
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Quote:
Originally Posted by GTKrockeTT View Post
just got my tune from you guys and have a complete 3 stage w/parts sitting in my garage. can't wait to install given this is what i can expect out of my 2007 E91!
Quote:
Originally Posted by GTKrockeTT View Post
minus the custom tune, of course.
Glad to hear you have our tune This thread should be inspiring to get this project in the works

Quote:
Originally Posted by mapleridge View Post
nice work.
Thank you for the support

Quote:
Originally Posted by andrey_gta View Post
Very nice,

Why dont we see the waves at DISA points?? ( JUST NOTICED THE RPM starts at 2500)



Edit: Quick search has this car at USA e90 330i levels maybe even tuned 330i levels

Link to No Disa, 328 XI & AA revision tune http://activeautowerkeblog.wordpress...s-no-problems/
With our Performance Software we are able to iron out the DISA waves with for much smoother and crisper pulls throughout the RPM Band. The reason this vehicle was dyno'ed at 2500 RPM is because we would have to ease into the wide open throttle if not the automatic transmission would downshift and the throw the dyno off.

Quote:
Originally Posted by optimaxed View Post
Large gains in mid range and onwards great work !
Thank you so much for the positive feedback and kind words.

Quote:
Originally Posted by Clammy View Post
I just finished reading the entire "Official" flash thread, and have decided that I'll do the tune first, when the weather gets nicer here, and then see about sourcing the parts for the 3-stage manifold. Based on the other thread, I am expecting significant gains with the tune alone.

Cheers!
Thank you so much for reading our Offical Flash Thread and have decided to follow through with our Performance Software for your N52. The 3 Stage Manifold is great mod and can provide solid power and numbers as you can see from our dyno over stock.
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      03-18-2013, 01:51 PM   #18
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All -

I just wanted to jump on here as this was my E91 328i wagon that Active was kind enough to improve upon! Viral and I spoke this morning so I'll just echo some of what he's has posted.

So far so good with the tune and manifold. I've had no codes or CEL's from the installation and yes, the power gains are real. The night the tune was finished I drove the car straight from Miami to Sebring for the 12 Hours of Sebring to stretch it's legs a bit. I noticed Sunday morning on the way back home that the car felt as though it had acclimated more so to the tune and new equipment as the engine feels more useable below 3,000 rpm and above 4,000 rpm the car feels noticably stronger.

At 4,000 rpm and above I think I felt the biggest difference. Whereas the 328i felt a bit anemic when you had your foot to the floor this pulls harder and longer making passing easier. As I told Viral - this definitely isn't a 335i however, the manifold with the Active stage 2 tune has made engine much more enjoyable and usable across the entire powerband. The only downside to my car is the fact that it's an automatic.

Specs of the car as I had it when it came down to Active:

2007 E91 328i w/ Automatic and 88,600 miles
BMW 330i (Euro spec 330i w/ DI) airbox with K&N cone filter
BMW Performance Exhaust
BMW Performance Strut Brace
OZ Alleggerita's running Michelin Pilot Super Sports

I'd highly recommend a professional installation for the manifold and have some spare hoses on hand. Active was able to recycle my old hoses as they were extremely careful when both removing and then putting in the new unit but these parts are prone to breaking as they age. Active did a great job on mine! I think most anyone who wants a bit more out of the 328i (the 335i turbos scared me) will like this mod as it is done essentially with all OEM parts sans the Active tune, definitely improved my enjoyment of the car so far!

Feel free to let me know if you have any questions about living with the tune, etc.
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      03-18-2013, 03:14 PM   #19
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Also I will be sure to clean my car before putting up shots of it next time!
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      03-18-2013, 03:19 PM   #20
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Quote:
Originally Posted by Murph5000 View Post
Also I will be sure to clean my car before putting up shots of it next time!
How dare you post a dirty car!

This is awesome though man! Seriously got me considering this, just need to find a 330i manifold now! Did you order yours or find a used one?
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      03-18-2013, 03:37 PM   #21
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i wonder how similar the gains would be with a 325i
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      03-18-2013, 03:53 PM   #22
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Quote:
Originally Posted by Dylanize View Post
How dare you post a dirty car!

This is awesome though man! Seriously got me considering this, just need to find a 330i manifold now! Did you order yours or find a used one?
Yeah, I know, I'm embarrassed - I wanted to clean it but with timing with work - I worked til 9:30 the night before and had to leave at 3AM the next day to make it to Miami to make the appointment so I was wiped out! Sebring didn't help me recover, either.

As for the manifold - I sourced mine from a salvaged Z4 3.0Si (06 or 07, I think - buddy helped me find one) that had the engine replaced from water damage. However, as for the hoses - I bought all of those new from the dealership. With the CCA discount I think it was around $100? I'll have to dig up the post but some people here have found the intake manifolds through a car parts recycling site which is a good idea. Honestly, I'm glad I didn't spend $1k on new parts for this mod - all in I probably spent $200 - $300 on parts for the manifold.

I believe on other threads people showed all of the part numbers which confused me at first until I realized that the actuators and adjusters are already on the 330i (or Z4/X3 3.0Si) manifold - they're just built into the intake. Once I realized that, it was just the hoses and gaskets I needed to buy. I would recommend getting the manifold first - then evaluating what hoses you need. My sourced manifold came with an oil separator on it which I didn't need so Active removed it but I may have bought the wrong hose because of the ports on the back of the manifold. Active used my old hoses and made a workaround by just capping off one of outlets that wasn't needed as the 328i N52's have the oil separators built into the crank case but I do think there is a more appropriate hose for this - I just need to source one and install it at a later date.
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