[Johnny D]

I finally have everything I need to do the three stage intake swap. I have the rest of today and tomorrow off. After assessing the work it will take, Im actually nervous. Im mechanically inclined, but dang if it isnt cramped in there...

Anyone else done the swap themselves? Looking to find if anyone can give me a tip on any trouble issues. So far, looks like the only tough parts will be the further most bolts and some of the oil separator parts.

[VTECaddict]

It's pretty spacious. If you want to see cramped, look at an RSX...

[mike-y]

it's actually pretty cramped around the backside of the intake manifold (the Z4 has more room than the E90). The hardest part will be udoing the little plugs on the back, underneath part of the IM. Popping off the vent hoses is a pain too, be careful not to break them, they snap very easily (ask me how I know). An extra set of hands can help once you undo all the IM bolts. One person can hold up the manifold, while the other disconnects the hoses. I was able to do it all by myself, so it's possible if you are alone.

Don't worry about the oil separator until you get the IM off, just leave it attached and swap it to the new manifold after it's out of the car.

[MaximusJ]

^^ this.

Also, take your time. When the back's starting to hurt; take a break. I had back pains for 3 days after doing that job. They said it was gonna take 3h. Took me close to 6.

[DESI4life10]

On a 328, it wasn't so bad at all.

I had another set of hands to lift the manifold while I finish unplugging the last set of wires.

We did it in about 5 hours.

It may look cramped, but once you remove the airbox and throttle body, and put the power steering reservoir to the side, it doesn't look too bad.

I also used a 10" long 90 deg bend needle nose pliers (helps with removing the vent hose).
The biggest pain for me was disconnecting the electronic box from under the manifold. I suggest you remove the bar it is connected to otherwise you risk breaking the tabs off (which is what I did). Good thing is that the tabs are still strong enough when broken and will have no problem putting it back (I applied some glue to fasten the tab to the box).

[Johnny D]

I was going to work on it today, but my helper couldnt make it. I will get this done this weekend. I have my AA flashes ready to go!

So instead, I worked on some cosmetics.
http://www.e90post.com/forums/showth...0#post11313100

[MaximusJ]

DESI: Thank god I dont have a 328. Everytime you talk about the process, it makes me wonder if we have the same engine at all. lol

Looks like a lot of differences other then the oil separator.

[DESI4life10]

Originally Posted by MaximusJ

DESI: Thank god I dont have a 328. Everytime you talk about the process, it makes me wonder if we have the same engine at all. lol

Looks like a lot of differences other then the oil separator.

LOL..it's actually easier than the 325. Our brake booster line is outside so we don't have to take that out. :-)

It was actually a very easy process for us. Didn't have to remove the vent hose from the crankcase.

[Johnny D]

And Im stuck...

cant get the harness off this bracket.

[DESI4life10]

LOL...That was the part I am talking about.

Your better off taking the 2 screws off the bracket that is holding that box. Follow that bracket and you will find the screw on each end. More than enough room to open it up.

you you will just have the break the tap closet to the bracket (what happened to me by accident)

[onebadmofo]

Cramped engine bay? Say thanks you never had to work on 3000GT (GTO)

[Johnny D]

Originally Posted by DESI4life10

LOL...That was the part I am talking about.

Your better off taking the 2 screws off the bracket that is holding that box. Follow that bracket and you will find the screw on each end. More than enough room to open it up.

you you will just have the break the tap closet to the bracket (what happened to me by accident)

Tried that unfortunately for me the only T27 head I have is an all in one. Not enough room to fit it in there and get it off. You think I could go ahead and work on, once I get the manifold unbolted I might have more room to get in there and get the screws out?

[DESI4life10]

It might be a bit tight though. But it just may work.
The slack in the wire is minimal.

[Johnny D]

Its late and dark, Im going to pick up where I left off in the morning. Thanks for the help.

[Johnny D]

Spoke to a BMW Mechanic I know from another forum. He advised to use a small pick. Worked like a charm! Ill finish the install and tune tomorrow and post some initial thoughts. I hope to find a local dyno for numbers.