BMW E46 M3 AFE Magnum Force CAI stage 1

Installation Guide

AFEpower.com

2014 ver 1.0

Author: Stefan Yotz

Before you start:

The BMW e46 M3 is an incredible work of automotive art and mechanical design. A cold air intake is a
tremendously economical way of both improving stock performance and how your car sounds. This is
an excellent place to upgrade your car as the return on investment is very high both in direct value and
in the time to do the work and Advanced Flow Engineering (AFE) is a fantastic place to start.
The Advanced Flow Engineering cold air intake stage 1 is a substantial change from the OEM airbox
design and filter. At peak it adds 11 horse power and 10 pounds of torque which is a dramatic increase
you can both hear and feel. Adding real horsepower to a car as well designed as the BMW M3 can be a
challenge, but this product actually does it.
I wont repeat all of the posted statistics as you can refer to them here, but will focus on how it feels and
sounds like to have this CAI installed.
Assumptions:
The example used for this DIY is a 2004 BMW M3 convertible though other models will be identical or
very similar. The product selector through the AFE website will ensure you get the right CAI for your
vehicle. This install includes two optional accessories in addition to the CAI S1 kit, the MF intake system
scoop and MF torque booster tube.
If you do not have these two accessories, which you should purchase anyway, skip to step 12.
Goal:
Work through the CAI S1 kit installation and make it simple and easy, allowing anyone who can turn a
wrench to be successful.
Disclaimer:
This process worked for me beautifully but that doesnt mean it will automatically do so for you. Work
slowly and carefully, dont force anything and dont rush. For an hour of time, you can complete a
significant upgrade to your car that you are going to both hear and feel. Dont hesitate to ask questions
or ask for help if you run into a roadblock.
Lastly... do yourself a favor as you get in and out of your car multiple times: DO NOT put tools in your
pocket. Its temping, but one wrong move and you can punch a screwdriver through your seat. DONT
DO IT.

AFEpower.com

2014 ver 1.0

Author: Stefan Yotz

Parts and Tools:

Must have:
Magnum FORCE Stage-1 PRO 5R Intake System; BMW M3 (E46) 01-07 L6-3.2L 54-10461
socket, nut driver
10mm socket or wrench
13mm socket or wrench
ratchet and extension
4mm allen wrench
Torx bit T-20
Standard (flat) screw driver
Philips (+) screw driver
Needle nose pliers
Nice to have:
Magnum FORCE Intake System Scoop; BMW 3-Series/ M3 (E46) 01-06 L6 54-10468
Magnum FORCE Torque Booster Tube; BMW M3 (E46) 01-07 L6-3.2L (Blk) 54-10469-B
10mm ratcheting wrench
10mm deep socket
Shop work gloves
Magnetic screw bowl
Lots of light and space
Forum information E46 Fanatics Engine and Performance Forum
Music (I recommend BB King, nothing like the blues while doing car work)
Patience

Contacts:
Advanced Flow Engineering
E46 Fanatics Forum
E46 Fanatics Engine and Performance Forum

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2014 ver 1.0

Author: Stefan Yotz

Intake Scoop and Force Tube Installation

*Assumptions: Installation order will be intake scoop, force tube and then the CAI kit but could be done
in any order you desire.
1.

Starting fully stock, lets look at what we have one we pop the hood. The picture is of a
completely stock M3 and OEM air filter system.
If you have some old towels or shop rags around, take this opportunity to wipe down the
surfaces and clean up a bit. It will cut down on mess on you and the new parts going into your
car.
Plus... you know you will want to show the CAI S1 off, so clean up the engine space a bit!

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2014 ver 1.0

Author: Stefan Yotz

2. Use a flat bladed screwdriver or needle nose pliers, gently pull or pry (4) pressure pins
securing the intake and set the intake aside. Dont pull the center pin of the pins out
completely.

3. Remove two screws indicated below and set in a safe place.

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2014 ver 1.0

Author: Stefan Yotz

4. Gently pull the shroud forward and slide the scoop behind and down into place.

5. Secure the scoop with the two screws you set aside, with the frame post through the center
hole of the scoop.

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2014 ver 1.0

Author: Stefan Yotz

6. Set the intake back into position and secure with the (4) pressure pins you set aside.

Congratulations as the scoop is done! Consider marking the progress with an AFE Power sticker!

Lets move onto the Torque Booster Tube but two things to note before we start.
First, DO NOT remove the strut bar with the car off the ground or on jacks. Doing so can cause the bar
to crack or break when you lower the car. There are no alignment or suspension concerns removing the
strut bar while on the ground.
Second, this install will show the factory airbox in stages as this tube can be used with that as well. I
wanted to show all options even though the CAI S1 will be installed next.

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2014 ver 1.0

Author: Stefan Yotz

7. Remove the two 13mm nuts on the left side of the strut bar.

8. Remove the two 13mm nuts on the right side of the strut bar and set all aside in a safe place.

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2014 ver 1.0

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9.

Loosen both clamps on the factory intake tube and remove it. Set it aside as you wont need
it again. Note: In some cases you can remove the (note) vacuum line from the plenum for
more space but I didnt need to, so I didnt.

10. Put both of the new supplied hose clamps onto the tube, and slide into place on the plenum
and intake box. (note) Keep both clamps loose to make the S1 install next easier.

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11. Put the strut bar back into place and secure both left and right sides with the 13mm nuts.
Tighten until snug.

Well done! The torque booster tube is installed and ready for the stage 1 cold air intake.

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2014 ver 1.0

Author: Stefan Yotz

Cold Air Intake S1 Installation

12. Remove the factory wiring harness from the Mass Air Flow (MAF) sensor, and tuck out of the
way. Remove by squeezing at the indicated arrows.

13. Use t-20 torx bit to remove the MAF from the intake box and set aside CAREFULLY! MAF units
are notoriously fragile. BE CAREFUL and I treated mine like it was blown glass.

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14. Remove the front snorkel and loosen the two indicated clamps to release the airbox top.

15. Remove the airbox top and existing airfilter, setting both aside as you wont need them again.

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16. Remove the plastic cover from the headlight controller by gently lifting and freeing plastic
tabs. Use 10mm socket and remove the (2) bottom bolts. I also removed the top nut for
more space. Remove the lower half of the airbox from the car and set aside. You will not
need it again.

17. Remove the rubber mount from the tab. Use this opportunity wipe down the area clean for
the new CAI S1. Less grime here means less potential grime into the new filter.

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2014 ver 1.0

Author: Stefan Yotz

18. Secure the aluminum adaptor to the heat shield the (4) M6 x 10mm button head screws
provided, using the 4mm allen wrench.

19. Install heatshield and intake into place, secure using 10mm socket with the two bolts you
removed. (Note 1) Use provided nylon spacer on lower tab here. Tighten top nut if you
removed it. Replace headlight controller cover. (Note 2) Use 10mm socket and M6 nut and
washer to secure the heatshield frame.

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Author: Stefan Yotz

20. Install the MAF sensor into the aluminum adaptor using the (2) provided M4 screws, and
reconnect the wiring harness. Note for install orientation: The opening in the MAF points
towards the front of the car, not towards the back.

21. Install the aFe filter, and tighten all clamps using nut driver or standard screw driver.

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22. Install the aluminum cover with (4) M6 x 12mm button head screws using 4mm allen wrench.
I found installing the lowest right screw first helped bring the rest into alignment the best.

23. Double check all functionality again: check all clamps are snug, the headlight module cover is
in place and its rubber socket covers sealed. Look for any extra parts left over and if not,
you are done! Clean up and put your tools away. Button up the car and take it out for a first
drive!

Congratulations! All in all this isnt a terribly hard project but just something to take slowly and carefully
to ensure everything is done properly.
That said taking the work slowly and patiently, it isnt that hard and you saved yourself a healthy
amount of money from having a third party or vendor do the install.
After a few hours of drive time, check everything again and tighten anything that may have worked
loose.
Congratulations again and enjoy the benefits of the aFe CAI stage 1 system!

AFEpower.com

2014 ver 1.0

Author: Stefan Yotz

Written by Stefan Yotz 5/2014

Unlimited and unrestricted usage granted to all
There is no warrantee or guarantee to this guide and is provided in all good faith and best effort.

Huge thanks to:

Advanced Flow Engineering
Paul Hardley Vice President Product Management
Ryan Takashima Director of Marketing & Global Sourcing
E46 Fanatics Forum
E46 Fanatics Engine and Performance Forum

AFEpower.com

2014 ver 1.0

Author: Stefan Yotz