AA / HKS / M3 Self Install

What a better way to spend a friday afternoon swearing to my self in my garage, lol.

So my stage 2 kit arrived today, went through everything and was suprised how well everything was packed and sealed. So I got right into it and started unpacking everything.













I have had the car in a ready state for a while now sitting on jack stands and have already removed items like the intake, front bumper, fan clutch, fan shroud, pulley's, belts, belt tensioner, front cross brace.

This is the old fuel rail vs the new one that comes with the stage 2 kit. The stage 1 and 1.5 us the stock fuel rail.

This ment I had to remove the stock fuel line which was a BI*%!#h because it's like bolted to the block twenty times lol and runs under the starter.







This is nice, OBD-II to USB for tuning the car via my garage.



There are a lot of small little spaces in that dam S54, all worth it though

Welcome to the F/I family and I am loving that fuel rail man . Stage 2 is pretty damn sick and props for the self install. Will you be upgrading the clutch/flywheel? How much of a nitrous shot will you be running?

p.s. I see BELLY in one of the pictures

Quick question

First off nice kit.

Second I/m trying to order a stage 2 for my 325ci. AA is saying they are all out of the HKS blowers, every one like not one in stock for any kit period. How is it that you got your kit yesterday and they are telling me today that they have nothing in stock and there is NO HKS blowers in the US and maybe only 100 of them over in japan but the HKS facility over there is shot to hell because of the earth quake and they pretty much told me I may not even see the blower this year. I'm pretty pissed as I got financed and a check cut out to them and now I'm paying on a loan that I have nothing to show for.

I'm sorry if it seems I'm venting to you but AA is pretty much like yea we can't help you and we have NO idea when the blower will come in if ever.

Originally Posted by 02black330ci

Welcome to the F/I family and I am loving that fuel rail man . Stage 2 is pretty damn sick and props for the self install. Will you be upgrading the clutch/flywheel? How much of a nitrous shot will you be running?

p.s. I see BELLY in one of the pictures

Clutch and fly wheel is next on the list, as far as the nitrous I'm first off looking at doing a spray bar kit until I get my fuel cell stuff in order. Adam and Loren have gave me some great advice in the past. Thanks Guy's

I've ran nitrous n/a in the past with this car and will likley do it boosted too, if I stick with the AA tune I would have to have them retard like 3 degrees timing for ever 50 shot or so, other wise maybe Pro EFI.

The belly is due to me drinking lots of beer and swearing at my car lol

Originally Posted by '02 ZSP

Quick question

First off nice kit.

Second I/m trying to order a stage 2 for my 325ci. AA is saying they are all out of the HKS blowers, every one like not one in stock for any kit period. How is it that you got your kit yesterday and they are telling me today that they have nothing in stock and there is NO HKS blowers in the US and maybe only 100 of them over in japan but the HKS facility over there is shot to hell because of the earth quake and they pretty much told me I may not even see the blower this year. I'm pretty pissed as I got financed and a check cut out to them and now I'm paying on a loan that I have nothing to show for.

I'm sorry if it seems I'm venting to you but AA is pretty much like yea we can't help you and we have NO idea when the blower will come in if ever.

The only reason I got my kit today is becuase I purchased it in full in June, hope every thing works out for ya, there could be delay's though.

Wishing all the people in Japan to keep there haeds up.

Originally Posted by Sweed

The only reason I got my kit today is becuase I purchased it in full in June, hope every thing works out for ya, there could be delay's though.

Wishing all the people in Japan to keep there haeds up.

It's the 10th day of June and I went to purchase it completely today lol. How many kits could they have sold in 10 days?

And yea I hope it works out for me, I've been prepping the car all year for this, replaced nearly everything to make it mechanically like new and all for nothing it seems. The outlook is grim to say the least, and I have a loan out on something I cannot get which there website did not inform me of. Not too please about that haha.

Anyways, good luck with your kit, keep us posted on your progress.

Looks like a good start! Another Albertan to the mix!

Subscribed.

Nice NX bottle there with the remote opener.

This is nice, OBD-II to USB for tuning the car via my garage.

Is this standard in stage 2?

Good luck!

Originally Posted by Sweed

Clutch and fly wheel is next on the list, as far as the nitrous I'm first off looking at doing a spray bar kit until I get my fuel cell stuff in order. Adam and Loren have gave me some great advice in the past. Thanks Guy's

I've ran nitrous n/a in the past with this car and will likley do it boosted too, if I stick with the AA tune I would have to have them retard like 3 degrees timing for ever 50 shot or so, other wise maybe Pro EFI.

The belly is due to me drinking lots of beer and swearing at my car lol

S/C + nitrous + ProEfi =

As far as yelling at your car, we have ALL been there , but the beer definitely makes up for it

Ya the M3 is like a relationship, you can only put up with it so for so long then you have to take a break, but in the end you both want it so by the time you come back it's some what new and meanful again.

Now to some more blood sweat and tears.

Here is the Oil Cooler mounted and connected, the fan shroud had to be trimmed about an inch off the bottom as well to make future room for the intercooler.


The front grilles had to be trimmed on the inside to make clearance for the hood, the drivers side oil line may have to be turned to compansate for the hood latch.


This is the hood with everything trimmed and fitting nicley.


The Oil can can be positioned on either side of this compartment due to the two different factory bolting points, this can is very adjustable in swing allowing to basically move it if needed.


The power steering fluid tank relocated to the front of the engine bay.


The pullies were next along with the belt tesioner, I will be using an 80mm pulley on this project which is smaller than the org stage 2 pulley. This is because I'm at 2800ft above sea level and would not be able to hit full boost at this elevation with a stock stage 2 pulley( thx Loren ). Note: If I drive this set-up at sea level I would void my warrenty due to overboosting but then nitrous voids it any way so mah.


Excuse me ahead of time for grammer and spelling for I'am not the an English teacher, as mentioned ealier about the OBD-II reader it is not part of the stage 2 set-up but is available upon request. The injectors used in the set-up are the stage 2 60Lb injectors.

So far so good, If I were to give any advice when doing an install like this it is patients, everthying is bolting up nicley and the fittment is flawless. Only excpetion is that my new AA fan clutch never made it with the kit so will have to add that later.

This is all the pulley's and tensioner's mounted.
Water Pump: Torque to 8 ft/lbs
Crank: 18 ft/lbs
Power Steering: 18 ft/lbs


S/c Bracket and Pulley's


New SMG Can


In-line Pump and Filter


Blower and Fuel Regulator Mounted

Denso Irridium plugs gaped to 0.023 (IXU275337)


This pic is of my headlight ballast on the driver's side, I have a 2006 so not sure when they moved it from where it was before (Inside fender well). They sit right behind the head light right in the way of the ram air pipe.


This is the ballast removed, there are extended wires so that's alway's nice. I'm not sure where I will be mounting it but it's out of the way for now.


This allowed the ram air pipe to fit through


The stock fuel pump is kept but it has to be altered with bigger fittings, this shows the AN6 90 degree added in and the stock port is plugged off.


I wanted to test fit the manifold to line everything up

Looking good bro! Did my own install as well... Fun times!

Originally Posted by ///M3AN ONE

Looking good bro! Did my own install as well... Fun times!

Thanks man, I've bin wanting to do this for a long time now. Bye the way how do you find the sound of your HKS blow off compared to the AA one.

Honestly... Can't really tell the difference, got it more for looks, lolz!

Welcome to the club!

Originally Posted by toy4to

Welcome to the club!

Thx it's long over due.

Here is a finalization of dealing with the stock fuel pump

Just a side note, before re-installing fuel pump make sure that the level indicator swing arm is still clipped into place, messing around unseated it earlier, it clips in place firmly.


The brown plastic tube was the old fuel line connecting the pump to the fitting, I removed this due to being brital and replaced it with some fuel hose.


I tip when re-installing the fuel pump housing, to get a perfect seal take off the housing gasket and mold it around the tank gasket, then fit it into place allowing the lock ring to easly seat.


This is the how it should look when finished, epoxy was added around the new fitting to help stay it in place.

The new fuel line is routed next to the stock fuel lines, access is allowed bye poping open the other cover on the driver's side.



New Fuel line dropped down to follow factory lines. I ended up taping off the end of the new fuel line temperaily so no debri got in side the hose while routing it.


The old fuel pump and regulator are taken out but the sleeve and mounting bracket are re-used for the new one.


This is the new fuel pump and filter that run along with the stock pump. The new pump will be wired in parallel with the stock pump, that way each pump surges from it's inputs at the same time.


The by-pass for the regulator uses the stock fuel line to return fuel back to the tank. This connection is right beside the fuel filter. The stock return line dumps into the driver's side fuel latch. All connections fitted perfectly and no adjustments had to be made.

Glad to see the Progress of the install can't wait to see the final pics