Keith’s E46 M3 build log.

[Keith_MN]

Turner airbox install & notes.

Got the full kit on the BF sale last year. Given recent reviews and the value proposition, I took a jump.

Get yourself a Lisle 30500 pliers or equivalent for the boot clamps.
I used the replacement boots with the OEM oetiker clamps. The boots are slightly bigger in diameter than the OEM boots, so the clamps will not engage to the second locked position without serious deformation. I left them clicked on the first lock and the intake feels very solid. We will see what happens with that, but it still feels better than worm drive garbage (which is what I used for the intake side clamps, turned out of view).

Struggled getting it seated for longer than I care to admit. Finally discovered that the very bottom of boot #5 was folding over and causing the problem.
Even fully seated now, the intake "angled" up enough to not fully engage both slots for the two 10mm nuts on the bottom. Not enough flex in the boots to bend it down. This also made the IACV connection extremely difficult to get seated. Another person pressing down on the intake would have helped.



Unlike some of the others, the airbox clears the driver side radiator shroud with no trimming. I have a fresh clip on the shroud keeping it snug against the radiator.





You can see my map sensor installed next to the brake booster. I decided to use the Auto3Design harness which makes the maf/map/iat all plug & play.

You can also see my dip stick below the mouth of the intake. I don't love the location but in the end the ease of functionality wins out. I used a conduit bender to get the dipstick tube lined up. Would definitely prefer to have a CSL style dipstick, seems like something that could be reproduced without too much trouble.

All back together with obligatory sticker tune. I have found that the front corner of the snorkel on #1 does touch the insulation of the hood, again another symptom of it angled up more than it should. It seems like it did settle downwards ever so slightly after some miles, enough that I took out 1 of the 3 washers stacked to get the strut tower bar to clear.

[bavarian3]

Looks good! Bummer to hear about these fitment issues. I personally removed the hood insulation. Not due to airbox fitment issues though.

What tune did you use?

[Keith_MN]

Looks good! Bummer to hear about these fitment issues. I personally removed the hood insulation. Not due to airbox fitment issues though.

What tune did you use?

Yeah it's not terrible, just sharing for future buyers. To be expected to some degree with aftermarket. I'm sure Karbonius is better but for this car I think I'd rather spend the $1k difference elsewhere.

Just the CSL tune for now. Goal was to get that loaded and if the car drove well (it does), live with that for the short term while I get all the details wrapped up. Will post my experience with that next...

[Slideways]

For the Turner box, you can loosen the single bolt holding the bracket under the intake manifold and it can be moved up to meet the two rubber mounts. That way, the rubber mounts won't be stressed and the intake won't be pulled down or bracket bent upward. For the ICV, you can pull out the 90 degree connector that clips under the airbox a few mm and secure it with a hose clamp. That will make it much easier to fully clip into the airbox. Best to not have tension on this stuff to avoid future issues.

[Keith_MN]

For the Turner box, you can loosen the single bolt holding the bracket under the intake manifold and it can be moved up to meet the two rubber mounts. That way, the rubber mounts won't be stressed and the intake won't be pulled down or bracket bent upward. For the ICV, you can pull out the 90 degree connector that clips under the airbox a few mm and secure it with a hose clamp. That will make it much easier to fully clip into the airbox. Best to not have tension on this stuff to avoid future issues.

Interesting. I had that bracket loose on install and didn't notice any slack in the fitment. Will investigate...

[Slideways]

Interesting. I had that bracket loose on install and didn't notice any slack in the fitment. Will investigate...

There should be some slack in it IIRC and you can access it with the unfiltered section removed and a long extension.

LMK if you need any clarification for the ICV hose/connector. Tension on that connector might cause it to break off the airbox.

[Keith_MN]

Got the car running and then life got busy again. Car was blocked in the garage for two weeks, just got it out on Monday night and broke 100 miles on it finally. Haven't thoroughly romped on it but getting deeper into the throttle. I can feel some flat spots but it's minor, runs well and sounds great. I have a few more minor items to troubleshoot/tweak and then will be looking into scheduling some dyno time. Found an Audi shop near me that may work out.

So anyways, sitll working on a tune/flash "diy" type post that I will put in this thread that should be another good reference for those looking.

I came across some pics the other day and mostly just wanted to post these of my old 540 from 2012.




And a random from today. Parked next to the E46 I have seen before at my son's doctor's office. Very faded rear decklid and failing headliner, but otherwise clean.

[Keith_MN]

Updates!

Not long after my last post, I decided I'd get it up in the air again to for a few updates and would also finish up the last of the coding I needed to do.

When I bought the car, I found that the four "bumper carrier screw connectors" that slide into the socket of the bumper were missing. I replaced those but had a hell of a time getting the bumper to accept them. I ended up sanding them all down a touch, using a bit of lube and then they finally went. Well wouldn't you know that once we're in the heat of summer, the bumper won't stay seated on those carrier screws. Ordered another four of those and got them replaced. No sanding this time, just a tiny bit of silicone.

While the bumper was off, I installed the driver side fog light duct for the intake. Nice 3D printed two piece unit that I got from discoelk
The horn is mounted there and the harness doesn't allow a lot of room for moving it. I flattened and re-bent the bracket in a mild "Z" shape and it fits nicely using the original mounting location.







Also replaced the mostly mismatched bumper mounting hardware with all fresh OEM screws and speednuts. Satisfying.

Next I got into the intake again. I wanted to do a condition check, attempt to angle it lower and smooth out the ICV port.
Visual on the intake looked good for everything.
I had been getting a pretty noticeable high pitch whistle at low rpms/light throttle. I found a great tip from Slideways that the ICV port should be smoothed to reduce whistling. I stuck my finger in there and i felt a defined edge for sure, but not what I would call a sharp edge. I spent a few minutes with some 500 grit, cleaned it up and called it good. It felt a little better but hard to be certain.


Next I loosened up the three mounting points, pushed the hell out of it (not really) and tightened it back down. Definitely got it lower, especially in the front which is where it really needed it.

That's a good thing because I got a RE bar to stick on it.


To help prevent unsolicited smooches between these two, I cut up some 3mm aluminum sheet that I had laying around to act as a little spacer. Came out quite nicely.


Ordered some black stainless flange nuts to finish this job off and it's good to go.

Replaced the "headlight cover strips", was shocked at how utterly affordable those were. Mine were trashed.
Replaced the plastic vent on the hood, mine was a bit faded. Ceramic coated that for all the car show points.
Hmm...oh working on a modified Rennline bracket with a Ram phone mount. More to come on that hopefully.

But anyways back to coding. Large eyeroll. Can't get NCS to work and my patience level with that kind of stuff is at an all time low, especially considering the car runs fine as is. ...but...I want to get the light off the dash and do a few module updates. I have a few more things to work through before I come crying for help.

I have been using karter16 DME tool to teach myself a little more and holy heck is that tool nice. What a great resource that is actually intuitive. Thank you again karter16 !!

Some of the swap updates for the partial bin didn't take, so I made those updates and took the car out to make sure everything was good. No problem there but I did have one unexpected thing. The whistle from the ICV port is dramatically reduced. I honestly can't believe the difference with such little work. So glad I did that.

So at this point I'm a whopping 300 miles in, post manual swap, clutch, rod bearings, csl intake, yada yada.



I was very happy with how the car drove with the community patch CSL file (again thank you karter16 ). As I was starting to drive it more throughout the RPM, I could feel some flat spots. Subtle, but there. Was gonna do the dyno thing but knowing how time works for me, let's try this first....

Chatted up Bry5on and he got me set up with ye ole Mullet tune.

Loaded that last night and went for a quick rip. First impressions:

Smooth.

Period. And very happily, that's the best thing I can say. It already drove well, it just smoothed it out and made it feel like it was ready to go. Raining today, but can't wait to get it out this weekend for a nice drive. Maybe I'll make my wife drive it!



These are a few of my favorite things...

[karter16]

Great update! looks awesome!!

Replaced the "headlight cover strips", was shocked at how utterly affordable those were. Mine were trashed.

Ah man I really need to do this and new hardware same as you - glad to hear they're affordable.

I have been using karter16 DME tool to teach myself a little more and holy heck is that tool nice. What a great resource that is actually intuitive. Thank you again karter16 !!

Thanks for the kind words - easy to use and intuitive is exactly what I was going for, so great to hear it hits the mark for you. Also another shoutout to (in no particular order) George Hill, heinzboehmer, Bry5on and ac427 for their feedback and ideas that have massively helped the app in the "inuitiveness" department!

[Bry5on]

Love the mountain bike + M3 combo! And glad you’re happy with the mullet!

edit: since we're sharing, this is the mullet development vehicle..

[discoelk]

Man, I feel that latest post.

Edit: The horn interference with the intake duct is odd. Is that horn factory? Can you take some more pictures and I can update the design and send you the new revision?

[Keith_MN]

Love the mountain bike + M3 combo! And glad you’re happy with the mullet!

edit: since we're sharing, this is the mullet development vehicle..

Sick. I see you sprung for the black finish on the 1up, good choice. Best tray rack you can buy. I have the same.

I never ride when I'm in SD, the good stuff looks too far away and I'm usually only there for a few days with fam. Maybe next time.

Took my boy to school this morning in the E46 and loving it. Just wants to rev.

Man, I feel that latest post.

Edit: The horn interference with the intake duct is odd. Is that horn factory? Can you take some more pictures and I can update the design and send you the new revision?

Never occurred to me since it all looked so factory, but yep it wasn't in the factory location. My car had a front end fender bender (thus some of the bumper hardware was wonky when I took ownership), the horn relocation must have been part of that for whatever reason. Add that back to the list for future review.

Is that a Celica/Supra peeking in your garage?

[discoelk]

Yeah, I think the horn is just a weirdo placement. Real oem shows it behind the bumper.

Indeed the car is a Celica Supra. Owned it since high school. In the middle of a M54 swap, 5 lug etc. it might run this year.

[Keith_MN]

Yeah, I think the horn is just a weirdo placement. Real oem shows it behind the bumper.

Indeed the car is a Celica Supra. Owned it since high school. In the middle of a M54 swap, 5 lug etc. it might run this year.

Nice! Big soft spot for old Toyotas.