E36 325 Supercharger Kit

INSTRUCTIONS
1992-1995 E36 325 &1995 M3 SUPERCHARGER
WITH C30 BLOWER.
1
Introduction
Congratulations on your purchase of an Active Autowerke Supercharger, and
welcome to the AA Tuning family. Your supercharger kit was developed to
provide a level of driving enjoyment that cannot be matched.
Enclosed in this packet you will find general guidelines, recommended
maintenance schedules and detailed installation instructions for your
supercharger. Please read all the material thoroughly and become familiar
with our recommendations. If anything is unclear or ambiguous, please do not
hesitate to contact us for further clarification. We are here to help.
Operating Instructions for
AA supercharged cars
Always allow your engine and supercharger to warm up for at least one
minute before placing the car in gear. In colder weather (below 50
degrees Fahrenheit), we recommend at least two-to-three minutes of
warm-up time.
Always use the best fuel (93 octane) available. If 91 octane is the only
available fuel, add an octane booster if you detect any knocking. Active
Autowerke calibrates the software to operate on 91 octane, but some cars
may experience slight knocking or detonation. Excessive knocking will
damage the motor, so pay close attention to any hint of knocking.
On Steptronic or automatic transmission models, we recommend that the
transmission be set in “Sport” mode when the car is driven hard. This will
allow the transmission to shift more quickly to prevent any excess slippage.
Additionally, after driving hard in an automatic-equipped car, you should allow
the car to cool off for at least one minute before shutting off the motor. This
will allow your transmission fluid to cool off. It is also a good idea to follow this
procedure in order for the supercharger to cool off properly.
It is also recommended that you check the supercharger oil level in the
reservoir at least once a month. The level should read at the lower dipstick
mark with the engine running in neutral or Park.
Following these recommendations will ensure that your supercharger
provides many miles of thrilling driving enjoyment.
If you have any questions, please e-mail or call us.
E-mail: [email protected]
Phone: 305-233-9300
2
INSTRUCTIONS
BMW E36 1995 M3 & 1992-1995 325
AA Supercharger System
BREATHER HOSE – INTAKE VACUUM HOSES & BUMPER
BREATHER HOSE
Remove stock air box
Remove engine fan assembly by using a 32mm
wrench.
-Fan mounting nut has a left hand thread. Remove
by striking on the wrench to break the seal, then
unscrew the fan
-Reinstall fan back before starting engine to prevent
overheating.
The fan is retained on the supercharger installation.
Remove screws on both sides.
3
Remove eyelets on both sides of core support cover
then remove cover.
Remove HFM and boot.
Disconnect breather hose and idle valve hose from
boot. Idle valve hose will be extended towards the
new throttle elbow.
Remove the old breather hose from the valve cover
and attach the new hose with filter. The open end
will later be attached to # 1 pipe.
4
The vacuum line for the blow off valve will be
spliced into the fuel pressure regulator vacuum line.
This line is under the intake manifold, just below
#6 cylinder. T into the line with the vacuum hose
provided. The other end should be routed towards
the blow off valve.
Remove front splash guard from under the front
bumper
Remove screw inside left inner fender that holds
on the front bumper end.
Repeat the same for the right side
Remove left & right front bumper impact strip
-Using a small screwdriver, first start by placing
under the Tow Hook cover and pry up. Follow on
the other Impact Strips
5
Using a 13mm socket, unbolt the (4) bumper nuts.
-Start to pull front bumper off.
-Watch for the fog light connectors and the outside
temp sensor probe. All of these will need to be
carefully removed to prevent possible breaking
With the front bumper off and the auxiliary fan
visible, you will see the side panel shields for the
front electric fan.
Using a cutting dykes or a snips, cut the side of the
electric fan shroud. See picture for clarification.
6
CHARCOAL CANNISTER PURGE VALVE – CHECK VALVE
Remove the charcoal canister and relocate to the
battery tray with bracket provided.
Mount canister with fittings towards engine.
Disconnect vent hose from Purge Valve and add hose
with grey check valve.
-Make sure arrow on grey valve points towards the
engine.
The ¼ inch vent line coming from the purge to the
canister has to be extended with 4 ft of 6mm vacuum
line.
7
Connect the 6mm vacuum line to the purge valve and
route towards the new canister position. Attach line
to the smaller nipple.
Route line along fire wall. Tie strap against fire wall.
The blue line that was attached to the canister now
has to be extended. Cut of the end of the blue plastic
line making it straight, slide the reduced end (6mm
silicone hose) of the 3/8 rubber hose over the blue
line. Route the rest of the 3/8 hose towards the
canister.
Picture shows 3/8 line reduced down to 6mm blue
silicone hose. This hose goes over the blue plastic
line.
Connect 3/8 line to the large canister nipple. Tie strap
against fire wall.
8
SUPERCHARGER BRACKET
Remove A/C belt. Remove uni-belt from engine.
-Both belts are automatically tensioned via tensioner
pulleys
-On each pulley, the center is covered with a plastic
cap. Using a small screwdriver, pry off cap to expose
the hex key in the middle.
-Remove the Idler Pulley with a 16m socket.
With a 8mm hex key in the middle of the pulley and
by turning clockwise, the belt tension will slacken
making removal of the belt possible.
-Remove the belt.
NOTE: The same procedure is required for
the A/C belt removal. It uses the same
tensioning pulley system.
The factory belt tensioner carries a pulley and a
separate tensioner shock.
-Remove the original tensioner. It is secured by (3)
bolts. A 8x50, and 8x35.
-Picture shown is the old tensioner.
9
A new tensioner using no shock will replace the
original set up.
-Do not use the long 8x50mm bolt. Use back the
original 8x35mm bolt and a new 8x35mm bolt &
washer supplied with the new revised tensioner.
Install new tensioner.
Remove the top alternator bolt 10x150. Remove the
bottom alternator bolt 10x160mm. These will not be
used back.
Looking at the P/S pump and bracket, there is an
upper bolt that is used to mount the P/S.
-Remove the bolt (8x84mm) and replace with a
BLACK button head bolt (8x90mm).
WILL CAUSE DAMAGE TO BELT IF NOT
REPLACED.
The top SC bracket hole is also the mounting hole for
the alternator idler pulley.
-Reuse the 10x150 alternator bolt that was removed.
-Reinstall this 10x150 bolt first through the idler
pulley then through the aluminum spacer.
NOTE: There is a step side with a collar on
the spacer. The collar fits inside the idler
pulley.
10
Mount the bottom idler pulley by first placing the
spacer behind the pulley. The ridge on the
spacer must sit inside the pulley. Use the
10x35mm Allen bolts and torque down to 18 ft lbs.
-Install the 160mm bolt in the bottom hole before
installing bracket. On some models the bottom
alternator bolt uses a nut in the back, you will
have to use the 180mm bolt provided.
NOTE: Bolt will not go in without removing
radiator if not installed in bracket first.
Mount the SC using a 5mm hex key.
-These bolts are long and need to be torque 10 ft/lbs.
Install the E36 THB bracket to the SC bracket.
-This is the Top Hose Bracket THB.
-It is bolted to the SC bracket so that the top radiator
hose DOES NOT come in contact with the SC Pulley
Picture shown Top Radiator Hose resting on installed
THB bracket.
-Hose is further secured with a tie strap
11
Another picture showing THB installed
Mount the second idler pulley after supercharger is
mounted.
-Pulley does cover one of the supercharger mounting
bolts.
Look at the belt diagram outlay and routing.
-Mount the belt..
-Route the belt leaving supercharger pulley till last.
-Use 16mm socket to pull back tensioner while
slipping belt over supercharger pulley.
-Belt fits exact and may require two people to install.
Many times you can only get the belt over the first
groove of the supercharger pulley and will have to
use a 22mm socket to rotate the engine until the belt
slips on properly.
-If you have a 7 groove pulley leave the back groove
empty. For a 8 groove pulley leave front and back
groove empty.
Belt has 6 grooves pulley can have 7or 8
grooves .
12
MOUNT INTERCOOLER & PIPES
After removing the front bumper mount the
intercooler brackets to the inside shock
tower mounts.
Mount the Intercooler bracket to the
DRIVER’S SIDE Front Bumper Shock
mount.
-The bracket is made to adjust in any
direction..
Mount the Intercooler bracket to the
PASSENGER SIDE Front Bumper Shock
mount.
-The bracket usually uses a spacer between
the two pieces. On some cars you may not
need the spacer depending on the type of
bumper.
You will have to reconfigure the brackets
if you have an aftermarket spoiler, or a
325 with smaller intercooler.
13
Mount the Intercooler to the brackets using
hose clamps.
-Intercooler mounts on both sides have slots
for a more finite adjustment.
Angle brackets in any suitable
position to center align the
intercooler.
Mounting the right side of Intercooler.
Most of the time the intercooler should fall
just below the aux fan motor (round part).
This usually aligns it with the front grill
(stock M3 spoiler)
Install throttle elbow with 3 to 21/4 inch
reducer hose.
Throttle elbow has 7/8 fitting for idle valve
hose. Some applications may need to be
extended to reach idle valve hose. If no
extension is needed, slide idle valve hose on
and clamp.
14
SUPERCHARGER DISCHARGE
Install a 2.0” aluminum elbow with hose to
the SC discharge.
-Install a 2.0”-2.25” Reducer hose to the
aluminum elbow
Note priming bulb on SC hose only on
pre 1995 Rotrex oil systems. New systems
use aluminum canister and self prime.
#2 PIPE
Attach #2 Pipe to the 2.0”-2.25” reducer
-Rotate and twist the #2 Pipe until the body
clearance seems satisfactory.
Note priming bulb on SC hose only on
pre 1995 Rotrex oil systems. New systems
use aluminum canister and self prime.
#3 PIPE
Using the 3.0”long x 2.25” hose attach #3
Pipe to #2 Pipe. 325 with small intercoolers
will use a 2 inch pipe and hoses.
This pipe goes above the sway bar and runs
along the frame rail.
NOTE: #3 Pipe will touch heavily on the
metal P/S hose.
15
Using a large screwdriver, pry the P/S hose
towards the engine area until #3 pipe has
sufficient clearance.
Shows how #3 Pipe looks after adjustment
to the P/S metal line and clearance to other
body parts.
Using a 3.0” long x 2.25” hose attach #3 to
the driver side of the intercooler.
-The driver’s side intercooler bracket has
adjustments to help alignment.
325’s with stock spoilers will need to use
2 inch intercoolers and piping.
INTERCOOLER DISCHARGE HOSE
Install the 2.25” Aluminum Elbow with the
2.25” Silicone Hose to the Intercooler outlet
(passenger side)
-Use the clamps supplied
2 inch intercoolers will use a 2 inch
discharge pipe, reduced down from a 21/4
#4 pipe.
On some cars you may have to swap
around the elbow and the 45 degree pipe
to clear the A/C line.
16
Join the45 degree to Pipe #4 with the
silicone hose and clamps supplied.
NOTE METAL A/C LINE AND HOW
PIPES HAVE TO GO AROUND IT. #4
BLOW OFF PIPE WILL SLANT
DOWN A LITTLE.
#4 PIPE
#4 Pipe is a straight pipe with a fitting for
the by pass valve.
Picture has extension on pipe only on
some models.
#4 PIPE SUPPORT
Using E36STRPBB bracket, mount the
driver’s side of #4 pipe. This bracket
mounts to the P/S pump housing.
-This helps to position #4 pipe.
ON SOME CARS THE STEERING
PUMP IS DIFFERENT AND THIS
BRACKET WILL NOT WORK, YOU
WILL HAVE TO DEPEND ON THE #5
PIPE AND THE DISCHARGE PIPE TO
SUPPORT AND POSITION #4 PIPE.
17
#5 PIPE
Slide #5 pipe up towards the throttle elbow.
Attach to elbow with a 3inch to 21/4
reducer. You may have to move hoses out
of the way to properly align #5.
If the car has traction control then a #5
pipe with bends at both ends should be
used with 3 inch to 21/4 reducer.
Attach a 2.25” 90 degree aluminum elbow
to #4 Pipe and then to #5 pipe.
Note the #5 pipe (pointer) and the #3 pipe
run above the sway bar and the Bypass hose
runs under #5 pipe.
There are cases were you may have run
these pipes differently. (Bigger
intercoolers, oil coolers, etc.
Bypass valve
Bypass usually come pre-mounted on #4
pipe.
Run Bypass hose from back of SC area
down to Bypass valve and attach, make sure
to run hose so that there are no kinks.
18
SUPERCHARGER INTAKE
Connect the (2) 3.0” 90 degree
aluminum elbows together.
-Attach one of 3.0” elbows to the
Supercharger intake. This is the back port
of the SC.
-Rotate elbows till there is proper clearance
between shock tower.
THE SHOCK TOWER IS VERY
CLOSE ON SOME MODELS SO THE
ELBOWS HAVE TO ROTATE
UP.MAKE SURE IT CANNOT TOUCH
THE HOOD WHEN CLOSED. WILL
DAMAGE CAR !!!
BREATHER HOSE & BYPASS HOSE
Attach Breather hose from valve cover and
By pass hose to inner elbow. You will have
to do this before you tighten elbows.
HORN RELOCATION
At least one horn usually has to be
removed It may be in the way of the
K&N Air filter.
Use a Hack saw, die grinder or air saw to
cut off the horn bracket.
OPTIONAL: On some cars
19
Horn bracket removed.
#1 PIPE
Attach #1 Pipe to the elbow assembly on the
back of the SC.
Attach air filter to the HFM (HFM
ARROW TOWARDS BLOWER) then
HFM to the #1 pipe.
May have to stretch air cleaner around
HFM opening with a small screw driver.
Extended HFM wire to HFM using the 4
wire extension supplied.
HFM WIRING
Since the Factory HFM is being relocated
further forward, the factory HFM wire
harness going to the mass meter will require
extending.
WIRING SCHEMATIC
-Splice HFM wires harness with extension,
match color to color
-Crimp and shrink wrap using heat to shrink
the insulation.
20
SC OIL COOLER & LINES
Pre-assemble the oil cooler to the mounting bracket
supplied. Slip cooler down behind front grill. If the fit
is too tight you may have to remove front bumper to
install.
-Line fittings on the Oil Cooler must be
mounted on top.
Use the existing holes in the Core Support to mount the
oil cooler bracket.
C38 BLOWER USED FOR
ILLUSTRATION PURPOSES. HOSE
ROUTING IS EXACT FOR C30
BLOWER.
The inlet oil line goes on the drivers side of the SC with
the other end to the BOTTOM of the reservoir.
The outlet side goes on the passenger side of the SC
with the other end to the oil cooler.
21
The oil cooler line with filter (arrow towards SC) runs
from the BOTTOM of the reservoir behind the
passenger head light across the front of the aux fan
back through the drivers head light to the SC INLET.
Run the line UNDER the Oil Cooler making sure the
bumper can still go on.
Outlet line runs from passenger side of SC OUTLET to
the top of oil cooler.
22
Return line from oil cooler goes to the top of the
reservoir.
23
OIL LINE DIAGRAM.
Arrow on filter points towards SC
24
FUEL INJECTORS - SOFTWARE
FUEL INJECTORS (Pictures of 1996 car for
instructional purposes)
-Remove the fuel injector cover.
-Pop up the cover using a small screwdriver.
Using a 10mm nut driver or socket, remove the (2)
nuts holding the fuel rail.
Pull clip on each fuel injector ring.
-Pop up and off the electrical connections OFF the
fuel injectors.
-Pull out the fuel injectors carefully.
Remove the factory fuel injectors.
-Lubricate the fuel injector seals going into the fuel
rail as well as the seals going into the intake
manifold.
-Use a small amount of engine oil as a lubricant.
Do not use silicone spray.
Install injectors into rail first, then the complete
rail into the manifold. If you install the injectors
into the manifold first, they may look short
because they are too deep into the manifold.
Reinstall fuel injectors and reinstall back the cover,
etc.
25
SOFTWARE
Remove the Insulated cover by the
Passenger Firewall.
-This insulates heat from the engine DME.
Remove the plastic cover.
A chip is supplied for 1995 cars.
See detailed instructions for removal below.
26
Application:
'92-'95 E36
325i, M3 1995 ONLY
HOW TO INSTALL YOUR NEW AA TUNING E-PROM
E36 ECU REMOVAL INSTRUCTIONS
Open the hood
Facing rearward looking towards the windshield.
Focus to the upper left hand (passenger side) you
should see a grayish soft foam cover, remove the (3)
black plastic buttons that are on top. Pry out the
plastic tab centers to remove plastic tabs.
Remove insulated foam cover.
Make sure ignition is off.
Now you should see a hard plastic cover, remove the
(4) top screws to remove cover.
You will see the ECU box attached to a wire
harness.
Remove engine computer "2". This is the ECU that
you need.
ECU labeled "1" is the automatic transmission
computer.
27
Pull it out, the ECU just slides out.
If you are ordering a E-PROM, write down the last
(3) #s of the BOSCH #s.
example: 0-261-200-xxx
Do not disconnect harness as yet. After ECU is
removed completely, disconnect harness
READ THIS PROCEDURE FIRST BEFORE PERFORMING ANY FURTHER WORK. COMPREHEND AND
UNDERSTAND. IF FEEL UNSURE, CONSULT A PROFESSIONAL. DAMAGE TO THE ECU CIRCUIT BOARD
CAN OCCUR.
93-95 ECU #413, 506
92-93 ECU #402,403,413
On the top side of the ECU you should see(2) stickers Looking at the ECU from top with the BOSCH
and 6 little bolts.
labels. There are (4) torx screws.
Do not remove theses bolts.
-Remove these screws. With the cover off,
You should see 6 tabs. Bend the tabs so you can
remove the white plastic cover.
slide the cover up from it's original place.
-Flip the ECU over, upside down. There is a small
white plastic pin in the middle. Remove this pin.
Now you should see the inside of the ECU.
-Flip the ECU back, facing right side up.
In the upper right, there's a white cover on
top of a chip, looks like a "H".
-Hold the ECU with the plug housing facing away
HERE LIES THE E-PROM underneath.
from you. Grip the ECU metal mounting ears with
both hands and push up on the upper printed
NOTICE: Before removing the E-PROM, note the
circuit board where the 2 plastic pedestal
divot on the side of the E-PROM
connects to the circuit board.
CAREFULLY take off the chip, use a de-magnetized
flat head screwdriver (thin as possible) and SLIDE it
CAREFULLY under the chip.
Slowly push the E-PROM off its original place from
the bottom.
DO NOT PUSH ON THE CORNERS OF THE UPPER
CIRCUIT BOARD. IT CAN BREAK.
-Be careful, the circuit board should
unsnap, leaving the front section still attached to
Install the AA E-PROM, aligning the divot to the same the plug housing.
side as the old one. Carefully insert the e-prom pins
-Gently slide the circuit board away from the plug
into the holes
housing. This is the hardest part, but it will
separate.
Forcing the pins will only break off the tabs
making the E-PROM useless.
Now you should see the inside of the ECU.
In the upper right, there's a white cover on top of
a chip, looks like a "H". HERE LIES THE E-PROM
underneath.
NOTICE: Before removing the E-PROM, note the
divot on the side of the E-PROM
CAREFULLY take off the chip, use a de-
28
magnetized flat head screwdriver (thin as
possible) and SLIDE it CAREFULLY under the chip.
Slowly push the E-PROM off its original place from
the bottom.
Install the AA E-PROM, aligning the divot to the
same side as the old one. Carefully insert the eprom pins into the holes
Forcing the pins will only break off the tabs
making the E-PROM useless.
Attention:
Software e-proms with a adaptor board
The AA e-prom with the GREEN looking “KEY” adaptor board is to be
installed as a WHOLE unit, do not separate the E-Prom from this board, the
E-prom must be installed with this board in place.
Align the divot to the matching divot on the ECU socket as instructed in the
attached instructions.
The software e-prom can only be removed if AA Tuning has made special
arrangements to send a new e-prom to replace the existing new one.
WARNING!
The pins on the adaptor board are very delicate; please
make sure they are aligned with the holes in the ECU socket before pressing
down on them.
If you need technical support please call:
AA Tuning
Monday – Friday 9:00 AM – 6:00 PM EST
(305) 233-9300
29
FINAL CHECK
Add fluid to reservoir till it is full, start the car and
watch for the level to go down. Add fluid as it goes
down. System usually takes about 7/8 of the bottle.
With the car idling , screw in the cap then remove
and check level it should be at MIN mark. If fluid is
higher than this you could have foaming out of the
cap at high RPM.
If fluid does not go down Turn off car and recheck
lines. Inlet line should gravity feed.
-Check belt tension and pulleys, proper routing of all
pipes and hose to prevent possible chafing.
-Check all vacuum hose connections.
-Reinstall the Front Bumper.
-Road test
If the belt tends to run off the pulley, you
may have a belt bias problem. Flip the belt
around and retest.
Install AA SC plaque on core support. Use Silicone
glue for adhesion or drill and rivet.
30
AA Tuning Supercharger Maintenance Items
OIL SERVICE
Replace engine oil & filter
at least every 3,000 miles
with good quality
synthetic oil
OIL FILTER
DIFFERENTIAL Replace oil with Redline
Mobil 5w30, 10w30
Castrol 5w30, 10w30
BMW Synthetic 5w30
Motul 5w40
11-42-1-730-389 Oil Filter
1993 BMW 325i
1995 BMW M3
1996-1999 BMW M3
11-42-1-427-908 Oil Filter
1996-1998 BMW 328i
Redline 85w140 GL5
SPARK PLUG
85W140 GL5 gear lube
every 7500-10,000 miles
Replace with factory
spark plugs every 10,000
- 15,000 miles
AIR FILTER
12-12-9-069-877 FGR8KQC
1996-1998 BMW 328i, M3
AA SC USES K&N air filters RU3190
1993-1995 BMW 325i
1996-1998 BMW 328i
12-12-9-063-428 F7LDCR
1993-1995 BMW 325i
1995-1999 BMW
M3
SC BELT
Check every 5,000 miles
060895
6PKx2236 Continental with
85mm Pulley
6pkx2245 Napa (Gates)
1995 BMW M3 C30
6pkx2240mm with90mm
pulley
1992-1995 325 C30
SC OIL
Check oil level every
5,000 miles. Replace
with Rotrex friction oil
every 40,000 to 50,000
miles or every 2 years if
driven less than 5,000
miles per year
6539002
SC traction oil SX100
BMW Specified 2 Year
Interval
BMW Specified 2 Year
BRAKE FLUID
COOLANT
31
AA Tuning Supercharger Maintenance Items
OIL SERVICE
Replace engine oil & filter
at least every 3,000 miles
with good quality synthetic
oil
OIL FILTER
DIFFERENTIAL Replace oil with Redline
SPARK PLUG
AIR FILTER
SC BELT
SC OIL
85W140 GL5 gear lube
every 7500-10,000 miles
Replace with factory spark
plugs every 10,000 15,000 miles
AA SC USES K&N air filters
Check every 5,000 miles
Mobil 5w30, 10w30
Castrol 5w30, 10w30
BMW Synthetic 5w30
Motul 5w40
11-42-1-730-389 Oil Filter
1993 BMW 325i
1995 BMW M3
1996-1999 BMW M3
11-42-1-427-908 Oil Filter
1996-1998 BMW 328i
Redline 85w140 GL5
12-12-9-063-428 F7LDCR
1993-1995 BMW 325i
12-12-9-069-877 FGR8KQC
1996-1998 BMW 328i, M3
RU3190
1993-1995 BMW 325i
1996-1998 BMW 328i
1995-1999 BMW M3
RU3130
2001 BMW 330i
5060880
6PKx2236 with 85mm Pulley
1993-1995 BMW 325i
1996-1998 BMW 328i
1995 BMW M3
1996-1999 BMW M3
679-2240
6PKx2240 with 90mm Pulley
1993-1995 BMW 325i
1996-1998 BMW 328i
1995 BMW M3
1996-1999 BMW M3
Check oil level every 5,000 6539002
miles. Replace with
SC traction oil SX100
Rotrex friction oil every
40,000 to 50,000 miles or
every 2 years if driven less
than 5,000 miles per year
every 2 years if driven less
than 5,000 miles per year
BRAKE FLUID
COOLANT
BMW Specified 2 Year
Interval
BMW Specified 2 Year
Interval