BMW E46 M3 AFE Magnum Force CAI stage 2

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 2 is a substantial change from the OEM airbox
design and filter. At peak it adds 12 horse power and 11 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 won’t 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 one optional accessory in addition to the CAI S2 kit, the MF intake system
scoop.

If you do not have this accessory, which you should purchase anyway, skip to step 7.

Goal:
Work through the CAI S2 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 doesn’t mean it will automatically do so for you. Work
slowly and carefully, don’t force anything and don’t rush. For an hour of time, you can complete a
significant upgrade to your car that you are going to both hear and feel. Don’t 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. It’s temping, but one wrong move and you can punch a screwdriver through your seat. DON’T
DO IT.

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 Parts and Tools:
Must have:

Magnum FORCE Stage-2 PRO 5R Intake Systems; BMW M3 (E46) 01-07 L6-3.2L 54-10462
¼ socket, nut driver
10mm 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
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

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 Intake Scoop Installation
*Assumptions: Installation order will be intake scoop and then the CAI kit but it could be done in any
order you desire.

1. Starting fully stock, let’s 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 S2 off, so clean up the engine space a bit!

AFEpower.com 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 and pins aside. Don’t pull the center pin of the pins out
completely.

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

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 4. Gently pull the shroud forward and slide the scoop behind it 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.

AFEpower.com 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!

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 Cold Air Intake S2 Installation
7. 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.

8. 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.

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 9. Remove the front snorkel and loosen the two indicated clamps to release the airbox top.
Loosen the intake hose clamp if you haven’t already done so.

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

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 11. 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.

12. Remove the rubber mount from the tab. Use this opportunity wipe down the area for the
new CAI S2 kit. Less grime here means less potential grime into the new filter.

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 13. Remove the stock (or aftermarket) intake tube and clamps and set aside. Secure headlight
control module again with the lower bolt, and top nut if removed. Restore cover.

14. Install trim seal onto the heatshield and drop into place. Do NOT secure at this time.

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 15. Slide rubber coupler and clamps onto tube place through heatshield housing. Join the tube to
the plenum body. Double check this connection to ensure it is well sealed on the plenum and
tube. Be patient, this can be a slow process. I found actually putting my arm into the tube I
could check for gaps at the plenum connection from the inside.

16. Once the coupler is set properly, moderately tighten both clamps to hold in place while
making other adjustments, but still loose enough to allow some movement.

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 17. Secure tube to heatshield using M6 hardware (2) hex head M6 x 1 x 25 screws and (2)
washers (flat #6) to (2) M6 hex nuts. Use 10mm socket to tighten and 10mm wrench to hold
the nut. Secure 10mm bolt (A) removed previously, and (B) use M6 hex nut and washer to
secure shield.

18. Install flow diverter to heatshield using provided button head screws with 4mm allen wrench.

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 19. Reinstall MAF sensor using (2) provided cheesehead slot (M4 x 7 x 16) screws. Make sure that
the (A) provided MAF gasket is in place, and the (B) provided washer (wavy #6) are between
the MAF and the tube. The MAF sensor opening faces towards front of the car, not the back.

20. Tighten both clamps on the intake tube, reconnect the MAF harness and install the aFe filter
and clamp.

AFEpower.com 2014 ver 1.0 Author: Stefan Yotz

 21. 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 isn’t 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 isn’t 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 2 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