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BMW E36 M3

Twin Screw Supercharger Kit Level I and II Installation

OBDI TS level II installed shown below

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OBDI level II installed shown below

Thank you for purchasing the Active Autowerke twin screw supercharger system, it has been designed and thoroughly tested for maximum performance and reliability.

Please read the instructions thoroughly before attempting the disassembly and assembly of this system. If you feel that you are not capable of doing this job please find a qualified technician of at least a “B status” to do the job.

No special tools are required to do this installation, basic hand tools are the only tools required.

We recommend a fresh set of stock spark plugs before installation of the supercharger and fresh oil in the motor Suggested fuel octane at a minimum is 91 based on USA R+M/2 method, if 93 or 94 is available then use it. The system is warranted against any defects in any components for 1 year with unlimited mileage. The warranty does not cover any incidental damages or labor to remove and replace any components

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Suggested time for total installation of this system: Level I = 10-12 hours Level II = 16-18 hours Suggested service : 1) Engine oil and filter every 5,000 miles at maximum , we recommend a good

quality synthetic motor oil of at least a 5W30, 10W30, or 15 W50 weight depending on your geographic location and time of the year

2) Spark plugs at least every 15,000 miles 3) Air filter K+N, RU 3130 every 6 months, if dusty conditions, please use discretion for more frequent service interval. 4) Supercharger oil change every 20,000 miles, oil = 15W50 or 20W50 synthetic motor oil. Fill is exactly 4 oz. Table of contents Car prep _______________________________4 Front bumper disassembly________________20 Misc. body prep________________________ 22 Component installation___________________26 Prep of engine wiring harness & vanos oil line adjustment_____________________________35 Belt routing_____________________________41 Hose routing and coolant flow______________42 Electrical wiring level2 systems_____________43 Vacuum hose diagrams________________45-46 Inlet pipes and hoses_____________________47 HFM connections________________________51 Filling oil in sc___________________________53 Filling and bleeding aftercooler______________54 Bypass valve installation___________________57 Road testing_____________________________58

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Car Preparation and relocation of a few items Engine compartment disassembly:

1. Locate the battery in the trunk on the right side. Disconnect the battery negative terminal.

2. Remove DME –

OBD II vehicles

Ship to Active for Programming ( applicable only to OBDII equipped vehicles). An ECU form has been provided for this, if you did not get one, you can go to the website www.activeautowerke.com and download one from the “tech center” section, please fill it out and attach it to the DME.

- For OBD I vehicles, a new E-prom has been provided for you to install . DME removal 1

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DME removal 2

OBDI DME (BOSCH) ECU part number: 0-261-200-413 325i 10/92-11/95 0-261-203-506 M3 03/94 – 12/94 0-261-200-413 M3 01/95-11/95 OBDII (SIEMENS) has several part numbers. 328i 5WK90351 328i 5WK90355 M3 5WK90172 M3 5WK90354

Remove Screws

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DME removed with wire harness attached

Removal and modifications of throttle body :

3. Remove air filter box, HFM, throttle body hose. Note: The HFM, HFM air box and HFM booth will not be reused. A new HFM has been provided. On OBDII vehicles, remove bolts for ASC throttle body, disconnect connector for ASC throttle body, disconnect actuator cable and remove ASC throttle body (OBDII only). The cable must remain intact in the vehicle, it will not be reconnected, tuck it away under the existing hardware,

On OBDI vehicles, remove the throttle body put it aside and save existing

bolts, they will be reused. Note: the water cooling hoses and the purge valve hose must be removed as well in this step.

On OBDII vehicles, remove the throttle body put it aside, the bolts for the throttle

body will not be reused. New studs have been provided. On OBDI and OBDII vehicles the throttle cables must be removed, a new cable has been provided. 4. Remove alternator cooling duct, it will not be reused.

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OBDI engine bay shown below

Alternator cooling duct removal

REMOVE REMOVE HOSE Clamp down here

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5. OBDI and OBDII vehicles, remove idle control valve electrical connector and remove the valve with hoses. The valve will be reused but the hoses will not. 6A. OBDI 1995 OBDI vehicles only: Remove the charcoal canister and relocate to passenger side of engine bay using the supplied hoses and bracket Charcoal canister re-location

Relocate charcoal canister from location A to location B with bracket and hoses provided

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Remove small vacuum hose from canister and unclip larger hose Cut off connector from larger hose Connect hoses provided and route along the rear of the engine to new location B Mount the new bracket supplied to canister and mount as shown below in location B

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6. Drain coolant enough to allow removal of upper radiator hose, remove hose

Save hose clamps from the hose, the hose will not be reused, a new hose has been provided. 7. Disconnect cruise control cable from throttle body. It will be reconnected later .Disconnect the throttle cable. Disconnect coolant hoses from the throttle body. The coolant hoses will not be reconnected, they will by pass the throttle body. On OBDII throttle body, locate the 2 water cooling fittings ( brass looking fittings and cut them off flush where they meet the aluminum housing of the throttle body, this is necessary for proper clearance. ON OBDI vehicles, there are 2 rubber caps provided to cap off the 2 water cooling hose connections and one small rubber cap to block off the purge valve hose connector. Note: the purge valve hose will be connected later in the back of the supercharger inlet housing.

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8. Remove fuel rail cover by carefully prying the bolt covers with a thin screwdriver, remove the attachment bolts (10mm head) and extract the rail cover

9. Remove the 2 hold down bolts for the fuel rail (10mm head) and lift the fuel rail straight up (relative to the direction of the injectors)

10. Remove the cable assembly from the fuel injectors and set over the top of the engine/valve cover.

11. Set the fuel rail out of the way. On OBDII vehicles It is not necessary to disconnect the fuel lines. The fuel lines will be reused. On OBDI vehicles the fuel lines to the fuel rail will not be reused, new lines are provided. Remove all lines in engine bay all the way down to the hard metal lines at the frame rails. On early 95 M3 cars the fuel filter is attached to the engine block, on these vehicles, we recommend to remove the fuel line down to the top of the filter. On 95cars new fuel lines are provided with new hose clamps.

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12. OBDI only. Remove fuel lines from underneath car at frame rail, they will not be reused, new fuel lines are provided.

13. Remove intake manifold support brackets from the manifold and the engine block/engine mount, they will not be reused.

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14. Disconnect vacuum lines from under intake manifold, these vacuum lines will be reused on the new intake manifold and the supercharger inlet housing ( a vacuum line drawing is provided in these instructions) 15. Disconnect IAT (intake air temperature) sensor electrical connector from the intake manifold. 16. On OBDII vehicles disassemble cyclone separator and other items under intake manifold. Disconnect crankcase vent line from valve cover. The cyclone separator and valve cover hose will not be reused. A new valve cover breather hose is provided.

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IAT Sensor Cyclone

Breather Hose

OBD II Valve Cover Breather Hose Assembly

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17. On OBDI vehicles, the valve cover breather hose connector that used to go to the intake manifold (small vacuum hose fitting) must be blocked off. A small vacuum plug/cap is supplied for this.

On OBDI vehicles, the valve cover breather hose will be reused. 18. Remove intake manifold mount nuts (7 X 11 mm head nuts)

19. Pull the manifold off the engine and set aside, the intake manifold will

OBD II Valve Cover Breather Hose Assembly INSTALLED

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not be re-used, a new one is provided. 20. OBDII vehicles, remove oil drain hose from the cyclone separator to oil dipstick, install the rubber cap provided on to the dip-stick. See picture below. OBDII vehicles only: At this time install the supplied dipstick support bracket. See picture below.

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21. Release belt tension on AC belt and remove belt, put aside for reinstallation later. 22. Release tension from main drive belt and remove belt, the stock belt will not be reused, a new one has been provided. Please take note of the new belt size and put aside . You will need the size for reference later when it come times for a replacement. 23. Remove the main belt tensioner from the front of engine, a new one has been provided with new bolts. Now is a good time to install the new main belt tensioner supplied, torque the bolts supplied to 18 ft-lbs.

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24. Remove 2 alternator mount bolts, do not remove alternator, new bolts have been provided to remount the alternator along with the new supercharger bracket.

Alternator Mounting bolt

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Front bumper disassembly:

25. Pry out trim sections from front bumper 26. Remove fasteners from under tray and “pork chop” trim sections. The plastic under tray must be removed as well.

That is if it is still there, by now most of them have broken off or fallen off from age. It will not be reused, if you choose to reuse it you may have to trim small sections of it as needed for clearance

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27. Reach up to side of left side brake duct and disconnect air temp sensor from brake duct. 28. Remove connectors from fog lights 29. Remove 4 primary bumper mount bolts – remove bumper by pulling straight forward and set in a safe place

Remove 13mm Head Nut. 2 on Driver’s Side 2 on Passenger Side

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Miscellaneous body preparation: Inside of cabin area: 30. Remove stock throttle cable. First you must remove the under dash trim panel. Remove the 2 upper screws, and 1 screw underneath. CAREFULLY pull the panel backwards until the tab comes free from the center console. Disconnect the electrical connections and set the panel aside

Disconnect the end of the throttle cable from the throttle pedal. Using a very long, skinny screwdriver, press against the underside of the plastic clip for the cable. Give a sharp blow to the end of the screwdriver to pop the lower end of the clip free. A lighter pry on the upper side of the clip should release it. Pull the cable out from up in the engine bay.

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31. Modify alternator cooling duct as shown (this is optional, we recommend it for a nicer cleaner looking installation). Also another option is to purchase the European spec radiator support cover which has a very clean look.

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32. Remove the driver’s side corner lamp by prying gently on the release tab that holds the lamp. See picture below.

Modified Cover OPTIONAL

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Remove driver’s side head lamp as shown below

33. Remove horn from horn bracket (location A) and cut bracket from under left side headlight. Using a small hammer, tap the remaining pieces flush. Relocate and Mount horn to bumper mounting (location B) as shown

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Component installation: Throttle cable installation on to the chassis: 34. Install the new throttle cable, apply force until the cable clip is secured by “snapping” into place. Confirm the installation by tugging on the cable. 35. Connect the end of the throttle cable to the throttle pedal

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36. Reinstall the interior trim panel – don’t forget to reconnect the light and buzzer connectors

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Level 2 ONLY… Mounting of intercooler pump heat exchanger and pump: 37. Mount intercooler pump bracket as shown, On the 4 doors vehicles, there is a small hole just below the metal inner fender where the inner plastic wheel housing is attached, this hole is left blank and is easily visible. On the 2 door vehicles, a sheet metal bolt that holds the inner fender wheel house has to be removed and the supplied bolt with nut is used to attach the pump ( see picture below for a better view of this bolt location)

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38. Mount intercooler pump in bracket with proper orientation as shown

39. Mount intercooler heat exchanger to outboard bumper strut mounts by removing nuts from studs, mounting supplied bracket to studs and heat exchanger

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40. Connect hose provided from the pump outlet to the heat exchanger inlet. 41. Locate the after-cooler reservoir / tank and mount it on the base behind the passenger side shock tower, a 6 mm threaded hole is provided by BMW and is not used, use the bolt provided and bolt the tank to the base.

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42. Locate ¾” coolant hose that runs from tank to pump. Hose #1 Hoses are marked for your convenience and pre cut to proper length. Route as shown. Install with hose clamps. Tighten clamp on fill tank. NOTE: we have cut the hose from the tank to the pump inlet a bit longer for those of you who have installed euro style headlamps, if you do not have euro style headlamps you can cut the hose to proper length. Picture below shows euro style headlamp with suggested hose routing.

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Preparing of engine wiring harness, vanos oil line adjustment, installing new fuel lines and modification of existing coolant throttle body water hoses : 43. On OBDI vehicles: Take a pair of dykes and cut the tie straps that hold the engine harness to the engine bracket that it is attached to, this is needed to free up the wires for : A) the throttle position sensor connector B) the air temperature sensor C) the idle control valve Note: on 95 (OBDI vehicles) there is a small 3 wire harness provided to extend the connector for the throttle position sensor. Use the time now to cut the throttle position sensor wire and extend it with the wires provided.

It is very important that the above wires have enough length to reach the sensors otherwise the entire supercharger assembly has to be removed to correct this!

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44. OBDII vehicles, the bracket that holds all the wiring harness to the engine block has to be removed and the harness left loose for the sensor wires to have extended lengths, secure the other wires that are not pertinent for the : 1) Throttle position sensor 2) The air temperature sensor 3) The idle control valve Take the coolant hose that used to go to the throttle body and route it so that it goes straight to the cylinder head connection. You have just by-passed the throttle body heating. There is no provision to heat the throttle body with the twin screw sc system, but this is not a problem. See picture below:

Throttle body hoses modified

OBD II only.

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OBDI vehicles, the coolant hose that used to go to the throttle body is now connected to the hose that used to go to heater in the air box. Cut as shown below in the picture and connect with the brass 3/8” connector provided by Active Autowerke.

Take the vanos oil line and loosen the banjo bolt at the oil filter housing, use the supplied jig and align the hose as shown below. Tighten the banjo bolt securely after adjusting.

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45. OBDI only: Locate the fuel lines supplied and install them , the longer line (supply)goes to the front of the engine , route it so that it comes up behind the oil filter housing, make sure it does not interfere with the steering shaft or other moving parts, route the other line (return) to the rear of the engine. These lines will be connected after the fuel injectors and fuel rail are installed

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Installing the main supercharger / intake manifold system:

46. Take the main assembly and slowly lower it on to the engine cylinder head while aligning the intake manifold studs onto the intake manifold. Support the manifold while catching the 7 X 11 mm head nuts, run the nuts down but do not tighten them. Leave them loose so that the intake manifold/supercharger assembly can move up and down for later alignment of the supercharger snout bracket to the engine. 47. At this time double check the wires for the air temp sensor, Throttle position and idle control valve are ok and length is good. 48. Take the snout bracket and slide it over the snout of the supercharger drive while aligning it to the 2 mounting holes. Insert the bolt with the idler pulley and spacers, run the bolt down until snug, also install the counter sunk bolt in the bottom hole of the bracket until flush. Now tighten the intake manifold nuts to approximately 13 ft-lbs. If you cannot get a torque wrench on them, use your discretion. 49. Now torque the snout bracket bolts, the upper bolt to approximately 35-37 ft-lbs, tighten the lower one until the head of the allen key feels like it will start stripping (it is difficult to properly torque this bolt with such a small head). Note: some alternators have no threads on the back side so a 10 mm nut will have to be used to secure the bolt.

Note: We recommend to apply “anti seize “ on these bolts so that they can be removed for any service work later on.

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Tighten the pinch bolt on the top side of the snout bracket, it is a 6 mm hex bolt with a 5 mm head, approximate torque is 8 ft-lbs.

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50. Locate the new supplied fuel injectors and install them now. Install the wiring harness onto the fuel injectors.

On the OBDI vehicles install the new fuel lines to the fuel rail.

51. Install the supercharger drive pulley on to the shaft and hand tighten the bolt ( 10 mm allen ).

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For illustrative purposes a line drawing below shows the snout bracket with applicable fasteners:

52. Install the adjustable idler pulley with bolt and nut provided. The pulley may have been pre-installed on to the bracket when shipped to you. Snug the bolt down making sure that the pulley can slide in the slot.

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53. Install the new main drive belt supplied routing it as shown in the diagram below. Adjust the “adjustable idler pulley “in the slot for maximum contact around alternator pulley and tighten the bolt. At the same time it is important to check the main tensioner for adequate travel, if the tensioner does not have enough travel it will not absorb or take up enough slack when loading on the belt occurs. We recommend at least 1” of travel on the tensioner pulley. At this time tighten the supercharger belt as much as you can, it is a bit difficult because it is not easy to hold the supercharger from turning. We recommend taking a socket wrench and just hold it in place and then hit it with you hand. Do not be concerned about tightening the bolt, when the engine starts the bolt will tighten automatically. Install the A/C belt

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At this time you can install the engine fan clutch along with the fan Install the new upper radiator hose as well, fill the cooling system and leave open the bleed screw.

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Level II 1995… Installing the rest of the after-cooler/intercooler water hoses

from the heat exchanger to the intake manifold:

54. Locate the hose supplied that goes from the heat exchanger to the intake manifold lower inlet fitting and route it along the frame up into the engine bay so that the hose has a smooth route, be careful not to kink it. This is hose #3 55. Locate the hose supplied that goes from the intake manifold to the reservoir and mount it as shown in the line drawing below. This is hose #4 Hose routing and coolant flow

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Picture of # 4 hose installed:

This should complete the hose connections to the after-cooler system.

Level II 1995…

Electrical connections for the aftercooler pump: 56. Locate the supplied wiring harness with relay and route it on the vehicle as shown in the line drawing.

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Picture of relay mounted level II

Wiring connections at engine main relay level II

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Wiring diagram level II

57. Connect vacuum hoses as follows: Vacuum hose layout: OBDI

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Vacuum hose layout: OBDII

58. On OBDII vehicles, relocate the air pump electronic solenoid valve as shown in the picture below, the valve has to be removed from its mounting bracket and allowed to sit between the intake manifold and the oil filter housing

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Connecting the inlet pipes and hoses: 59. Locate the vacuum brake booster hose connection on the inlet housing of the supercharger and also the purge valve hose connection, connect them as follows :

Note: the factory hose between the purge valve and the intake manifold must be removed, a new one is supplied

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60. Connect the inlet pipe #2 as shown in the picture: OBD I vehicles will use the original throttle body bolts to hold the throttle body to pipe #2 OBD II vehicles will use the supplied studs and nuts

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Connect idle control valve electrical connection and hose to inlet housing

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61. Connect pipe #1 as shown along with HFM adapter hose, HFM and air filter, reinstall head lamp assembly, connect valve cover breather hose

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62. Locate the original HFM connector and cut the wire off leaving enough wire at the old plug. Take the new wiring harness that has the new connector plug and connect the wires. We recommend to solder the wires and shrink wrap the connections for a positive connection.

OBDI HFM wire harness

OBDII has a similar looking harness with an additional small black box attached to the harness; see below picture of this box mounted on inner fender of vehicle. OBDII vehicles HFM Calibrator mounted

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63. Locate the supplied support bracket for the throttle body: OBDI :

OBDII: 64. Locate the supplied oil for the supercharger and open one of the 2 fill caps ( 6 mm allen key) Pour the oil into the supercharger until all contents are empty from the bottle. NOTE: the oil is nothing more than synthetic motor oil 15W50 or 20W50, exactly 4.0 ounces is required, no more no less. Service life of oil is 20,000 miles as recommended by Autorotor. To replace oil, simply drain from the 6 mm head allen plug at lower side of supercharger.

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Level II 1995… Filling and bleeding the after-cooler/intercooler system: 65. Remove all bleed caps from the after-cooler at the intake manifold and the heat exchanger ( if equipped ), pour in a mixture of BMW coolant/antifreeze and distilled water in a 50/50 mixture until all the air has escaped from the heat exchanger, cap off the head exchanger bleed screw, continue to pour in fluid until all air escapes from the front air bleed on the intake manifold, cap off the front bleed cap, continue to pour in until all air has escaped from the rear cap, then cap off the rear . Note: this procedure may take a while for the air to escape, sometimes up to 20 minutes. Sometimes running the pump for a few seconds can help to push the air through. Note: the pump will not run if the DME is not connected. The DME allows the engine main relay to close which in turn will power up the coolant pump relay. We recommend that you run the pump for a good 10 minutes to make sure all air has escaped before locking the cap on the reservoir. You can check this by looking at the fluid moving inside the reservoir while the pump is running, you should see a continuous flow of liquid with no air pockets.

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Now is a good time to check for any external leaks in the system.

66. Re-install the front bumper cover and check to make sure that there is not interference between the heat exchanger and the bumper. Re install the “pork chops” and all undercarriage parts. Remember to reconnect the fog lamps and the air temperature sensor.

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67. Locate the intake manifold air temperature sensor that was removed from the original intake manifold, on : OBDI: Screw in the air temp sensor into the adapter supplied and tighten very carefully, be careful and do not over tighten, the adapter is very thin and can break if you are not careful. Connect the electrical connector to the sensor. OBDII: IAT adapter and sensor shown:

OBDII : screw in the adapter supplied into the manifold and then tighten, also be careful, slide in the air temp sensor, it should “click” right into place. Connect the electrical connector.

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OBD II IAT shown

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68. Locate the bypass valve and slide into place as per the picture shown:

69. By now all hose and vacuum lines should be connected. Reconnect the DME and double check that oil is in the supercharger, the motor. All brackets and bolts should be tight. 70. Start engine check for visible leaks, double check the coolant flow inside the reservoir on level 2 systems. 71. Let engine idle for at least 20 minutes to make sure everything is properly

lubricated. Then test drive. 72. When test driving, make sure that the engine is not knocking under acceleration, if you hear knock, stop acceleration and gently drive car back to the workshop. Call Active Autowerke ASAP..

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Active Autowerke 9940 S.W. 168 Terrace Miami, Florida 33157

305-233-9300

Dial 226 or 233 for technical

assistance

AA Tuning Supercharger Maintenance ItemsOIL SERVICE Replace engine oil & filter

at least every 3,000 mileswith good quality syntheticoil

Mobil 5w30, 10w30Castrol 5w30, 10w30BMW Synthetic 5w30Motul 5w40

OIL FILTER 11-42-1-730-389 Oil Filter1993 BMW 325i1995 BMW M31996-1999 BMW M3

11-42-1-427-908 Oil Filter1996-1998 BMW 328i

DIFFERENTIAL Replace oil with Redline85W140 GL5 gear lubeevery 7500-10,000 miles

Redline 85w140 GL5

SPARK PLUG Replace with factory sparkplugs every 10,000 -15,000 miles

12-12-9-063-428 F7LDCR1993-1995 BMW 325i

12-12-9-069-877 FGR8KQC1996-1998 BMW 328i, M3

AIR FILTER AA SC USES K&N air filters RU31901993-1995 BMW 325i1996-1998 BMW 328i1995-1999 BMW M3

RU31302001 BMW 330i

SC BELT Check every 5,000 miles 50608806PKx2236 with 85mm Pulley1993-1995 BMW 325i1996-1998 BMW 328i1995 BMW M31996-1999 BMW M3

679-2240 6PKx2240 with 90mm Pulley1993-1995 BMW 325i1996-1998 BMW 328i1995 BMW M31996-1999 BMW M3

SC OIL Check oil level every 5,000miles. Replace withRotrex friction oil every40,000 to 50,000 miles orevery 2 years if driven lessthan 5,000 miles per year

6539002SC traction oil SX100

every 2 years if driven lessthan 5,000 miles per year

BRAKE FLUID BMW Specified 2 YearInterval

COOLANT BMW Specified 2 YearInterval