1

INSTRUCTIONS

1992-1995 E36 325 &1995 M3 SUPERCHARGER

WITH C30 BLOWER.

2

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: aatuning@activeautowerke.com Phone: 305-233-9300

3

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.

4

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.

5

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

6

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.

7

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.

8

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.

9

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.

10

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.

11

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

12

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 .

13

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.

14

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.

15

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.

16

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.

17

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.

18

#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.

19

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

20

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.

21

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.

22

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.

23

Return line from oil cooler goes to the top of the reservoir.

24

OIL LINE DIAGRAM. Arrow on filter points towards SC

25

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.

26

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.

27

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.

28

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

On the top side of the ECU you should see(2) stickers and 6 little bolts. Do not remove theses bolts. You should see 6 tabs. Bend the tabs so you can slide the cover up from it's original place.

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-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 e-prom pins into the holes

Forcing the pins will only break off the tabs making the E-PROM useless.

92-93 ECU #402,403,413

Looking at the ECU from top with the BOSCH labels. There are (4) torx screws. -Remove these screws. With the cover off, remove the white plastic cover. -Flip the ECU over, upside down. There is a small white plastic pin in the middle. Remove this pin. -Flip the ECU back, facing right side up. -Hold the ECU with the plug housing facing away from you. Grip the ECU metal mounting ears with both hands and push up on the upper printed circuit board where the 2 plastic pedestal connects to the circuit board.

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 the plug housing.

-Gently slide the circuit board away from the plug housing. This is the hardest part, but it will separate.

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-

29

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 e-prom 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

30

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.

31

AA Tuning Supercharger Maintenance Items OIL SERVICE Replace engine oil & filter

at least every 3,000 miles with good quality synthetic oil

Mobil 5w30, 10w30 Castrol 5w30, 10w30 BMW Synthetic 5w30 Motul 5w40

OIL FILTER 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

DIFFERENTIAL Replace oil with Redline 85W140 GL5 gear lube every 7500-10,000 miles

Redline 85w140 GL5

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

12-12-9-063-428 F7LDCR 1993-1995 BMW 325i 12-12-9-069-877 FGR8KQC 1996-1998 BMW 328i, M3

AIR FILTER AA SC USES K&N air filters RU3190 1993-1995 BMW 325i 1996-1998 BMW 328i

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

BRAKE FLUID BMW Specified 2 Year Interval

COOLANT BMW Specified 2 Year

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