DINAN D760-0660A Cold Air Intake Instruction Manual

DINAN D760-0660A Cold Air Intake

INSTALLATION INSTRUCTIONS

• PART NUMBER D760-0660A
• APPLICATION: 9/98-2002 E38 740i

PARTS LIST

1. 1 4″ Intake Tube
2. 1 Air Filter w/ clamp
3. 1 Inlet Filter
4. 1 Inlet Hose
5. 1 Silicone Hose
6. 1 90-110mm Hose Clamp
7. 1 80-100mm Hose Clamp
8. 1 25-40mm Hose Clamp
9. 1 22-32mm Hose Clamp
10. Air Pump Bracket
11. 1 Air Pump Bracket
12. 1 M6 x 16 Bolts
13. 2 6mm Wave Washer
14. 3 6mm Flat Washers
15. 1 Protection Sock
16. 1” Union Coupler

Congratulations for being selective enough to use a Dinan Cold Air Intake. We have spent many hours developing this system to assure that you will receive maximum performance and durability with minimum difficulty in installation. Please take the time to read these instructions thoroughly before proceeding. When performing the installation, read the entire numbered instruction before working on the car. If you feel that you do not have the requisite skill, please arrange for a qualified repair facility to perform the installation. Required Tools: 8 and 10mm sockets with ratchet and extension, small screwdriver, T-50 Torx Socket, 3/8 Torque Wrench, Utility Knife, Power or Air Jig Saw, scribe, medium grit sand paper or file. If you encounter any difficulties during the installation, or if these instructions are not clear to you, please call Dinan’s Technical Support Staff @ 800-341-5480.

INSTALLATION INSTRUCTIONS

1. The Front bumper must be removed to gain access to where to tube is installed. See Figure 1: remove the two screws on both sides that attach the bumper to the inner fender wells (1).
2. See Figure 2: Remove the bumper mounting bolts with a T-50 Torx socket.
3. In order to separate the bumper from the inner fender wells pull in the direction of the white arrows (See Figure 1). Pull the bumper slightly forward, but do not remove!
4. See Figure 3: The bumper attaches to the lower engine covers underneath the car in front of the wheels. Press upwards on the tabs the black arrows point to, and pull forward on the bumper at the same time in order to separate the parts. Pull the bumper slightly forward, but do not remove it!
5. See Figure 4: The wires for the fog lights must be disconnected at the fog lights. Squeeze the connector as the arrows show, and pull away from the fog light. If the car is equipped with headlight washers then the hose must also be disconnected. Remove the lock (2) and pull off the hose (3). Block off the hose so the fluid does not leak out. Once these have been disconnected then slide the bumper all the way out and set aside.
6. The Intake snorkel that was feeding the Air Box with air on the front of the car must be removed. Remove the two bolts that secure it to the car and undo the hose clamp at the airbox. Remove the snorkel, it will not be reinstalled on the car.
7. Remove the factory air box from the vehicle. Start by removing the 10mm head bolt securing the air box to the mounting bracket on the front right fender.
8. Release the clips holding the Airflow Meter to the Factory Air Box and pull the Airflow Meter out of the Air Box.
9. Disconnect the air pump inlet hose at the top portion of the Air Box.
10. Loosen the hose clamp that attaches the Air Box to the hose that comes out of the right fender. Lift the Air Box straight up and remove from car. Push the hose back through into the fender (it may help to pull from inside the fender). This last hose supplies unfiltered cooling air to the computer compartment, and will be left loose next to the Dinan Intake Tube (see Figure 8).
11. Prepare to remove the air pump. Start by undoing the electrical connector on the bottom of the air pump. Then unclip the outlet hose from the side of the air pump, and slide off the inlet hose at the top of the air pump.
12. Remove the two nuts and one bolt holding the air pump bracket to the chassis, and remove the air pump and bracket from the vehicle. Note the location of the rearmost nut – the Dinan “S-aped” Air Pump Bracket will attach to this hole at a later step. Set the air pump assembly aside for now.
13. Remove the air pump inlet hose assembly from the vehicle and discard.
14. See Figure 5: In order for the intake tube to fit, a portion of the hole where the Air Box inlet was, and the tray under the Air Box, must be trimmed. This is located at the right front of the car behind the headlight. Using a jig saw or cut-off wheel, trim out the outlined section as shown. Note that half of the round section must be trimmed.
15. After trimming, fit check the Intake Tube to make sure it will clear and the bolt can be attached. The tube is inserted from the bottom, with the Dinan logo towards the Airflow Meter. The Intake Tube bolts to the existing hole where the intake snorkel attached (see Figure 8), using the supplied 10mm head bolt and wave washer. Trim more material if the tube does not fit. Sand or file the cut edges smooth.
16. Place the smaller 80-100mm hose clamp over the small end of the Silicone hose and slip it over the Air Flow Meter. Install the Intake Tube into place, and attach the tube to the other end of the Silicone hose with the larger 90-110mm hose clamp. There is some play available when tightening down the tube. In order to place the tube in its correct final position, make sure the Air Flow Meter is level and straight and looks aesthetically pleasing. Tighten the tube to the car in this position.
17. Unbolt the air pump from its bracket, keeping the rubber mounts with the air pump. Discard the bracket as it will not be reused.
18. Attach the Dinan Inlet Hose Assembly to the inlet at the top of the pump. This must be a friction fit – DO NOT use any lubricant at this attachment!
19. Assemble air pump onto Dinan Air Pump Brackets using the three flanged nuts as shown in Figures 6 and 7 Carefully note the locations of the pump inlet and outlets relative to the brackets. Also note that the longer leg of the “S-shaped” bracket is the end that attaches to the pump (you may wish to leave this nut slightly loose for now, and tighten it after the next step).  If the circular bracket hasextra holes, only use the ones Pump Outlet marked with a “7
20. Install air pump into car. Using the supplied 10mm head bolt, washer, nylock nut, attach the “S-shaped” bracket to location noted in Step 12. Using the remaining washer and nylock nut, attach the leg of the circular bracket to the headlight mounting stud just below the low beam (see Figure 8).
21. Reattach outlet hose, and electrical connector to the air pump.
22. Install the Dinan Inlet Filter onto the Inlet Hose and secure with the 25-40mm and 22-32mm hose clamps (see Figure 8).
23. Install the Air Filter on the lower opening of the intake tube with the supplied hose clamp (see Figure 8). Make sure the filter does not interfere with the mounting of the front bumper. Double-check that there is nothing in the filter for the engine to ingest. Install protection sock onto air filter.
24. Reinstall the bumper. Remember to connect the fog lights and washer lines if necessary. Make sure the ends of the bumper correctly slide into their corresponding connectors. It might help to lubricate the thin weather strip on top of the bumper with some silicon lube. Reattach the screws for the inner fender wells. Tighten the bumper mounting bolts to 41 N-m (30 ft-lb).

You are now done installing the kit. Enjoy!

FOR BEST PERFORMANCE, WE RECOMMEND THAT THIS INTAKE BE USED WITH THE APPROPRIATE DINAN PERFORMANCE SOFTWARE FOR YOUR VEHICLE. There are two methods to install the software:

• A Dinan Exclusive Dealer can download the software directly into your ECU. In this instance, you may proceed directly with the intake installation. Please contact your Dinan representative to locate the facility nearest you.
• You can send your ECU to Dinan for programming. Please contact your Dinan representative so that we may prepare for its arrival.

NOTE:

• We recommend replacing the air filter every 30,000 miles. The Dinan part number is D403-0410.

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