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  #1  
Old 05-23-2019, 07:49 AM
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Cold air intake for 3.0d

I've been working on some intake and filter ideas for my 02 3.0d.
I was wondering if some could help on an idea of changing the Oval maf housing for a round one?
I've replaced maf housings before for bigger ones on VWs but I am unsure how the e53 will read a round housing?
Does anyone have any info on this?
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  #2  
Old 05-23-2019, 04:47 PM
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Good luck with finding any info on flow rates and MAF response etc.

While the factory intake seems complex (because it is...) it includes a number of systems that you'll need to take into account of if you are looking to modify anything up that end.

The first (largest?) hurdle is that the oval MAF housing mount is part of the valve cover..!



You can see the MAF position at the lower right in the image above. To make any change here, you are going to need to hack up your valve cover.

Parts of the crank case breather and oil recovery systems (CCV) are built into the air filter frame on the valve cover too. There's a system of pipes that run from the breather assembly to the turbo compressor intake, under the air filter housing, so if you modify and/or remove the factory air intake and filtration arrangement, you'll need to develop a replacement for that system too.

I'm no expert on turbo diesel engines but given that the factory system is designed to deliver sufficient air to meet the demands of the turbo at full boost (about 2 bar I think) I'm guessing that "opening up" the intake so it can breather better won't make any real-work difference to performance. As the boost system controls (limits) the power level based on a number of factors such as throttle demand, engine rpm, engine temp, load, etc. I'm not sure that making more air available will make any difference.

Not wanting to pour cold water on your plans, just making sure you are aware of how deep this dive might get!!
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Old 05-23-2019, 05:00 PM
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Just been reading up a bit more on this and it seems if you are chasing more power from your diesel, there's an order to doing mods: -

1. ECU tuning - start here. Lots of "ECU chipping" solutions about.
2. Intercooler - increase size (flow rate and cooling efficiency).
3. Air intake - increase air intake capacity, to take advantage of greater ECU tune range and intercooler capacity.

So it would seem that increasing the air intake capacity isn't really going to help, at least as a first step, without the other mods in place first.

Of course, I'm assuming you goal is an increase in engine efficiency or power but maybe you are just after more intake noise!

As an aside, our engines already have a "CAI" of sorts. The intake air is ducted directly from behind the BMW "kidneys" so there's little engine bay heat reaching the intake.
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Old 05-23-2019, 05:05 PM
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Don't need to hack anything, it will have a custom induction pipe from the turbo and will be including a oil catch can.
There are a few ideas I have with something as simple as cutting the pipe coming up to the maf in half, turning the to half to the 9 o'clock position attaching it back to the bottom up pipe, so it gives you room for a cone filter or carbon bmc cold air feed.
Oh and noise is not what I want, I just want a better filter set up. I have been checking the heat of the original filter in this nice weather we are having, and even with the cold air feed its far too warm sitting above the turbo and manifold.
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Old 05-23-2019, 05:21 PM
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3.0d are great for bhp gains, but just to get betting air in and getting it back out the other end makes and turbo car run better
I am renewing everything I can from pipes & hoses to rewiring and replacing the old earth cables with new one both diffs, transfer case and auto transmission fluids done today, with engine oil change tomorrow.
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Old 05-23-2019, 05:29 PM
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Quote:
Originally Posted by nickid View Post
3.0d are great for bhp gains, but just to get betting air in and getting it back out the other end makes and turbo car run better
I am renewing everything I can from pipes & hoses to rewiring and replacing the old earth cables with new one both diffs, transfer case and auto transmission fluids done today, with engine oil change tomorrow.
It's going to feel like a new car! :-)

I replaced a bunch of vacuum lines when I did my manifold replacement a while back. Checked over everything else - it all seems in pretty good nick for a car with over 200,000kms.

Recently had to remove my (failed and noisy) mechanical fan - boy, does that ever make the engine feel frisky! Contemplating an all-electric replacement, as the removal of all the weight from the water pump is very attractive.
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Old 05-23-2019, 11:33 PM
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Has anyone here successfully downloaded their own ecu map, had it tuned (or tuned it themselves) and reloaded it via lapotop/OBD2?

I'd be interested in going down this route, as there are no tuners in my area and don't really want to be purchasing a hand held device like BSR PPC or Superchips Bluefin.

I've done a fair bit of research, but I can't find any information on anyone who's done it before.
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Old 05-24-2019, 12:05 PM
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Quote:
Originally Posted by wpoll View Post
It's going to feel like a new car! :-)

I replaced a bunch of vacuum lines when I did my manifold replacement a while back. Checked over everything else - it all seems in pretty good nick for a car with over 200,000kms.

Recently had to remove my (failed and noisy) mechanical fan - boy, does that ever make the engine feel frisky! Contemplating an all-electric replacement, as the removal of all the weight from the water pump is very attractive.
I am doing the same thing with the fan. I did replace my fan with an electric one on my 3.0i and I get what you mean by it feels frisky, mine felt smooth not as noisy.
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Old 05-25-2019, 04:33 AM
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If you’re going to go with a custom tune, then just ditch the maf entirely, then you’ll hAve the freedom to make an intake however you like. Otherwise, get creative (brave) and just pull the actual maf sensor itself out of the oval housing, and mount it in a round pipe where ever works?
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  #10  
Old 05-26-2019, 08:16 AM
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I've a spare maf to mess about with.
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