BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS www.vf-engineering.com SUPERCHARGER (V3) INSTALLATION GUIDE FOR BMW E36 (‘96-’98 M52) (INCLUDING M3 ’99 S52) (VFK28-01, VFK38-01,VFK40-01) NOT CARB APPROVED NOT LEGAL FOR USE ON PUBLIC HIGHWAYS IN STATE OF CALIFORNIA. WARNING: DO NOT BEGIN INSTALLATION PRIOR TO READING THE PRE INSTALL NOTES ON PAGES 2-4 VF ENGINEERING www.vf-engineering.com M-F 9:00AM – 5:30PM (PST) 1365 N. Dynamics St.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS IMPORTANT PRE-INSTALL NOTES: - SPECIAL INSTALL NOTES ***This installation guide serves as an outline of the steps needed to install your supercharger system and is not intended to guide a novice through the installation. If you do not have the proper tools, knowledge and experience to carry out the installation, please seek help from a professional.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS ECU MODIFICATION REQUIRED **Please print out the ECU return form (see next page) and include in the package along with your ECU! This kit requires ECU modification known as “flashing” which is electronic overwriting of the original engine management software with new software designed for to work in conjunction with your system, and has been included in the price of your supercharger upgrade.
BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS www.vf-engineering.com ECU RETURN FORM ** THIS FORM MUST BE COMPLETED BY THE VEHICLE OWNER ** This form should always be used when sending your ECU to VF-Engineering for software programming. ECUs sent to VF without this completed form will experience processing delays. VF does not cover the cost of ECU shipping or damage resulting from shipping. Please complete payment info below or call to provide payment for return shipping.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS Preparation for the installation: During the installation process you will be handling some of the following items you may wish to replace while you are working on the vehicle, and therefore purchase before commencing the installation: Engine oil and oil filter Spark Plugs (VF-Engineering recommends the use of NGK Part# BKR7E on M3 models) Suggested gap 0.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS INSTALLATION INSTRUCTIONS 1. Disconnect the ground terminal from the battery which is located in the trunk. 2. Locate and remove the Engine Control Unit (also known as the DME) from the vehicle by unscrewing the black cover (A) to reveal the DME itself. Disconnect the main harness connector by prying out the metal clip and gently lift the connector off the DME.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 5. Remove complete intake system: throttle body coupler (A), Mass Air Flow (MAF) sensor (B), airbox (C) and alternator duct (D). 6. Unscrew the fan coupler from the water pump pulley. (***Note the coupler is reverse threaded!) Remove the fan blade and store for later use. 7. Remove the upper radiator hose from engine (C). Remove the AC serpentine belt by de-tensioning its spring loaded tensioner at point (A).
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 8. Remove front bumper by unscrewing 2 torx bolts through front lower grill. Remove all screws from the wheel well liners on the sides of the bumper. Disconnect the horns and fog lights (if applicable). Working at the front of wheel wells, remove the left and right inner panel fasteners. Slide bumper forward to remove. If equipped with headlight washers or parking distance control (PDC), disconnect their connections to the bumper in prior.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 11. Disconnect the crankcase hoses from the valve cover, connection at the bottom of the oil separator, and remove the oil separator from underside of intake manifold behind the throttle body, via its three anchoring bolts. Make sure the rubber grommet is removed from inside the manifold as well. 12. Grease the grooves on the 3/8 NPT tap supplied. Tap the intake manifold till the tap thread is just past half way.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 14. Remove the OEM intake manifold support bracket, located underneath the manifold. 15. Clamp the new double ‘S’ shaped crankcase hose to the upper fitting on the oil separator, with the short side of the hose connected to the separator.(***NOTE: shorter hose shown in picture below) Return the oil separator unit to original position and secure using the three aluminum spacers and bolts supplied.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 16. Clamp the original crankcase vent hose back onto the lower connection of the oil separator. The upper crankcase (S) hose will continue on and connect to a port on the side of the supercharger intake pipe. 17. Install the replacement intake manifold support bracket in the original location. 18. Step 18 removed as kit was updated from V2 (oil fed) supercharger to V3 (self-lubricated unit) 19.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 20. Fit ¼” barbed check valve (A) in-line with EVAP (B) solenoid valve vacuum line. Ensure that the white side of the check valve is facing the direction of the EVAP solenoid. This valve may be located on the d/side frame rail area on some models. This check valve is a back up valve in case the OEM valve fails. Its purpose is to prevent manifold pressure travelling the wrong direction in the EVAP system (fuel tank ventilation).
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 21 Edited out. 22 Edited out. 23 Fit ⅛” barbed check valve in line with the vacuum hose connecting from under the intake manifold to exhaust flap actuator vacuum reservoir. The white side of valve is to face the vacuum reservoir. SOME ENGINES WILL NOT HAVE THIS VACUUM LINE.(***NOTE: Fitment of this check valve is only required on engines fitted with a vacuum reservoir for an exhaust valve actuator. All kits are supplied with this valve.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 25 A small diameter crankcase ventilation hose runs from the top of the valve cover to the underside of the traction control throttle body. Disconnect it from the throttle body (A) and cap the exposed port on the throttle body with the cap and clamp provided in the kit. When fitting the supercharger intake duct later in the instructions, you will need to cut this crankcase hose vent a bit shorter.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 25 Cut the MAF plug off of the OEM wiring, leaving approximately 3” of original wiring left connected to the plug, and extend the MAF harness using the extension harness provided. MAKE SURE YOU ARE SIMPLY EXTENDING THE HARNESS. IF COLORS DON’T MATCH, ENSURE THAT YOU ARE EXTENDING THE CORRESPONDING WIRE CORRECTLY. THE RESISTOR SHOULD BE INSTALLED INLINE IN WIRE THAT GOES TO PIN #2 ON THE MAF CONNECTOR.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 31 Hold complete supercharger and bracket assembly and carefully lower into position over the alternator pulley (A). While lowering the assembly, guide the support brace (B) to the vacated bolting hole in the oil filter housing and secure together with a few turns of the new M8x120 bolt supplied.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS escape from the unit when it gets hot. The brass fitting next this, is a dipstick and when unscrewed you will find a “hatched” level stick attached to it. The oil level should be within the hatching. The supercharger unit has a braided steel oil drain line which is only used to drain the oil out at the following service intervals. This oil line should zip tied aside free from obstruction at all other times. Oil change intervals.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 34 Slide the supercharger intake duct (A) onto the supercharger inlet and leave the clamp loose. Simultaneously guide the long end of the hose from the bypass valve (B), as well as the complete bypass assembly under the supercharger and up-toward the open spout on the underside of the intake duct (A) and clamp. Guide crankcase vent hose (C) onto open spout (D) on intake duct and clamp.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 36 Slide the supercharger discharge duct with silicon couplers and all clamps in place (at both ends of duct) onto the supercharger while simultaneously connecting the hoses from the bypass valve and the Idle Air Stabilizer to the underside of the duct. You can adjust fitment by trimming the length of the rubber hoses on the bypass valve in the even that any components interfere with each other.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 37 Connect MAF (A) sensor to the end of the supercharger intake duct. Couplers are purposefully cut to be short to aid with clearances and help fitment of the air filter. Ensure clamp heads (B) are not resting against other parts as chaffing will cause damage. The MAF unit is directional so verify that the arrow (C) on the MAF is pointing upwards, representing the direction air travels through it.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 38 Use the 45 degree silicon elbow fitting to join the air filter to the coupler on the end of the MAF sensor. Your kit contains a cylindrical airbox for the air filter, but due to variations in BMW production, the air box may need trimming to allow for variations in fog lights. The airbox can be removed for dry climates, but VFEngineering recommends utilizing the airbox in most conditions.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 40 See the image below for proper belt routing of the new longer main serpentine belt supplied with the kit. Use the factory spring tensioner to apply belt tension. Re-fit the OEM AC belt using the factory spring tensioner. 41 Install the new top radiator hose supplied with the kit (A). Check for at least 3/8” clearance at point (B).
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS 42 Check over your installation and follow instructions from the beginning to check for thoroughness. Reconnect battery and start the car. Verify there are no fuel leaks from the injectors and check all oil line connections at both ends. Check under car and verify all work. Once certain all systems are verified you can re-install the front bumper, and engine cover,.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS PREVENTITIVE MEASURES Change spark plugs to 1 range cooler for extreme driving and hot climates. Supercharger oil must be replaced at 2500 miles from install and then every 7500 miles. You can purchase the oil from www.vortechengineering.com Change engine coolant temp senor whilst installing the supercharger kit (often a cause of fuelling issues on cars of any age).
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS VF-ENGINEERING SUPERCHARGER KIT LIMITED WARRANTY Subject to all the terms, conditions and exclusions set forth in this document, Zurich Engineering, Inc. (“VF-Engineering”) provides the following warranties to the original purchaser of certain VFEngineering products. For reference purposes, “you” and “your” mean only the original purchaser of the warranted VF-Engineering product. YOU MUST ALSO READ OWNERS MANUAL. 1. 2. i. ii. iii. iv. v. vi.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS xl. Removing or defacing the original Vortech serial number tag; xli. Improper installation, not following installation instructions provided, or installation by an unskilled person; xlii. If the supercharged car is driven after an uncorrected fault has been detected; or xliii. Any faults/irregular noises are not advised to your vendor. 10. Power increases with Zurich Engineering, Inc.
www.vf-engineering.com BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS VF-ENGINEERING SUPERCHARGER KIT OWNERS MANUAL The following information and recommendations are designed to promote years of trouble free service for your supercharger. Care recommendations have also been outlined for your vehicle and maintenance of your supercharger kit. MAINTENANCE INSTRUCTIONS FOR THE SUPERCHARGER KIT and SUPERCHARGER UNIT Caring for your kit (mandatory procedures) 1.
BMW E36 (‘96-’98 incl. ‘99 M3) US MODELS www.vf-engineering.com PRODUCT REGISTRATION FOR WARRANTY. ***THIS DOCUMENT MUST BE RETURNED COMPLETED TO VALIDATE WARRANTY. Please retain a copy for your records. ( ) 1 YEAR WARRANTY Complete and mail form to: VF-ENGINEERING 1365 N DYNAMICS STREET, SUITE (E), ANAHEIM, CA 92806 USA. www.vf-engineering.
