Right guys i thought id show you guys how i tackled the replacment of my standardnair box for my bsr optiflow kit.
Contents of box are as above in previous post...
Right first off heres a pic of what yours should look like to start off if your standard!
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you need to remove the ducting to the airbox by removing the two screws holding it on as in this pic
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You then need to remove the egr harness which is located at the rear of airbox on top!
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next remove the maf harness from the sensor, clips are self explanitory to remove very easy!
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now remove the magnetic harness too, this clip is a lil tricky but you just need to open the spring clip with a flat head or something similar and it just pops out allowing the harness to pull away!
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Now undo the turbo intake pipe by loosening the jubilee clamp with a 7 or 8 mm socket and then pull it away from the airbox also pull away the secondry air pump by squeezing the clip and pulling it away too as i have here.
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now you need to release the one use clips from the silicone pipes where the hard pipe of the egr meets top and bottom. Both clips need to be thrown away after and replaced with the jubilee clamps provided in the kit! The first is located at the top right hand corner of the airbox
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and then the bottom one which is located behind the turbo intake pipe, the clips need to be removed with electrical snips and cut between the meeting layers for easy removal, as prying with a flathead can damage pipes and other parts in close proximity if you slip!
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Now you have removed the hard pipe pull all the remaining hoses and harness out of the way so you can pull the airbox to the right so it comes away from the fender mount and then straight up and out! Once tou have done this you should be left with the open gap which airbox once stood. Now you can prepare the first part of bsr kit by fitting the harness holders and egr hardpipe cable ties which all clip in via the clips attached to items supplied! You can now drop the first part of heat shield into the mouting bushes which you will be able to see in the open gap! Once in just push all harness into place on clips as pic
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Now go back to the airbox and remove the maf sensor and housing off of the unit! Now you can fit this to the second part of the heat shield with the plugs and screws provided! Then fit the second part into the bay and connect via the 3 bolts provided to secure together and also fix to fender using the L bracket and bolt provided!
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once this is done and secure you are nearly there. Now fit the turbo intake pipe back onto maf and plug in harness making sure its neatly passed through box, same goes for magnetic harness also passed neatly through box. Then plug in egr harness also left neat and conncet up the two egr pipes you removed earlier nipped tight with the new jubilee clamps provided. May want to do the hard pipe first. Once everything is fitted back as should be you can now fit the two filters first little secondry pupmp filter is to be passed through and fitted to pipe using new clamp, you may have to snip off old connector to get the new clamp around! Now fit the larger filter to the maf inside the box and nip up tight but being carefull not to split rubber. Once this is all done replace your old intake duct by replacing both screws you removed at first and run in gap supplied on top of box should be neat and fit well! Once this is complete check all connections and harnesses before turning over vechile or you may get an error which you will have to get cleared! You should end up with this
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remember to clean everything up so you leave no greasy marks all over your engine
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Now this is fitted it really does make a difference sound wise as gives that distinctive whooshh that i love! Hasnt made any noticable gains in throttle response but neither has it lost any so isnt really making any difference as of now except for the noise which i prefer to have! Sounds really good and is quite loud actually! Now need to replace the turbo intake pipe which i am still awaiting! As alwawys will show you guys how i tackled it when inget to it. Ohhh and also fitted replacment led number plate units and are rwally worth the money much better than led bulbs in standard cases look great!
