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How To: Fit a BMC CDA to a 75hp 1.4 16v

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Thanks to veedub1955 for this step by step guide on how to install a BMC CDA to the Lupo/Arosa 1.4 16v 75bhp

As you can see in pic number 1 this is what you get with the kit, it includes the silicon hose and breather with it.

The kits not exactly a bolt on affair so Ive decided to do this how to

Tools needed:-

Posidrive screwdriver

10mm Socket or spanner

5mm allen key

T25 torx driver or socket

Stanley Knife

Hacksaw

Optional:

File/Grinder

7mm socket or spanner

Whats included in the kit

1Kit.jpg

Basic layout of original air box

2Basiclayout.jpg

First undo the existing cool air inlet pipe, here's the first screw

3Undoscrew1.jpg

And here's the next, also pull off the oil breather pipe which the new supplied breather is going to be

installed on later.

4Undoscrew2andbreather.jpg

Now undo the 4 5mm allen key bolts that hold the rocker plastic cover on and remove

5Undorockercoverscrews.jpg

Now undo the 1st of the two screws that hold the air box on with your T25 torx, if you havnt got one of

these then a well fitting flat head screwdriver should undo this with a bit of care. Better pic 2 follow

6Undoairboxscrew1-1.jpg

Now undo the seven posidrive screw that hold the top of the air box on locations with screws in as below

7Undoairboxcoverscrewsx7-1.jpg

Now undo the second torx screw that holds the air box on and remove air box, this is also held on by a

rubber grommet and might be a bit tight to remove

8Undoairboxscrew2-1.jpg

Now you have to install the reducer ring on the throttle body, here is the throttle body width

9Throttlebodywidth.jpg

The smallest reducer supplied is a bit bigger than the throttle body and you might think it wont fit

but with a bit of care tightening it will, without any air leaks

10Reducerwidth.jpg

Take care with the supplied jubilee clip that it doesn't foul the opening of the throttle cable when

screwing on

11Installreducer.jpg

The silicon hose is bigger than you need and you will have to trim down. Mock up the position of the

induction box and mark where you want to cut it.

12Mockuphosepositionforwidthandmark.jpg

I always put the jubilee clip on before cutting and either use it as a guide, or use it to mark a ring right

round the hose so you get a neat cut. I tried using a hacksaw at first to cut but it didn't give a clean cut

and had loads of swarf that can get in your throttle body, so I used a sharp stanley knife and this gave

it a clean neat edge. BE CAREFUL

13Cuthoseforwidth.jpg

Now mock up hose for height of induction box, mark and cut as above

14Mockuphosepositionforheight.jpg

Now push the silicon hose onto the reducer, it doesn't need a jubilee clip a ) cause only two are supplied and

B ) you might over tighten the clip and break the reducer, it is a real tight fit and doesn't leak. NOW FOR THE

MOST IMPORTANT BIT CHECK THE THROTTLE CABLE CAM DOESN'T FOUL or you will either not gain full

throttle or the throttle could stick open and have disastrous results YOU HAVE BEEN WARNED. So adjust the

height accordingly

15Pushonsiliconehoseandcheckforf-1.jpg

Now it is time to measure the mounting brace bar for length, mock up the mounting ring and find a suitable

mounting point as below, the cam cover screw has plenty of thread on it, so is perfect

16Measuremountingbarforlength.jpg

Now cut to length with you hacksaw, Ive rounded the edges off to save sharp edges, and frayed tempers

plus its a neater job

17Cutandchamfermountingbar.jpg

Now install mounting bar and tighten the supplied 10mm nut and bolt to the ring, and undo the 5mm

allen bolt of the cam cover, install and tighten

NB THE INDUCTION BOX IS THE WRONG WAY ROUND IN THIS SHOT, CHECK ON THE ENDS OF THE INDUCTION

BOX AND IT WILL TELL YOU THE RIGHT WAY ROUND (DOH at least I realised before EVERYTHING was put back lol)

18Installmountingbar.jpg

Now to install the supplied breather, it is a tight fit and WILL pop off a few times but you will

get there eventually :rolleyes: I cable tied round the fuel rail but didn't tighten the tie too much so

as to not crush the breather pipe or rail

19Installoilbreatherandmount.jpg

Now cut to length the induction pipe and pop on, you don't need jubilee clips here as not enough are supplied

but I'm going to get some and add a a later date

20Cuttolengthinductionpipe.jpg

Now replace the rocker cover plastic cover and go and test :shades:

21Installrockercoverbackonandtest.jpg

Thanks for looking :rolleyes:

[nfbr's Hints and Tips]

This guide is virtually correct for people with the 1.0 Litre Lupos and Arosas too as their throttle body is also a 51mm External diameter!

Edited by nfbr
Cleaned by: nfbr.

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