veedub1955 Posted June 7, 2008 Report Share Posted June 7, 2008 (edited) Hi all here's a step by step guide on how to install a BMC to my 1.4S. I bought the kit from Kam Racingwho's sales service is excellent, here is a link to the club discount section Kam Racing Club Lupo discountAs 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 toTools needed:-Posidrive screwdriver10mm Socket or spanner5mm allen keyT25 torx driver or socketStanley KnifeHacksawOptional:File/Grinder7mm socket or spanner(N.B if anyone wants the stickers PM me for my address and send us an SAE 1st come first served )Whats included in the kitBasic layout of origonal air boxFirst undo the existing cool air inlet pipe, heres the first screwAnd here's the next, also pull off the oil breather pipe which the new supplied breather is going to beinstalled on laterNow undo the 4 5mm allen key bolts that hold the rocker plastic cover on and removeNow undo the 1st of the two screws that hold the air box on with your T25 torx, if you havnt got one ofthese then a well fitting flat head screwdriver should undo this with a bit of care. Better pic 2 followNow undo the seven posidrive screw that hold the top of the air box on locations with screws in as belowNow undo the second torx screw that holds the air box on and remove airbox, this is also held on by a rubber grommet and might be a bit tight to removeNow you have to install the reducer ring on the throttle body, here is the throttle body widthThe smallest reducer supplied is a bit bigger than the throttle body and you might think it wont fitbut with a bit of care tightening it will, without any air leaksTake care with the supplied jubilee clip that it dosent foul the opening of the throttle cable whenscrewing onThe silicon hose is bigger than you need and you will have to trim down. Mockup the position of theinduction box and mark where you want to cut it. I always put the jubilee clip on before cutting and either use it as a guide, or use it to mark a ring rightround the hose so you get a neat cut. I tried using a hacksaw at first to cut but it didnt give a clean cutand had loads of swalf that can get in your throttle body, so I used a sharp stanley knife and this gave it a clean neat edge. BE CAREFULNow mockup hose for hight of induction box, mark and cut as aboveNow push the silicon hose onto the reducer, it dosent need a jubilee clip a ) cause only two are supplied andB ) you might overtighten the clip and break the reducer, it is a real tight fit and dosent leak. NOW FOR THEMOST IMPORTANT BIT CHECK THE THROTTLE CABLE CAM DOSENT FOUL or you will either not gain fullthrottle or the throttle could stick open and have disasterous results YOU HAVE BEEN WARNED. So adjust theheight accordinglyNow it is time to measure the mounting brace bar for length, mockup the mounting ring and find a suitablemounting point as below, the cam cover screw has plenty of thread on it, so is perfectNow cut to length with you hacksaw, Ive rounded the edges off to save sharp edges, and frayed tempersplus its a neater jobNow install mounting bar and tighten the supplied 10mm nut and bolt to the ring, and undo the 5mmallen bolt of the cam cover, install and tightenNB THE INDUCTION BOX IS THE WRONG WAY ROUND IN THIS SHOT, CHECK ON THE ENDS OF THE INDUCTIONBOX AND IT WILL TELL YOU THE RIGHT WAY ROUND (DOH at least i realised before EVERYTHING was put back lol)Now to instal the flip#*$n supplied breather, it is a tight fit and WILL pop off a few times but you willget there eventually I cable tied round the fuel rail but didnt tighen the tie too much soas to not crush the breather pipe or railNow cut to lenth the induction pipe and pop on, you dont need jubilee clips here as not enough are suppliedbut im going to get some and add a a later dateNow replace the rocker cover plastic cover and go and test On the next installment im making a aluminum bell that will mount onto the plastic cover next to the radiatorand have bought a 1mtr lenth of 70mm pipe from eBay so as to get better flow and colder air into it, watch thisspace. Also when I next get some spare cash Ill get a Raceland manifold from KAM racing and do a full installhow to on this. Thanks for looking Edited June 24, 2008 by veedub1955 Quote Link to comment Share on other sites More sharing options...
Kam Racing Posted June 7, 2008 Report Share Posted June 7, 2008 good guide there... made the mistake of using hacksaw on the silicon hose when I was doing the BMC for my Polo. Luckilly I had plenty of spare hoses Quote Link to comment Share on other sites More sharing options...
Mike_M Posted June 7, 2008 Report Share Posted June 7, 2008 Nice write up Quote Link to comment Share on other sites More sharing options...
Adam Posted June 7, 2008 Report Share Posted June 7, 2008 Nice write up, and a good clean installation Quote Link to comment Share on other sites More sharing options...
timboc Posted June 7, 2008 Report Share Posted June 7, 2008 good guide! im going to be fitting the same to mine, any noticible gains? also how does it sound, as i have heard that bmc's are nice and quiet?? Quote Link to comment Share on other sites More sharing options...
timboc Posted June 9, 2008 Report Share Posted June 9, 2008 BUMP! anyone? Quote Link to comment Share on other sites More sharing options...
DanK Posted June 10, 2008 Report Share Posted June 10, 2008 Very good guide, im also going to be getting one of these and i think this is the first guide for a 1.4s so good job and thanks for the tips Quote Link to comment Share on other sites More sharing options...
veedub1955 Posted June 11, 2008 Author Report Share Posted June 11, 2008 Cheers guysThe sound is really good in first and second when you are accelerating then it quitens downnicely, big improvement in sound. Dont expect hugh differences in performance as you onlygoing to get them with other modifications as well although there is a noticable small improvement. I going for the bolt on mods at first and then the whole package should givenoticable gains. Doing the Ram air into the intake should make some improvement as wellIll post a guide when I get chance to go on the lathe at work and make a bell mouth for behind the front grill. Also putting coilovers on this weekend and will do the same how to guideon that as well Quote Link to comment Share on other sites More sharing options...
Niche Posted June 16, 2008 Report Share Posted June 16, 2008 (edited) The tip on cutting the silicon hose worked a treat. Ta very much.I also cut a hole in the silicon hose and extended my oil breather pipe into it with a few adaptors I had keeping the originial enclosed system.No oily smells coming through the vents, no oil condensation dampening up your engine bay, and the air filter doesn't get soaked in oil as the oil breather hose pumps out directly based above the throttle body.I'll post up a picture later this week. Edited June 16, 2008 by Niche Quote Link to comment Share on other sites More sharing options...
veedub1955 Posted June 16, 2008 Author Report Share Posted June 16, 2008 Nice one mate What exhaust system are you running Quote Link to comment Share on other sites More sharing options...
Alex_225 Posted June 16, 2008 Report Share Posted June 16, 2008 Very good guide that, really looks snuggly fitted. I should really cut the silicon hose on mine as seeing yours so neat makes mine look shoddy haha. Only thing that I found was that on my BMC DIA kit, I didn't need the reduce pipe to connect it to the throttle body. I just was just able to slot the hose over it and tighten with a jubilee clip. Was a snug enough fit anyway as well as having the clip to hold it tight. Quote Link to comment Share on other sites More sharing options...
Lupo D Posted June 16, 2008 Report Share Posted June 16, 2008 Can anyone tell me in simply word what that means...?My english is good but not too good...! Now push the silicon hose onto the reducer, it dosent need a jubilee clip a ) cause only two are supplied andB ) you might overtighten the clip and break the reducer, it is a real tight fit and dosent leak. NOW FOR THEMOST IMPORTANT BIT CHECK THE THROTTLE CABLE CAM DOSENT FOUL or you will either not gain fullthrottle or the throttle could stick open and have disasterous results YOU HAVE BEEN WARNED. So adjust theheight accordinglyThanks Veedub...! D. Quote Link to comment Share on other sites More sharing options...
Niche Posted June 16, 2008 Report Share Posted June 16, 2008 Nice one mate What exhaust system are you runningI'm not running a branded exhaust, its a fully custom stainless steel cat back exhaust made by LongLife.I'm ordering a silicon reducing hose tomorrow, one end is 70mm which fixes to the BMC, and the other end I think needs to be a 50mm so I can attach it to the original hot air/cold air system without any air leaks.Silicon Hose Reducer Quote Link to comment Share on other sites More sharing options...
veedub1955 Posted June 17, 2008 Author Report Share Posted June 17, 2008 Now push the silicon hose onto the reducer, it dosent need a jubilee clip (Put the big blue hose onto the black plastic ringthat makes the hose fit the accelerator body) a ) cause only two are supplied and (Only 2 big round clips are in the kit) Solo 2 grandi clip sono tornata nel kit B ) you might overtighten the clip and break the reducer, it is a real tight fit and dosent leak. (If you use a big round clip it may break the plastic reducer) Se si utilizza una grande rotonda clip può rompere il riduttore di plastica NOW FOR THE MOST IMPORTANT BIT CHECK THE THROTTLE CABLE CAM DOSENT FOUL or you will either not gain fullthrottle or the throttle could stick open and have disasterous results YOU HAVE BEEN WARNED. So adjust theheight accordingly (Make sure the bottom of the big blue hose does not touch the round bitwhere the accelerator cable goes round. It will stop the accelerator opening or make it stay open) Assicurarsi che il fondo del tubo Big Blue non tocca il turno bit in cui l'acceleratore cavo va round. Si fermerà l'acceleratore di apertura o di renderlo rimangono aperti Speranza che questo aiuti Lupo Milano Quote Link to comment Share on other sites More sharing options...
veedub1955 Posted June 24, 2008 Author Report Share Posted June 24, 2008 *** Update ***Now made a bell mouth at work out of billet ali and fitted see pics below, ill report on how it performsI got a 1mtr 70mm hose off ebay for £16 and fits perfectlyI can make some more of these if wanted if I can get 5 orders it will be worth it Quote Link to comment Share on other sites More sharing options...
dubsy Posted June 24, 2008 Report Share Posted June 24, 2008 i already have this done but the bell mouth your using looks a fair bit bigger how much will these be? Quote Link to comment Share on other sites More sharing options...
Niche Posted June 24, 2008 Report Share Posted June 24, 2008 (edited) Nice, my BMC is pretty restrictive as I've linked it to the original hot / cold air thingy.I keep forgetting to post up pictures but I'm going to be under the bonnet later so I'll post up a picture tonight for deffo. Edited June 24, 2008 by Niche Quote Link to comment Share on other sites More sharing options...
veedub1955 Posted June 25, 2008 Author Report Share Posted June 25, 2008 i already have this done but the bell mouth your using looks a fair bit bigger how much will these be?About £30 - £35 if I could get a few people interested, I know it sounds a lot but I machinedit out of solid billet ali, the back end is 70mm for the hose but I can do this any size Quote Link to comment Share on other sites More sharing options...
Niche Posted June 25, 2008 Report Share Posted June 25, 2008 I humbly present the worlds first BMC Induction Kit which you actually can't hear! (You can blatantly see why)I also humbly present the worlds first BMC with an internal oil breather pipe. Nick. Quote Link to comment Share on other sites More sharing options...
Lupo D Posted June 25, 2008 Report Share Posted June 25, 2008 That's the Top Vee...!Thanks for clearance...and good Italian...! Grazie Ragazzo...!D.Now push the silicon hose onto the reducer, it dosent need a jubilee clip (Put the big blue hose onto the black plastic ringthat makes the hose fit the accelerator body) a ) cause only two are supplied and (Only 2 big round clips are in the kit) Solo 2 grandi clip sono tornata nel kit B ) you might overtighten the clip and break the reducer, it is a real tight fit and dosent leak. (If you use a big round clip it may break the plastic reducer) Se si utilizza una grande rotonda clip può rompere il riduttore di plastica NOW FOR THE MOST IMPORTANT BIT CHECK THE THROTTLE CABLE CAM DOSENT FOUL or you will either not gain fullthrottle or the throttle could stick open and have disasterous results YOU HAVE BEEN WARNED. So adjust theheight accordingly (Make sure the bottom of the big blue hose does not touch the round bitwhere the accelerator cable goes round. It will stop the accelerator opening or make it stay open) Assicurarsi che il fondo del tubo Big Blue non tocca il turno bit in cui l'acceleratore cavo va round. Si fermerà l'acceleratore di apertura o di renderlo rimangono aperti Speranza che questo aiuti Lupo Milano Quote Link to comment Share on other sites More sharing options...
veedub1955 Posted June 26, 2008 Author Report Share Posted June 26, 2008 Lupo D Nessun problema dude Well thought out Niche fits perfectly, I may do the same with the breather as Ive noticed more petrol fumes than before with it, maybe coincidence Quote Link to comment Share on other sites More sharing options...
Niche Posted June 26, 2008 Report Share Posted June 26, 2008 (edited) That's not petrol fumes your smelling mate, what your smelling is oil! After a long drive you may be able to see some puff coming through your breather filter. That's what your smelling and it stinks!I done that on my Polo Coupe S for a month after my carb conversion and I developed a tickly poofy cough which took a month to get rid of! So I can highly recommend everyone does so!I used an extra bit of extra piping and two of these connectors...The hole in the 90 degree bend only needs to be half the size of the actual breather pipe as it stretches when you push the connector in making it completely sealed. I also used a mini cable tie and strapped it around the plastic connector part on the inside of the 90 degree bend locking it in place. Make sure its tight though otherwise it will slip off into your throttle body! The jagged edge of the connector will stop that happening so long as its pulled tight! Edited June 26, 2008 by Niche Quote Link to comment Share on other sites More sharing options...
sgtazza Posted July 21, 2008 Report Share Posted July 21, 2008 Guys,I have just collated all relevant bits to do a BMC cda with direct cold air feed. BUT.....what do i do about the pipe coming off the exhaust manifold that seems to link into the intake system? cos it aint got no place to go now!!Your help will be much appreciated. Quote Link to comment Share on other sites More sharing options...
Niche Posted July 22, 2008 Report Share Posted July 22, 2008 Nothing, just take it off, that pipe only assists the engine in the winter to help the engine warm up quicker. Quote Link to comment Share on other sites More sharing options...
sgtazza Posted July 22, 2008 Report Share Posted July 22, 2008 Nothing, just take it off, that pipe only assists the engine in the winter to help the engine warm up quicker.Ok, cool. I will be fitting it tonight. I thought the manifold would in effect 'blow' if the pipe wasnt connected, but i take it thats not the case.Cant wait to get a bit of GRRRRR out of the loop. lol Quote Link to comment Share on other sites More sharing options...
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