Tigz™ Posted June 12, 2008 Report Share Posted June 12, 2008 (edited) Thanks to veedub1955 for this step by step guide on how to install a BMC CDA to the Lupo/Arosa 1.4 16v 75bhpAs 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 spannerWhats included in the kitBasic layout of original air boxFirst undo the existing cool air inlet pipe, here's the first screwAnd here's the next, also pull off the oil breather pipe which the new supplied breather is going to beinstalled on later.Now 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 air box, 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 doesn't foul the opening of the throttle cable whenscrewing onThe silicon hose is bigger than you need and you will have to trim down. Mock up 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 didn't give a clean cutand 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 CAREFULNow mock up hose for height of induction box, mark and cut as aboveNow push the silicon hose onto the reducer, it doesn't need a jubilee clip a ) cause only two are supplied andB ) you might over tighten the clip and break the reducer, it is a real tight fit and doesn't leak. NOW FOR THEMOST IMPORTANT BIT CHECK THE THROTTLE CABLE CAM DOESN'T FOUL or you will either not gain fullthrottle or the throttle could stick open and have disastrous results YOU HAVE BEEN WARNED. So adjust theheight accordinglyNow it is time to measure the mounting brace bar for length, mock up 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 install the 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 didn't tighten the tie too much soas to not crush the breather pipe or railNow cut to length the induction pipe and pop on, you don't need jubilee clips here as not enough are suppliedbut I'm going to get some and add a a later dateNow replace the rocker cover plastic cover and go and test Thanks for looking [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 January 20, 2010 by nfbr Cleaned by: nfbr. Link to comment Share on other sites More sharing options...
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