MAJOR 545i aFe Intake Problem!!!
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Joined: Sep 2007
Posts: 1,712
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From: Encino, CA
My Ride: 04 545i - Titanium Silver/Black, Sport pkg, Comfort Seats w/ Lumbar, Premium Sound, power rear sunshade, Adaptive Xenon Headlights, Steptronic, Park Distance Control, Fold down rear seats w/ski bag, Aux jack, 6-disk changer, puddle lamps...
Engine: Custom Remus cat-back exhaust w/chrome square tips, K&N Air Filter, Charcoal Filter Removed, Sprint Booster :-), 50/50 mix of 91+100 Octane, EuroRev ECU Remap (coming soon lol), Dinan High-Flow Throttle Body (coming soon...maybe lol)
Interior: Portable Sirius Stilletto 100 w/car kit, Garmin Nuvi 680 mounted below rear-view mirror, LCI-style I-drive knob, Dark Poplar Center Dashboard Trim.
Exterior: E60 forum clings, 5% rear tint, ACS roof spoiler (painted black for distinct look against limo tint), ACS trunk spoiler, ACS add-on front spoiler and rear apron (awaiting installation), "18 Black Staggered BeBeS Style OER (emergency replacement for cracked sport 124 rims), black kidney grill, white accessory lighting (including license and trunk lamps), Angel-eye upgrade, AIB xenon-matched fog lamps, AIB V3's on order, red rear reflectors
I've discovered a serious design flaw on my 545i aFe intake. The rubber connector between the filter and the MAF sensor failed due to what looks like heat rot. I'm surmising the problem lies in the use of metal for the 'heat shield', the use of metal worm clamps, and the proximity to the radiator. The rubber facing the radiator has cracked and split. Fortunately the split didn't penetrate the inner part of the filter, as that would have allowed dangerous particles to be sucked in, leading to possible scoring of my cylinder walls!!! I can't even sell the fuckin thing! They had better replace this part! Pics of the problem are below. Please check your filters and post pics of it here if a similar problem exists with your filter!
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Joined: Sep 2007
Posts: 1,712
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From: Encino, CA
My Ride: 04 545i - Titanium Silver/Black, Sport pkg, Comfort Seats w/ Lumbar, Premium Sound, power rear sunshade, Adaptive Xenon Headlights, Steptronic, Park Distance Control, Fold down rear seats w/ski bag, Aux jack, 6-disk changer, puddle lamps...
Engine: Custom Remus cat-back exhaust w/chrome square tips, K&N Air Filter, Charcoal Filter Removed, Sprint Booster :-), 50/50 mix of 91+100 Octane, EuroRev ECU Remap (coming soon lol), Dinan High-Flow Throttle Body (coming soon...maybe lol)
Interior: Portable Sirius Stilletto 100 w/car kit, Garmin Nuvi 680 mounted below rear-view mirror, LCI-style I-drive knob, Dark Poplar Center Dashboard Trim.
Exterior: E60 forum clings, 5% rear tint, ACS roof spoiler (painted black for distinct look against limo tint), ACS trunk spoiler, ACS add-on front spoiler and rear apron (awaiting installation), "18 Black Staggered BeBeS Style OER (emergency replacement for cracked sport 124 rims), black kidney grill, white accessory lighting (including license and trunk lamps), Angel-eye upgrade, AIB xenon-matched fog lamps, AIB V3's on order, red rear reflectors
Originally Posted by brabusw209amg' post='702177' date='Oct 24 2008, 06:50 AM
thqanks for heads up. will check. did u contact afe???
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Joined: Sep 2007
Posts: 1,712
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From: Encino, CA
My Ride: 04 545i - Titanium Silver/Black, Sport pkg, Comfort Seats w/ Lumbar, Premium Sound, power rear sunshade, Adaptive Xenon Headlights, Steptronic, Park Distance Control, Fold down rear seats w/ski bag, Aux jack, 6-disk changer, puddle lamps...
Engine: Custom Remus cat-back exhaust w/chrome square tips, K&N Air Filter, Charcoal Filter Removed, Sprint Booster :-), 50/50 mix of 91+100 Octane, EuroRev ECU Remap (coming soon lol), Dinan High-Flow Throttle Body (coming soon...maybe lol)
Interior: Portable Sirius Stilletto 100 w/car kit, Garmin Nuvi 680 mounted below rear-view mirror, LCI-style I-drive knob, Dark Poplar Center Dashboard Trim.
Exterior: E60 forum clings, 5% rear tint, ACS roof spoiler (painted black for distinct look against limo tint), ACS trunk spoiler, ACS add-on front spoiler and rear apron (awaiting installation), "18 Black Staggered BeBeS Style OER (emergency replacement for cracked sport 124 rims), black kidney grill, white accessory lighting (including license and trunk lamps), Angel-eye upgrade, AIB xenon-matched fog lamps, AIB V3's on order, red rear reflectors
Originally Posted by brabusw209amg' post='702185' date='Oct 24 2008, 06:55 AM
maybe switch to K&N cone filter
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Joined: Apr 2008
Posts: 2,596
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From: New Jersey
My Ride: '05 545 Titanium Silver, Black Leather - Nav, Logic 7, Cold weather.
Mods:
Carbon filter removed.
M5 iDrive knob.
Umnitza license plate LEDs.
MP3
40% 3M tint
ACS Anti-Roll(sway) bars
RPI Scoop
G-tech Pro RR
CF Roundels
CF Wheel caps
There's a good chance everyone is switching back to stock anyway...this just gives them one more reason....
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Joined: Dec 2007
Posts: 1,706
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From: Calgary, AB - Canada / Buenos Aires - Argentina
My Ride: 2006 BMW M5
Email paulhardley@afepower.com
Show him the pictures! He is the boss.
this is happening because it was very hot. (You are in CA). If you want to replace it, get another Cone filter like K&N or install the stock back.
Show him the pictures! He is the boss.
this is happening because it was very hot. (You are in CA). If you want to replace it, get another Cone filter like K&N or install the stock back.
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Joined: Sep 2007
Posts: 7,053
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From: Jersey
My Ride: 2004 530i
Model Year: 2004
Originally Posted by miguex' post='702250' date='Oct 24 2008, 11:01 AM
........ If you want to replace it, get another Cone filter like K&N or install the stock back.
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Joined: Dec 2007
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From: Calgary, AB - Canada / Buenos Aires - Argentina
My Ride: 2006 BMW M5
Originally Posted by theXman' post='702317' date='Oct 24 2008, 10:14 AM
That decision has already been made (see post #3).