phone 800.535.2002 • fax 800.507.2002 • www.BavAuto.com

Summer 2013

PRSRT STD U.S. POSTAGE

PAID BAVARIAN

AUTOSPORT

Bavarian Autosport275 Constitution Ave.Portsmouth, NH 03801

the newsletter of Bavarian Autosport

Got a mushy, worn out clutch? Replace it witha crisp, precise UUC Motorwerks clutch.

When was the lasttime you changedyour microfilter?

Product Focus: UUC Motorwerks clutches and flywheels 1

Product Focus: aFe Scorcher™ 2

New photo contest announced 2

Ask Bavarian Otto 3

Win $3,500 worth of great gear! 3

Poster: Three beauties 4–5

DIY: Installing shocks/coil-overs 6

DIY: Installing a performanceexhaust system 7

DIY: Replacing microfilters 7

Product Focus: Ultimate car cover 7

July specials 8

table of contents

© 2013 Bavarian AutosportParts, accessories & knowledge since 1974.

Rather than admit the design of the SACis in any way responsible for the failure,a dealer is likely to claim the problem is “driver abuse” (we hear it all the time)and install the same SAC clutch again.For about the same money, you can upgrade to a UUC Motorwerks perform-ance clutch. UUC clutches eliminate theSAC mechanism, restoring traditionalclutch feel with crisp, predictable engagement. Plus they exhibit a level of quality and performance beyond any-thing else on the market.

Here are three other reasons youshould upgrade to a UUC clutch:

1. Direct-fit. No special flywheel is required (though we do recommend theUUC Motorwerks lightweight flywheel forperformance applications).

2. Greater clamping force. Much bet-ter than the stock BMW clutch.

3. Lower cost. Already a great value, allUUC Motorwerks clutches and flywheelsare 10% off during the month of July. Install it yourself and you can save hun-dreds more in labor costs! We show youhow in our 2-part video (see below)...

Over the past 10+ years, many owners of manual transmission BMWs have experi-enced mushy clutch feel, inconsistent engagement and premature clutch wear. Thereason is quite simple: in the early 2000s, BMW introduced the infamous “SAC” (SelfAdjusting Clutch) design: as the clutch wears, a mechanism built into the pressureplate is supposed to keep the clutch pedal engagement point in the same location. But the SAC mechanism over- or under-adjusts thepressure plate and therefore causes the clutch to slip orburn out prematurely. These clutches have also beenknown to shift position, causing the release fingerson the pressure plate to slip off the plate, keeping1/3 of the pressure plate engaged at all times.The only fix is a complete clutch job.

On most BMWsand MINIs,changing themicrofilter iseasy to do.

And it makes abig difference in your

comfort and health. See page 7…

CUSTOMER #:KEYCODE:

Scan the QR code above or see it atblog.BavAuto.com/go/clutchrepair

Top: after 30,000 miles. (Yikes!) Bottom: new one.

Shown here: UUCStage 2 clutch kit for a 540i97 thru 03. This kit includes a light-weight aluminum flywheel; not all kits do.

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2 | shop online www.BavAuto.com Very simple installation. Relatively simple; your BMW may need to be raised.

To enter or for more info, go to BavAuto.com/photocontest or visit Facebook.com/BavarianAutosport.

The Bavarian Autosport photo contest gets a makeover.Enter online – vote for your favorites! This year we’ve made it even easier for you to share images of you pride-and-joy withhundreds of thousands of other BMW and MINI enthusiasts. Just go to our web site orFacebook page, fill out the entry form online and upload your photos for all the world tosee. Also new this year, we’re asking people to vote for their favorite photos to narrowthe field and ultimately help us choose the winners. Everybody’s entry will be seen (un-less it’s inappropriate – we will be screening). In addition to giving $100 certificates tothe winners, we’ll have monthly prizes based on voting and random drawings. Full de-tails can be found online. Here’s a list of the contest categories: ■ Classic (2002, 3.0, etc.)■ 1 series 08 on■ 3 series thru 83■ 3 series 84 thru 91■ 3 series 92 thru 98■ 3 series 99 thru 05■ 3 series 06 thru 12■ 3 series 13 on■ 5 series thru 81■ 5 series 82 thru 88■ 5 series 89 thru 96■ 5 series 97 thru 03

■ 5 series 04 thru 10■ 5 series 11 on■ 6 series thru 89■ 6 series 04 thru 11■ 6 series 12 on■ 7 series thru 87■ 7 series 88 thru 94■ 7 series 95 thru 01■ 7 series 02 thru 08■ 7 series 09 on■ 8 series■ SAV (X1, X3, X5, X6)

■ Modern Z (Z3, Z4)■ Exotic (507, M1, Z8, etc.)■ MINI 02 thru 06■ MINI 07 on■ Group (more than one)■ BMW/MINI in Spring■ BMW/MINI in Summer■ BMW/MINI in Autumn■ BMW/MINI in Winter■ BMW/MINI in motion■ BMW/MINI by landmark■ Artistic

Winner! Classic BMW: Mike Pollock, North Carolina, took this shot of a 19732002tii owned by RJ Sterenczak. Upgrades and modifications include front brakes from a 320i with vented rotors, Quaife differential, performance bushings and more.

For this photo, Mike received a $100 Bavarian Autosport savings certificate.

product focus

Add up to 53 hp and 80 lb-ft oftorque to your turbo BMW.aFe Power’s new Scorcher powermodule for BMW turbo engines al-ters the pressure sensor signals toincrease turbo boost to an optimumlevel throughout the entire RPMrange. You’ll enjoy greater perform-ance and improved throttle re-sponse across a broad power band,as well as reduced turbo lag. Theoverall effect is better drivability...and much more fun!

Actual gains will vary dependingon the year and model of yourturbo. The Scorcher is available formost BMW twin turbo enginessince 2007. For model-specific ap-plications, ask your advisor or visitour online store ar BavAuto.com.

Save! Buy an aFe Scorcher in July -get a free $50 savings certificate

good on any future purchase.

True tales from the test track:In April, we installed an aFe Scorcher (left) in our own Scott T.’s 2007 335i (above).

After the initial test drive, Scott wrote: “It took about 20 minutes to install. When wewere done, we had added 45 hp. The car was fast to begin with, but now it’s just sick.”

The forecast for July? It’s gonna be a Scorcher™!

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I smell gas... Dear Bavarian Otto,I have a 1993 325i. It has tons of performance enhancements installed. Nowwhen I drive it home from work and put it in the garage, it has a strong gassmell. It is not leaking gas onto the ground or under the hood. Thoughts?Otto replies:Without having the car to look at, I am at a disadvantage, but if you are ab-solutely sure there are no other leaks, I would suspect a clogged charcoalcanister. This canister collects the fumes from the fuel tank vent and storesthem until they are burned in the engine. It does require periodic replace-ment (every 100K miles), or if you or the previous owner were in the habit(as many of us are) of filling the fuel tank right up to the top of the fillerneck, the canister is likely saturated with fuel and should be replaced. Thelocation of the canister varies from model to model and is usually found inone of three places: under the hood, under the spare tire well or mountednear a rear wheel. It is cylindrical in shape with two hoses going to it. On

your year and model, the canister is mounted under thehood, on the inner fender of the driver's side. The Bentleyrepair manual provides detailed instructions on how to re-place the canister. There is a general overview of the proce-dure on our blog; to read it, use your smartphone to scanthe QR code at left or go to blog.BavAuto.com/go/charcoal.

My convertible top hesitates... Dear Bavarian Otto,The convertible top on my 2006 325ci hesitates as it moves to the up posi-tion. I think it’s low on fluid. Can you tell me the location of the reservoir?I’ll probably have to order some fluid, too.Otto replies:The E46 3 series convertibles with power tops were made from 2000 thru2006. They include 323ci, 323cic, 325ci, 325cic, 330ci, 330cic and M3.The convertible top hydraulic pump and fluid reservoir are located in the

driver side of the trunk area, behind the side trim panel.The procedure is detailed in the Bentley repair manual. Wehave posted an abbreviated version on our blog. To read it,use your smartphone to scan the QR code at left or go toblog.BavAuto.com/go/convertible-fluid. You can purchasethe fluid in our online store at BavAuto.com.

Over 304 years of BMW/MINI experience isyours for the asking – free!If you add up all the years the advisors at Bavarian Autosport have been working on BMWsand MINIs – and helping people like you work ontheirs – it totals well over 300 years. That’s a lot

of knowledge under one roof. And it’s yours for theasking. Have a question about your BMW or MINI?

Search Bavarian Otto’s knowledge base of nearly 1,000tech Q&As at blog.BavAuto.com, or call 800.535.2002.

from blog.BavAuto.comask “bavarian otto”

call 800.535.2002 | 3Specific tools needed; repair experience recommended. Experienced technicians only.

Shift happens, but only at red line... Dear Bavarian Otto,I just bought an 89 325is automatic. I notice that it won’t shift into the nextgear while accelerating – it will go right to the rev limit (6,000 rpm). If I letoff the gas slightly, it will then shift into the next gear. It does this for thefirst three gears. I tried adjusting the transmission cable to .020 per theBentley repair manual. Any advice on what to check next? Otto replies:The automatic transmission in your E30 3 series is known as the 4HP22.The 4HP versions were available in some late ’80s and early ’90s 5, 6, 7 and8 series models with electronic valve body control, called EH. These modelshave a switch or button on the console that allows choosing of standard,sport and manual shifting modes. These transmissions can have problemswith the electrical circuitry, switches, valve control solenoids and the trans-mission control unit (TCU). Non-EH versions are fully hydro-mechanical,with no electronic control of the valve body, so they do not have these prob-lems. We would suggest that your shifting trouble may be due to a stickingshift valve in the valve body. The first course of action is to perform a fluidand filter change. Additionally, in this case, we would suggest a secondfluid change be performed after running the first one for a day or so. If, aftera few hundred miles, there is no improvement, a rebuilt valve body may bein order. This can be changed without removing the transmission. Refer toyour Bentley manual for instructions.

21 prizes in all, with values ranging from $200–3,500.Prizes include Bilstein shocks, Eibach springs, aFe intake kit,Burger Motorsport “Juice Box”, UUC short shift kit, Cool Carbonbrake pads, Sprint Booster, $500 gift certificate and much more!

Tickets are $5 each or 5 for $20. 100% of ticket sales will go toSusan G. Komen for the Cure. The drawing will be held October6th at Show & Shine. (You do not need to be present to win –winners will be contacted October 7th.) For more details or topurchase tickets, visit BavAuto.com/komen or call 800.535.2002.

Win up to $3,500 worth ofgear in our charity raffle!

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shock replacement/coil-over kit install | exhaust install | microfilter replacementdo-it yourself

6 | shop online www.BavAuto.com Very simple installation. Relatively simple; your BMW may need to be raised.

DIY: Replacing shocks/installing a coil-over kit.

1. Safely raise the front of car, with suspen-sion hanging.

2. Remove the wheels.

3. Disconnect the upper end of the swaybar link from the shock/strut bracket. Notethat the through-stud for the link’s upper joint(as well as the lower) must be secured usinga 16mm to 18mm, thin, open-end wrench.This particular link is 16mm (fig. 1).

5. Set aside the mounting bracket for theABS sensor wire, brake pad sensor wire (leftside only) and brake fluid hose. Note that othermodels may have these hoses mounted in abracket that is affixed to the shock/strut hous-ing. In these cases, remove the wires andhose from the bracket.

6. If the vehicle has adaptive headlights (self-aiming), disconnect the sensor link from thecontrol arm or the sensor bell-crank arm. Thesensors may only be present on one side ofthe vehicle.

7. Place a support or jack under the lowercontrol arm to support the suspension as theupper strut mount nuts are removed.

8. Remove the three 13mm nuts that securethe upper mount to the body (strut tower),under the hood (fig. 3).

To read the rest of this article and watch the DIY video, go to

blog.BavAuto.com/go/coil–over.

Parts used:■ Shocks/struts or a coil-over kit (BavAuto.com)■ Stock or sport springs, if desired (BavAuto.com)■ Shock install kits (compression bumpers, spring pads, etc. – BavAuto.com)■ Upper strut and shock mounts (BavAuto.com)■ Strut & shock mount gaskets as required (BavAuto.com)■ Rear shock mount reinforcing plates (BavAuto.com)

Tools used:■ Bentley repair manual (BavAuto.com)■ Non-marring pry tools (BavAuto.com)

■ Spring compressor (BavAuto.com)■ SafeGrip gloves (BavAuto.com)

■ 13mm thru 18mm ½" drive socket & ratchet set■ 4mm thru 8mm Allen keys or bits (for ratchet use)■ 13mm thru 18mm combination wrench set■ Assorted flat and Phillips screwdrivers

Figure 3Figure 2

Figure 4

9. Gently lower the jack or support (fromstep 6) and lower the strut assembly. Pull thestrut assembly up and out of the hub/spindle.A helper may need to push down on thehub/spindle as you pull the strut upward. (fig.4) If the clamp is too tight for the strut to pullout, use a cold chisel or large flat-bladedscrewdriver as a wedge to open the clamp abit. Tap the wedge into the split in the clamp(from the top). This will widen the clamp andallow the strut to be removed.

10. Once removed from the hub/spindleclamp, remove the strut assembly from thewheel well area. Fig. 5.

4. Remove the strut mounting pinch-bolt. Thebolt goes through the strut mounting clamp onthe wheel hub/spindle assembly and has a nuton the opposite side. (Some models do not usenuts; the bolt threads into the clamp). Fig. 2.

Figure 5

11. Use a spring compressor to compressthe spring on the strut assembly until you cantell that the pressure has been relieved from theupper and lower spring seats.

12. Remove the upper shock/strut nut thatis at the top of the assembly, in the center ofthe upper mount. You can use the methodshown at blog.BavAuto.com/go/shock-nuts, oryou can use an impact gun. DO NOT use animpact gun for re-assembly!

Continued on our blog...

Does your BMW have over 50,000 miles? If so, you are likely a candidate for a freshset of shock absorbers. Unlike older domestic vehicles, BMWs do not typically startto act like a jack-in-the-box when the shocks are worn out. The degradation is agradual loss of dampening that may not be noticeable because you’ve gotten usedto it over time. But rest assured, installing new shocks will restore your BMW’s rideand handling to its past glory.

Replacing shocks is not terribly difficult and the only specialty tool you’ll need is aspring compressor, which we sell. During the replacement process, you may alsofind that the compression absorbers, dust boots, spring isolators and upper mountsneed to be replaced. All of these parts are included in the various shock installationkits we offer. What follows is a do-it-yourself (DIY) guide to shock and strut replace-ment. For this article we are using a BMW 3 series 99 thru 05 (E46). Other modelswill be similar but may have significant differences in access or procedure; we highlyrecommend having the appropriate Bentley repair manual for your BMW or MINI – itwill cover standard shock and spring replacement for your year and model, as wellas fastener torque values. This article will assume that the applicable Bentley man-ual is available for reference.

Note: Even though we are installing the Bilstein PSS-10 coil-over kit on this3 series, the procedures are the same as you would use for a standard shock/strutreplacement, as well as for the installation of sport/lowering springs.

Figure 1

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Most BMW and MINI owners are good about changing their engine’s air filter, but theyrarely change the cabin air microfilter. (If your response is, “I didn’t even know my BMW/MINI had a cabin air microfilter,” you’re not alone.) BMW and MINI recommend changingmicrofilters every 15,000 miles. Otto recommends once a year (more often if the vehi-cle is driven in “dirty air” areas). After you have installed the new microfilter, you’ll noticethat the car smells fresher and the AC works better. On our tech blog (address belowright) we have installation instructions forthe replacement of microfilters in all BMWand MINI models – some are video DIYs,some are step-by-step guides. In this articleand video, we are replacing the microfilterin a 2013 MINI Cooper Countryman S All4.

1. Note the microfilter cover forward of theglovebox in your MINI.

Continued on our blog...

product focus

call 800.535.2002 | 7Specific tools needed; repair experience recommended. Experienced technicians only.

shock replacement/coil-over kit install | exhaust install | microfilter replacement

DIY: Installing a performance exhaust system.

DIY: Replacing microfilters.Our Ultimate car cover: bestfit, best features, best value.

To read this article in its entirety and watch the DIY video, go to

blog.BavAuto.com/go/microfilter.

Figure 1

Installing a new muffler or exhaust system is a task that may seem intimidating at first, yet most BMW/MINI owners should be ableto complete the job in two to four hours. Most exhaust systems are either “bolt-on” (i.e. a direct replacement of the original part) or“cut-in”, where an exhaust pipe is given a simple cut and the new system slips over the cut end of the pipe. In both instances, thenew system hangs from the original mounting points, with the tips fitting neatly in the opening in the rear valance below the bumper.

In this article and video, we will show you a typical cut-in system installation. The only specialized tool that you will need is a pipecutter, which we offer. Follow along as we install a Scorpion performance exhaust on a 2007 335i. (At the end of the DIY video ofthis installation, you can also listen to a sound comparison of the stock exhaust vs. the free-flow Scorpion performance exhaust.)Let’s get started...

Big time protection in a small package – only from Bavarian Autosport!The list of our Ultimate car cover’s advantages is long: lighter in weight so it’s easier to puton/take off; snug, custom fit; packs up small to store easily in your trunk; removable, ad-justable cinch straps for added security in high winds; embroidered logo (not printed like others); anti-theft cable/lock kit included; backed by a Lifetime Warranty. And, oh yes... it’s on sale thru July 31st – normally $184.95–229.95, it’s now just $164.95–209.95.

Above: fits like a tailored suit. Top right: packs up small. Bottom right: clip-on straps for safety in high winds.

To read this article in its entirety and watch the DIY video, go to

blog.BavAuto.com/go/exhaust.

Parts used:■ Scorpion performance exhaust (BavAuto.com)■ Würth exhaust assembly paste (BavAuto.com)■ Rubber exhaust hangers as needed (BavAuto.com)

Tools used:■ MechanicAll penetrant and lubricant spray (BavAuto.com)■ Exhaust pipe cutter (BavAuto.com)■ SafeGrip gloves (BavAuto.com)■ 10mm thru 15mm 3⁄8" drive socket and ratchet set with various extensions■ 10mm thru 15mm combination wrench set■ Assorted flat-blade screwdrivers and pry-bars.

Note: We suggest that you enlist the aid of a helper to support the mufflers duringmeasurement, removal and installation.

Procedure:1. Safely raise the rear of the vehicle usingdrive-on ramps or a floor jack and jack stands.

2. Raise and support the new muffler assemblyjust below the original muffler. Align the hangingpoints on both systems. Mark the original exhaustpipe in a location that will allow two inches of pip-ing to be inserted into the new muffler’s piping...

Continued on our blog... Figure 1

Save! During the month of July, take10% off the price of any microfilterpurchased at Bavarian Autosport.

N313SummerNews_July13.lyt16-LG_Newsletter Template Update Aug 2012 6/6/13 4:23 PM Page 7

july specialsmoney-saving deals on gear you can use right now Sale ends July 31, 2013. Don’t delay - order today!

Scorpion performance exhausts.More horsepower and better sound.

Orig. $399.95–1399.95 now $359.95–1259.95

10% offAll coil-over kits. See page 6...Orig. $749.95–5999.95 now $674.95–5399.95

Billy Boat performance exhausts.Like a shot of adrenaline for your BMW.

Orig. $657.95–1894.95 now $592.15–1705.45

$50 certificateFree with purchase of aFe PowerScorcher.™ Power module for BMWturbo engines. See page 2...

P21S car care products. Includingthe #1 rated carnauba car wax!

Orig. $5.95–99.95 now $5.35–89.95

Smartwax. Products developed for pro-fessionals, now available for car owners.

Orig. $5.95–59.95 now $5.35–53.95

free shippingOn any set of four VMR wheels. Seven great styles to choose from, insizes from 18" to 20". Just $799.80–1399.80 set of 4 plus shipping FREE!

VMR 705VMR V701

10% offCabin air microfilters. Better com-fort, better health! See page 7...Orig. $19.95–117.95 now $17.95–106.15

10% offUUC Motorwerks clutch kits &lightweight flywheels. See page 1...Orig. $544.95–2649.95 now $490.45–2384.95

save $20Ultimate car cover. A Bavarian Autosport exclusive! See page 7...Orig. $184.95–229.95 now $164.95–209.95

save $5Custom-fit dash covers. Protectsagainst sun damage – covers cracks. Orig. $49.95–59.95 now $44.95–54.95

After

Before

VMR B3 VMR 721VMR 718

10% off Scorpion and B&BSee page 7...

10% off Smartwax and P21S

phone 800.535.2002 • fax 800.507.2002 • www.BavAuto.com

save $45-127Bavarian Autosport pre-paintedwings and spoilers. Just a few ex-amples shown – more at BavAuto.com.Orig. $299.95–849.95 setnow $254.95–722.45

Pre-painted trunk lip spoiler for 3 series 99 thru 05, 4 door and 3 series 00 thru 05, 2 door.

Pre-painted wing for 3 series 99 thru 05, 4 door.

Pre-painted M3-style rear wing with recessed centersection for 3 series 92 thru 98 (except ti).

VMR V710

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