Hopefully Afe will response to your email. What about picking up bew intake boots?
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Weird! I've installed numerous intakes from AFE and other brands in e46s and never really had this problem. I still think the air box is set just enough back to cause this. Do you still have the factory airbox? If so I would swap them out to see what happens. I've seen both the heatshield being bent just enough to cause alignment problems and the velocity stack mass air flow sensor not being 100 percent put together.
Just trying to help you out.
Mikeyb--no worries. I'll try to get to it tomorrow. I'll re-install the stock airbox and take some pics. I have a good friend flying in from Ohio staying with me and she leaves tuesday so if I don't have time to get to it before then I'll do it next week.
Thanks!
Hey Chris did you ever figure out what was causing this?
No I didn't. Haven't had time to really dig around under the hood here at school. Engineering school is kicking my butt with all the work. Since there is a slight crack in the upper boot around the sensor input I may be switching my boots for some nice stett boots here in the next few months. I'll see if that fixes it. Other than that I can't think of too much else to do since there's not much wiggle room in there.
Wish I had found this thread earlier, probably irrelevant by now but I had the same issue. With me, the wiring harness that sits next to the intake boot near where the boot connects to the AFE intake can get stuck behind the boot squishing it. By moving the wiring harness in front of the boot you remedy the problem. Stett sells silicon boots; I may be getting them because the AFE likes to squash things and they are a lot stronger.
EDIT: Upon further inspection, I've already replied to this thread...lol
haha thanks for the reply though. On mine, the harness does sit in front of the boot. I think the aFe intake just pushes it back further and the boot isn't strong enough to push back. I'm hoping a silicone boot will fix it because I don't think there's any other option.