2009-2013 BMW X5 Dual Air Intake for Diesel M57 Turbo Inlet

Dual Intake

This was a project that took over 1 year to complete. I want to recognize Austin Chandler for helping with the R&D as well as Isaac Fischer at Fischer Motor Works for providing advice and filters when I was selling these in the past. Due to popular demand, I am listing here for anyone to use for free. 

Intake print settings
100% infill
overhang threshold 16 degrees, support everywhere
2 perimeters
Print with PETG or ABS with carbon/glass fiber only

Driver side intake reduce by 0.5% in the slicer. No idea why it turned out larger than the others.

I usually do 0.28mm line height but can also do 0.2, just takes a long time. I prefer using 3dxtech ABS with glass fiber, least amount of warp, but the strongest interlayer prints are PETG, but they can deform over time in the heat, that being said mine lasted a year without issue but I’m in Connecticut so not as hot during the summers.

Parts list (can get almost all from Amazon):

• 242 Viton O-Ring, 90A Durometer, Round, Black, 4" ID, 4-1/4" OD, 1/8" Width
• 3.0" to 3.5" reducing silicone coupler (if using turbo inlet, use 3.5" to 3.5")
• K&N RC-5000 x2 (4" oval inlet)
• Epoxy or glue
• Optional: Filter socks, not very effective IMO. During heavy rain the filters still get wet as they are in the grill. 

Turbo Inlet

Improved flow and sizing compared to stock. Also removes the annoying “Kazoo whistle” sound on the x5. Should also fit the 335d.

Turbo inlet should be SLS printed in CF Nylon for stability and heat resistance. Anything less WILL MELT. ONLY fits with this intake or possibly other intakes like fisher motor works. Original part from BMW is made from PA12 or 6 Nylon. The No CCV is for people who deleted the crank case ventilation or it vents to atmosphere. The file with the CCV deletes the CCV heater, which shouldn't be an issue for most people (European models do not include the CCV heater, more for Canada and cold places). May cause a check engine light.

• You will need two 47mmx50mmx1.5mm O-rings (Fluorine Rubber O-Rings) or use gasket maker to seal it to the turbo.
• 3.5" to 3.5" intake coupler if using the upgraded turbo inlet with this intake.

To install, remove old inlet, take out the existing screw assembly and transfer to the new inlet. Add the orings or gasket maker.

All parts are here for informational purposes only, not for use on road cars or race cars. Utilizing these parts may result in fatal engine damage (for example a print fails and gets sucked into the turbo) and I am not responsible for this.

Coffee donations if you want :) Venmo: @adamsmith88