First few pics are of my CAI that I'm using for a mockup until I get one made out of aluminum. The other ones are of my custom under drive waterpump pulley and tension pulley setup. Enjoy!
Under all the reflex is 4">3.5" reinforced silicone reducer, about 8" of ZZP tubing, 1/4" lexin box, and a 4" ID x 9" *&B filter. The compressor on '92-'95 would not fit with the 4" ID tubing but would fit with 3.5" ID tubing. This was not a big deal for me because I relocated the compressor to fit with my race battery in the same space a stock battery would fit / be.
The box is completely (100%) sealed by round rubber door seal. The SE (smaller) style windshield washer tank was used to fit the bigger box and to save weight. The headlight squirters are still operational (even though I don't use them) by tapping the bottom of the tank and running the 2nd pump inline as an inline pump.
Everything is has one layer of reflex.
Excess material was removed from behind the head light to allow for more surface area for the "ram air affect" when the headlight is out.
As you can see the box can fit the 4" ID x 9" filter with ease. Also see how deep the box is - this could help the Series 2 guys with placement of the PCM. The EVAP canistor was dropped 2.5" lower until I completly remove it.
A custom under drive WP pulley (5.5") Ryan CNC'd up for me. It is 1 lb. less then stock water pump pulley. An under drive water pump pulley will fit with out grinding the engine bracket but an oversized tension pulley (4"0) will not fit with it. If you want to run a lightweight water pump pulley (5") the weight difference will further improve, clarence with the side engine bracket is a non-existent, and an oversized tension pulley (4") can be used.
Showing plenty of space between the stock tension pulley and the under drive water pump pulley. Also it shows that an under drive water pump pulley WILL fit without grinding the engine bracket. Even though you may want to just for some peace of mind.
I've run with both setups - stock tension pulley and an oversized (4"). The stock tension pulley had less belt wrap but you could get more tension with a smaller belt. The oversized tension pulley (4") gave more belt wrap but less tension. When trying to run the oversized tension pulley (4") with more tension (smaller belt), it created about the same (if not the same) amount of belt wrap as the stock tension pulley. In my testing I had no belt slip running a stock tension pulley with less belt wrap and more tension.
This shows that an oversized tension pulley is not needed on a '92-'93 M62 with a smaller pulley - You just have to make sure to buy the right sized belt. Running this way will save weight and rotating mass.