BMW Cars 1999-06

Intake Manifold 2

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Removal & Installation



E36 Models

BMW uses fasteners with 7 x 1.0mm threads in many areas. Most of these fasteners use an 11mm wrench size. As 7mm fasteners are not as readily available as 6 x 1.0mm and 8 x 1.25mm fasteners, locating 7mm fasteners and thread repair kits could be a challenge. Take special care to not damage, loose or misplace fasteners when performing repair procedures. Carefully organize the fasteners as they are removed. If a 7 x 1.0mm nut is needed and not readily available, a standard size 1 / 4 x 20 or 1 / 4 x 28 nut can be threaded using a 7 x 1.0mm tap as an alternative emergency measure.

4-Cylinder Engines

The intake manifold is a two piece manifold. The throttle body is attached to the upper intake manifold and the positive crankcase breathing system is "sandwiched" between the upper and lower intake manifolds. Removing the manifold is not extremely difficult, however a bit time consuming. Because of the number of pieces that must be removed to access the manifold, make sure to label all cables, electrical connectors, fuel, coolant and breather hoses. Make a drawing of the routing of all cables, hoses and wiring harnesses.

  1. Relieve the residual fuel system pressure. For details refer to Section 5.
  2.  
  3. Note the radio security code and disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant into a suitable container.
  6.  
  7. Label and detach the electrical connector in the inlet duct for the mass airflow sensor between the air filter housing and the throttle body.
  8.  
  9. Loosen the intake air duct clamp at the throttle body and remove the upper air filter housing, mass air flow sensor and intake duct.
  10.  
  11. Remove the cover for the accelerator cable(s).
  12.  
  13. Label and disconnect the throttle cable and if equipped, the cruise control cable as follows:
    1. Using a suitable small flat-bladed prytool, carefully release the throttle cable barrel from the plastic clip of the linkage arm.
    2.  
    3. Move the throttle body linkage arm enough that the plastic retaining clip can be squeezed together and pressed out of the arm, the slide the cable sideways through the opening in the linkage arm.
    4.  
    5. Remove the plastic clip and place aside.
    6.  
    7. Carefully slide the cable out of the rubber seat in the throttle cable mounting bracket.
    8.  
    9. Remove the rubber seat from the mounting bracket and slide the cable through the bracket and place aside. If equipped with cruise control, repeat the procedure for the second cable.
    10.  

  14.  
  15. Label and disconnect the hoses and electrical connectors from the throttle body.
  16.  
  17. Using a small suitable flat-blade prytool, loosen the brake booster hose clamp on the right side of the manifold by inserting the prytool into the crimped portion of the clamp and pressing on the prytool while moving side-to-side to release the tension on the clamp. Remove and plug the hose.
  18.  
  19. Using an 11mm ( 7 / 16 inch) wrench, loosen but do not remove the upper manifold-to-support bracket bolts on both sides of the manifold, then remove the bolt and two nuts that secure the upper manifold to the lower manifold just to the left of the brake booster hose fitting.
  20.  
  21. Label and remove the coolant hoses and breather hose to the positive crankcase ventilation assembly mounted at the lower manifold opening, and remove the assembly. Make sure the openings in the lower manifold remains covered with clean shop towels.
  22.  
  23. Using a 10mm wrench, remove the dipstick tube mounting bolt and remove the dipstick, along with the guide tube and O-ring. Plug the hole in the oil pan with a clean shop towel. Inspect the O-ring and replace if brittle or damaged. Upon reassembly, lubricate the O-ring with a light coat of fresh engine oil.
  24.  
  25. Label the electrical connectors for the engine wiring harness and note the location and routing of the fuel lines.
  26.  
  27. Remove the fuel rail complete with the fuel injectors and place aside. For specific details, refer to fuel injector removal in Section 5.
  28.  


NOTE
Make sure when removing the metal fuel line for the fuel injector fuel rail, to not loose or damage the O-ring.

  1. Plug the fuel feed and return lines.
  2.  


WARNING
To avoid debris from entering the injector ports, If compressed air is available, using an air nozzle, and wearing eye protection, carefully spray compressed air around the base of the injectors. If excessive debris exists, spray the base of the injectors with an evaporating brake cleaner and spray again with compressed air. If compressed air is not available, spray the brake cleaner to clean as best as possible.

  1. Cover the fuel injector ports in the manifold with suitable plugs or clean shop towels to prevent debris from entering the intake ports.
  2.  
  3. Locate and remove the two bolts with a 13mm wrench at the front and rear lower portion of the intake manifold that secure the manifold to the support bracket.
  4.  
  5. Using an 11mm universal socket attached to a long extension and ratchet, loosen but do not completely remove the intake manifold-to-cylinder head mounting bolts starting from the outside nut and working inward.
  6.  
  7. To reduce the chance of loosing one of the 7 x 1.0mm manifold nuts, place a long retrieval magnet beneath the socket to catch the nuts as they are removed from the cylinder head intake port studs.
  8.  
  9. Lift the manifold off just enough to clear the mounting studs and feed the fuel lines between the intake runners and set aside to access the remaining engine wires, including those for the starter motor and alternator.
  10.  
  11. Label and remove the wires and carefully remove the harness up through the center of the manifold and place aside.
  12.  
  13. Lift the manifold out of the engine compartment. Cover the open intake ports with clean shop towels to prevent debris from entering.
  14.  



Click image to see an enlarged view

Fig. Loosen the booster's hose clamp by using a suitable prytool inserted into the opening and moving the tool side to side



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Fig. Once loosened, slide the clamp up the hose and disconnect the hose



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Fig. Removing the upper intake manifold from the lower intake manifold. Note, throttle body removed for photo



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Fig. The upper intake manifold has a support bracket on the left and right side



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Fig. Always cover an exposed intake opening with clean shop towel



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Fig. The crankcase breather system is located between the upper and lower manifolds and has a breather hose and two small coolant hoses



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Fig. The dipstick tube mounting bracket is secured to the lower intake manifold



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Fig. The engine wiring harness electrical connectors should be labeled for correct reassembly



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Fig. Use a line wrench on fuel line flare nut. Make sure to inspect the O-ring when removing this fuel line



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Fig. The fuel rail is held to the manifold with two bolts



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Fig. Protect the valve cover with a soft shop towel when easing the fuel rail away from the intake manifold



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Fig. Once the injectors are released from their ports, lift the fuel rail away from the manifold, leaving the breather hoses attached



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Fig. The lower intake manifold-to-support bracket bolts are located below the intake runners for cylinder Nos. 1 and 4-M44 engine shown



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Fig. The lower intake manifold-to-support bracket bolt under intake runner No. 4 is shown using a small inspection mirror



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Fig. A long handled retrieval magnet is placed under the socket to catch the manifold nut once it is loosened



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Fig. As the socket is pulled away from the stud, the magnet attracts the nut



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Fig. As you pull the socket away, the mounting nut remains on the magnet preventing any chance of being lost or dropped



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Fig. Lift the lower intake manifold just enough to clear the studs so the remaining wires can be disconnected



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Fig. The engine wiring harness is routed through the lower intake manifold runners



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Fig. With the lower manifold placed aside, the starter motor electrical connectors are easily accessed



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Fig. Peel back the rubber boot on the alternator and remove the wires



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Fig. Once all of the wires are disconnected, the harness can be fed up through the lower intake manifold



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Fig. Once fed through the manifold, place the wires aside



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Fig. With the wires places aside, the manifold is ready to be completely removed

To install:

  1. Installation is in reverse order of removal making note of the following points.
  2.  
  3. Replace all intake manifold gaskets with new gaskets.
  4.  
  5. Tighten and torque the intake manifold-to-cylinder head nuts evenly working from the inside outward, to the following specifications:

    M6: 88.5 inch lbs. (10 Nm)
     
    M7: 11 ft. lbs. (15 Nm)
     
    M8: 16 ft. lbs. (22 Nm)
     

  6.  
  7. Inspect the following O-rings and replace as necessary.

    Dipstick
     
    Fuel injector
     
    Dipstick guide tube
     
    Fuel feed line-to-fuel rail
     

  8.  
  9. Lubricate all O-rings with a light coating of fresh engine oil before reassembling.
  10.  
  11. Upon completion check for any fluid or vacuum leaks and repair as necessary.
  12.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the residual fuel system pressure, as outlined in Section 5.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the coolant from the radiator into a sealable container.
  8.  
  9. Remove the fastener for the throttle cable cover and pull the cover forward and off, then unclip the cable and pull the cable out with the rubber holder.
  10.  
  11. Pull the vacuum fitting from the brake booster and plug the openings.
  12.  
  13. Remove the engine and intake manifold covers, remove the bolt holding the ground strap on the front lifting eye and reinstall the bolt.
  14.  
  15. Remove the bolts holding the ignition coil wire harness plug plate. Be careful not to damage the rubber seals. Take off the ignition coil electrical plugs, then remove the plug plate complete with the electrical leads.
  16.  
  17. Remove the cylinder head vent hose and remove the air temperature sensor plug. Remove the tank venting hose and the coolant hoses from the throttle body. Remove the throttle valve switch connector.
  18.  
  19. Unclip the idle speed control valve mounted on the manifold, then disconnect the fuel hoses from the feed and return lines.
  20.  
  21. Remove the hardware holding the intake manifold to the cylinder head. Remove the intake manifold taking care not to drop anything into the exposed ports. Cover the exposed ports with clean shop towels.
  22.  

To install:

  1. Install the manifold onto the engine after cleaning the mating surfaces of both components and tighten the manifold bolts evenly from the middle outward, to the following specifications:

    M6: 88.5 inch lbs. (10 Nm)
     
    M7: 11 ft. lbs. (15 Nm)
     
    M8: 16 ft. lbs. (22 Nm)
     

  2.  
  3. Install the remaining components in the opposite order from which they were removed.
  4.  
  5. Check and top off all fluid levels as necessary.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Check for any fluid leaks.
  10.  

M44 1.9L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Fuel system pressure
     
    Negative battery cable
     
    Upper manifold section
     
    Rear mounting bracket and remove the coolant hose
     
    Front mounting bracket and disconnect the holder for the preheater
     
    Mounting bolts and lift off the upper manifold section, then the hose from the fuel pressure regulator
     
    Plug plate off the fuel injectors and the wire holding clamp
     
    Injection pipe with the fuel injectors attached, then remove the lower manifold section

    Click image to see an enlarged view

    Fig. Upper intake manifold and support bracket mounting bolt locations-M44 1.9L engines

     

  4.  

To install:

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Fig. Be sure the hollow bushings (1) are properly installed-M44 1.9L engines



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Fig. Check the dowel sleeves (1) for damage and correct installation position-M44 1.9L engines

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 88 inch lbs. (10 Nm)
     
    7mm fasteners: 11 ft. lbs. (15 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     

  2.  

M50/M52/S50 Engines
  1. Disconnect the negative battery cable and drain the coolant to a level below that of the throttle housing. Unscrew the fastener from the throttle cable cover and pull the cover forward and off. Unclip the cable and pull the cable out with the rubber holder.
  2.  
  3. Pull the vacuum fitting from the brake booster and plug the openings.
  4.  
  5. Remove the engine and intake manifold covers. Unscrew the bolt holding the ground strap on the front lifting eye. Replace the bolt before lifting the engine.
  6.  
  7. Unscrew the 2 bolts holding the plug plate and pull off the plug plate. Be careful not to damage the rubber seals. Take off the ignition coil electrical plugs. Remove the plug plate complete with the electrical leads.
  8.  
  9. Remove the cylinder head vent hose and pull off the air temperature sensor plug. Remove the tank venting hose and the throttle heating hoses from the throttle body. Remove the throttle valve switch plug. Unclip the idle speed control valve mounted on the manifold. Disconnect the fuel hoses from the pipes.
  10.  
  11. Unscrew the hardware holding the intake manifold to the cylinder head. Remove the intake manifold taking care not to drop anything into the exposed ports.
  12.  

To install:

  1. Install the lower manifold section onto the engine after cleaning the mating surfaces of both components. Tighten the manifold bolts evenly from the middle out to either end.
  2.  
  3. Install the remaining components in the opposite order from which they were removed.
  4.  
  5. Connect the negative battery cable, cycle the ignition ON and OFF several times to allow fuel pressure to build. Each time allow the ignition to remain ON for 5-7 seconds.
  6.  
  7. Check for fuel leaks.
  8.  

M52 2.5L, 2.8L, And S52 3.2L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Fuel system pressure
     
    Negative battery cable
     
    Coolant
     
    Throttle cable cover and throttle cable with the rubber holder
     
    Vacuum fitting from the brake booster and plug the openings
     
    Engine and intake manifold covers, remove the bolt holding the ground strap on the front lifting eye and reinstall the bolt
     
    Bolts holding the ignition coil wire harness plug plate. Be careful not to damage the rubber seals. Take off the ignition coil electrical plugs, then remove the plug plate complete with the electrical leads.
     
    Cylinder head vent hose and remove the air temperature sensor plug. Remove the tank venting hose and the coolant hoses from the throttle body. Remove the throttle valve switch connector.
     
    Idle speed control valve mounted on the manifold, then disconnect the fuel hoses from the feed and return lines
     
    Hardware holding the intake manifold to the cylinder head. Remove the intake manifold taking care not to drop anything into the exposed ports.
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 88 inch lbs. (10 Nm)
     
    7mm fasteners: 11 ft. lbs. (15 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     

  2.  

M54 Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Fuel system pressure
     
    Negative battery cable
     
    Coolant
     
    Throttle cable cover and throttle cable with the rubber holder
     
    Vacuum fitting from the brake booster and plug the openings
     
    Engine and intake manifold covers, remove the bolt holding the ground strap on the front lifting eye and reinstall the bolt
     
    Bolts holding the ignition coil wire harness plug plate. Be careful not to damage the rubber seals. Take off the ignition coil electrical plugs, then remove the plug plate complete with the electrical leads.
     
    Cylinder head vent hose and remove the air temperature sensor plug. Remove the tank venting hose and the coolant hoses from the throttle body. Remove the throttle valve switch connector.
     
    Idle speed control valve mounted on the manifold, then disconnect the fuel hoses from the feed and return lines
     
    Hardware holding the intake manifold to the cylinder head
     
    Intake manifold taking care not to drop anything into the exposed ports
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 88 inch lbs. (10 Nm)
     
    7mm fasteners: 11 ft. lbs. (15 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     

  2.  

M60/M62 Engines
  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Remove the center cover from the cylinder head cover.
  4.  
  5. Loosen the hose clamps on the idle speed control and the throttle valve assembly.
  6.  
  7. Disconnect the plug on the mass air flow sensor.
  8.  
  9. Unclip and remove the upper section of the air cleaner assembly along with the mass air flow sensor.
  10.  
  11. Remove the right hand cover from the cylinder head cover.
  12.  
  13. Raise and safely support the vehicle. Disconnect the plug for the oil level switch. Lower the vehicle.
  14.  
  15. Disconnect the plugs for the ignition coils.
  16.  
  17. Disconnect both knock sensors (For cylinders 1 and 2 along with 3 and 4), and the pulse sensor.
  18.  
  19. Disconnect the intake air temperature sensor, throttle valve potentiometer and the idle speed control.
  20.  
  21. Disconnect the diagnosis plug and the engine plug.
  22.  
  23. Unscrew the ignition coil ground wire, located near the rear engine lifting eye. Disconnect the temperature sensor (black) for the temperature gauge, and the temperature sensor (white) for the DME.
  24.  
  25. Remove the four bolts for the holder of the intake manifold cover. Remove the holder.
  26.  
  27. Disconnect and remove the throttle cable.
  28.  
  29. Remove the left hand cover from the cylinder head cover.
  30.  
  31. Disconnect the ignition coil electrical connectors.
  32.  
  33. Disconnect both knock sensors (For cylinders 5 and 6 along with 7 and 8), and the camshaft sender.
  34.  
  35. Disconnect the coolant expansion tank plug and spill hose. Remove the two mounting bolts, and move the tank aside.
  36.  
  37. Disconnect the oil pressure switch electrical connector and remove the wiring.
  38.  
  39. Remove the screws for the wiring ducts on the cylinder heads.
  40.  
  41. Disconnect the vacuum hoses on the radiator, and loosen the hose clamp. Pull the vacuum hose off of the brake booster.
  42.  
  43. Remove the tank vapor venting hose off of the throttle valve assembly.
  44.  
  45. Disconnect the fuel feed and return lines.
  46.  
  47. Remove the hose off of the end cover on the back of the manifold.
  48.  
  49. Remove the seven mounting bolts, and pull off the end cover together with the pressure regulating valve straight back to prevent damaging the vent pipe.
  50.  
  51. Remove the five intake manifold bolts, and remove the intake manifold upwards.
  52.  

To install:

  1. Scrape the gasket off of the manifold and the cylinder head. Replace the gasket, and position the intake manifold. Install the mounting bolts. Torque the bolts to 14-17 ft. lbs. (20-24 Nm).
  2.  
  3. Check and replace the seal and gasket for the end cover, if necessary. Position the end cover and install the mounting bolts. Torque the M8 bolts to 14-17 ft. lbs. (20-24 Nm), and the M6 bolts to 7 ft. lbs. (10 Nm).
  4.  
  5. Install the hose onto the end cover on the back of the manifold.
  6.  
  7. Connect the fuel feed and return lines.
  8.  
  9. Install the tank vapor venting hose onto the throttle valve assembly.
  10.  
  11. The balance of installation is the reverse of the removal procedure.
    WARNING
    Mixing up the knock sensor connectors will lead to engine damage.

  12.  
  13. Connect negative battery cable.

    Click image to see an enlarged view

    Fig. Connectors: 1- Diagnosis plug, 2- Engine plug-M60/M62 engines

  14.  

M62 4.4L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Fuel system pressure
     
    Negative battery cable
     
    Center cover from the cylinder head cover
     
    Hose clamps on the idle speed control and the throttle valve assembly
     
    Plug on the mass air flow sensor
     
    Upper section of the air cleaner assembly along with the MAF sensor
     
    Right-hand cover from the cylinder head cover
     
    Plug for the oil level switch
     
    Connectors for the ignition coils
     
    Both KS, for cylinders 1 and 2 along with 3 and 4, and the pulse sensor
     
    IAT sensor, TVS and the ISC valve
     
    Diagnostic connector from the mounting bracket and disconnect the engine wiring connector
     
    Ignition coil ground wire, located near the rear engine lifting eye, then the temperature sensor (black) for the temperature gauge, and the temperature sensor (white) for the Digital Motor Electronics (DME)
     
    4 bolts for the intake manifold cover, and remove the holder
     
    Throttle cable
     
    Left-hand cover from the cylinder head cover
     
    Ignition coil electrical connectors
     
    Both KS and the camshaft reference sender
     
    Coolant expansion tank plug and overflow hose, then remove the 2 mounting bolts, and move the tank aside
     
    Oil pressure switch electrical connector and remove the wiring
     
    Fasteners for the wiring ducts on the cylinder heads
     
    Vacuum hoses on the radiator, and loosen the hose clamp. Pull the vacuum hose off of the brake booster.
     
    Tank vapor venting hose from the throttle valve assembly
     
    Fuel feed and return lines
     
    Hose off of the end cover on the back of the manifold
     
    Mounting bolts, and remove the end cover together with the pressure regulating valve straight back to prevent damaging the vent pipe
     
    Intake manifold
     

  4.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 88 inch lbs. (10 Nm)
     
    7mm fasteners: 11 ft. lbs. (15 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)

    Click image to see an enlarged view

    Fig. Diagnosis connector (1) and engine connector (2) locations-M62 4.4L engines

     

  2.  

 
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