BMW 11617525752 Intake Manifold

To remove the intake manifold, first remove the heater/ventilation inlet air ducting from the rear of the engine compartment by rotating fasteners counterclockwise and removing the cabin filter cover, filter housing, and inlet ducting. Depressurize the fuel system, disconnect the negative battery terminal, and remove the fuel rail and injectors. For M56 engine models, special tools and expertise at a BMW dealership may be required for fuel rail removal. Open the jump-starting connection point and disconnect the starter motor supply lead. Disconnect the VANOS solenoid wiring connector, the breather hose from the valve cover, and the hose on the base of the tank venting valve. Release any wiring harnesses from retaining clips on the manifold and support bracket. Cut off the hose clamp on the power brake booster vacuum hose above the manifold and disconnect the plastic tube from the rubber hose. Remove the nuts securing the manifold to the cylinder head and the nut securing the manifold support bracket to the cylinder block, and withdraw the manifold while feeding the starter motor cable through it. For M54 engines, disconnect the fuel pressure regulator vacuum hose and recover the seals. Check and replace seals if necessary, and then install the manifold following the reverse of removal.For the exhaust manifold, follow similar steps to remove the heater/ventilation inlet air ducting as mentioned earlier. Raise the front of the vehicle and support it on jackstands, remove the engine splash shield and the front axle reinforcement plate/bar bolts. Attach an engine hoist or support fixture to the lifting eye at the front of the cylinder head to take the weight off the engine. Underneath the vehicle, remove the right-hand engine mounting with the support arm. Remove the plastic cover over the injectors by prying out plastic caps and removing screws. Trace back the wiring from the oxygen sensor and remove the nuts/bolts to separate the exhaust pipe from the manifold. Use the engine hoist to raise the engine slightly, then remove the front exhaust manifold and rear exhaust manifold while taking care not to damage the oxygen sensors. Discard the gaskets. For installation, apply anti-seize high-temperature grease to the manifold studs, replace the manifold gaskets, and tighten the manifold nuts to the specified torque. Tighten the front axle reinforcement plate bolts to the specified torque as well.

When replacing the intake manifold, the hood should be opened, and great care should be taken to disconnect the negative terminal of the battery, after reading the battery disconnection cautions. Then, take off the air cleaner housing and fresh air ducts and the brace from the strut towers as well as the housing of the interior ventilation microfilter. Unfortunately, the heater runs behind the left partition wall, so for this one, you will need to first take the rubber seal off the top of the heater bulkhead, then pull the vacuum line from the power brake booster, disconnect the line from the power brake booster, and then take both the line and the wiring. Take the plastic locks off and then slide the trim slightly ahead and then toward the up direction to take out the partition wall. Located on the left side and underneath the intake manifold, harness holder must be opened and electrical connector disconnected; both crankcase breather connections must be released as well. Carry on along the leftside and under side by unpinning electrical connectors, removal of fasteners along with slipping off of the engine wiring harness off the intake manifold. Locate the electrical connector at the oil pressure switch and remove it then above the engine remove the connectors to the oxygen sensor and un-couple the wiring harness from its holder and mark the connectors of the oxygen sensor to facilitate reconnection. Disconnect fasteners, which are located above the engine, and lift the intake manifold about 10 cm (4 in). From below remove the electrical connector and loose the fuel tank vent line at the back side of the throttle valve assembly, after that lift the intake manifold off the engine. To avoid the debris entering into the engine intake avoid opening intake ports. Removal is the process that works vice-versa of the installation; care is however taken to fit the seals.

Spin the hood into the servicing position, and unscrew the negative terminal on the battery with every caution indicated under the battery disconnection wordings. Take off the air cleaner housing with fresh air ducts and the brace at the strut towers, and also the housing for the interior air quality improving microfilter. To remove the left partition wall it is necessary to remove the rubber seal from the upper part of the heater bulkhead, to unhook the vacuum line for the power brake booster with disconnecting it from the booster, and withdrawing it together with the electric wires. Unlock the plastic clips on top and rear, push slightly forward on the trim and then pull the partition wall up. After that, pull the engine design cover and, being over the engine, unscrew the B+ lead bracket, resonance valve electrical connector, oxygen sensor connectors, electrical connector for the intake air temperature sensor and manifold vacuum line, noting the position of the oxygen sensor connectors to facilitate reassembly. On the depression of the cylinder head, remove the engine vent hose from the cylinder head cover by using its spring clip and remove the electrical connector of VANOS solenoid. On the fuel injectors separate the wire lock clip in one corner with the help of a small screwdriver and then remove the two main harness hold-down and raise the whole harness. Below the intake manifold, unscrew the electrical connector at the fuel tank venting valve, unscrew the hose at the quick disconnect fitting and then pull of the valve from the manifold. Remove the electrical connector of the idle speed control valve and also remove the throttle housing. Remove the Schrader valve cap on the fuel rail, and using a wrench on the top of the Schrader valve, open them to release pressure, then, turn the cap of the fuel tank, blow compressed air back into the fuel tank for only 5 seconds. At the rear of manifold, insert the unlocking pin by using the special tool to release the locking clip fitted internally into the fuel line connection end of the fuel supply line from fuel rail. On the underside of the car, and also unbolt the left engine mounting bracket and remove the knock sensor connector behind the manifold base, then the four nuts between the manifold lower support and the intake manifold mounting nuts. Ease out the intake manifold from the cylinder head, plan for any electrical connection or hoses that may be in the way and if there are any, be careful not to trap them and make sure to block the open intake ports to avoid droppings into the engine. The removal process is just the reverse of installation while there are new fuel injector seals and the condition of the intake manifold gaskets must be examined before the installation as well, they must be replaced if worn. Check the rubber gasket at the throttle housing and the idle speed control valve and change, if necessary, clean and smear the O-ring at the MAF sensor and air filter housing with assembly fluid and correctly orientate the arrow on the throttle link harness connector and plug connectors before fully tightening.