BMW 11617559523 Intake Manifold

To remove the intake manifold on a 2.0L engine, start by disconnecting the negative battery cable. Then, remove the engine cover, strut tower crossbrace, and sound insulator. Disconnect the wiring harness clips and move the harness out of the way. Remove the PCM control unit, release the quick-connectors for the fuel tank vent valve, and disconnect the electrical connectors to the fuel tank vent valve and throttle valve. Remove the charge air cooler hose and the intake plenum mounting nuts. Install the new intake plenum gaskets and tighten the nuts in stages. For a 3.0L engine, remove the fuel injectors and air filter housing. Disconnect the wiring plugs from the throttle body/manifold and release the wiring harness/cables from the retaining clips/bolts. Disconnect the breather hose from the manifold and remove the manifold retaining bolts. Lift the manifold and disconnect the hose on the base of the tank venting valve. Disconnect any hoses or wiring harnesses from the retaining clips on the manifold and support bracket. Remove the manifold from the cylinder head and check the condition of the seals. Replace them if necessary. To remove the exhaust manifolds on a 3.0L engine, raise the front of the vehicle and remove the engine splash shield. Remove the nuts securing the manifold outlets to the exhaust system and disconnect the electrical connectors for the oxygen sensors. Remove the cover over the ignition coils and the coolant expansion tank. Remove the rear and front exhaust manifolds, taking care not to damage the oxygen sensors. Discard the gaskets. When installing the exhaust manifolds, apply anti-seize high-temperature grease to the manifold studs and always replace the gaskets. Tighten the manifold nuts to the specified torque.

To remove the intake manifold on a 2.0L engine, start by disconnecting the negative battery cable. Then, remove the engine cover, strut tower crossbrace, and sound insulator. Disconnect the wiring harness clips and move the harness out of the way. Remove the PCM control unit, release the quick-connectors for the fuel tank vent valve, and disconnect the electrical connectors to the fuel tank vent valve and throttle valve. Remove the charge air cooler hose and the intake plenum mounting nuts. Install the new intake plenum gaskets and tighten the nuts in stages. For a 3.0L engine, remove the fuel injectors and air filter housing. Disconnect the wiring plugs from the throttle body/manifold and release the wiring harness/cables from the retaining clips/bolts. Disconnect the breather hose from the manifold and remove the manifold retaining bolts. Lift the manifold and disconnect the hose on the base of the tank venting valve. Disconnect any hoses or wiring harnesses from the retaining clips on the manifold and support bracket. Remove the manifold from the cylinder head and check the condition of the seals. Replace them if necessary. To remove the exhaust manifolds on a 3.0L engine, raise the front of the vehicle and remove the engine splash shield. Remove the nuts securing the manifold outlets to the exhaust system and disconnect the electrical connectors for the oxygen sensors. Remove the cover over the ignition coils and the coolant expansion tank. Remove the rear and front exhaust manifolds, taking care not to damage the oxygen sensors. Discard the gaskets. When installing the exhaust manifolds, apply anti-seize high-temperature grease to the manifold studs and always replace the gaskets. Tighten the manifold nuts to the specified torque.

Remove fasteners above the engine, then raise the intake manifold approximately 10 cm (4 in). From underneath, disconnect the electrical connector and release the fuel tank vent line behind the throttle valve assembly before raising and removing the intake manifold.

At high engine speeds, both DISA valves open, utilizing pressure peaks ahead of the closing intake valves and routing the intake air mass through resonance, overflow, and manifold runners.

The installation of the intake manifold is the reverse of removal, using new fuel injector seals, checking the condition of the intake manifold gaskets, and replacing them if necessary. Inspect the rubber seals at the throttle housing and idle speed control valve, replacing them as needed, and coat the O-ring seal between the mass airflow sensor and air filter housing with assembly fluid to facilitate reassembly, ensuring that the arrows on the throttle assembly harness connector and plug line up when fully tightened.