6-cylinder petrol engine and 520d engine
The intake manifold must be removed, for example, before removing the cylinder head or dismantling the engine. Special instructions for the 520d engine are given at the end of the chapter.
Withdrawal
Remove fairing cover.
Disconnect the vacuum hose from the intake manifold to the brake booster (disconnect from the brake booster). Some effort is required to remove the hose.
Remove the oil filler cap. Use a screwdriver to pry off the small plugs -arrows- and unscrew the bolts underneath. Remove both plastic covers.
Disconnect connectors for oxygen sensors. Disconnect the plug from the VAN0S solenoid valve.
Remove multi-socket connector for valve injectors and set aside.
Remove cover from intake manifold. Unscrew battery positive terminal -1- and compress 2 clips -arrows-. Unclip the plinth towards the bottom.
Disconnect the crankcase ventilation pipe.
Caution: Fire hazard, do not smoke. Remove escaping fuel with a cloth. Release the clamps and first disconnect the fuel supply hose -1- (from the filter), then the fuel outlet hose -2- from the fuel distributor. Always replace hose clamps with new ones after releasing.
Note: On some models, the fuel supply hose is attached directly to the fuel distributor. In this case, always replace the sealing ring with a new one and lubricate it with petroleum jelly before installation. There is also a version in which the fuel hoses are fastened using fixing clips - in this case, a special tool from BMW 161 050 is required to release the clips damaged ring lure.
Loosen fasteners throttle valve.
Attention: Do not disconnect the gas line and coolant hoses of the throttle valve preheating system.
Loosen the clamp and disconnect the oil return hose at the guide tube of the engine oil level indicator.
Remove the oil level gauge guide tube from the intake manifold.
Loosen intake manifold support and retaining bracket for coolant line.
Unplug electrical connector -1- at tank vent valve. Pull the valve out of the holder towards the top. Press clamp -2- and detach hose. Disconnect connectors at intake manifold for intake air temperature sensor and idle speed control valve.
Unbolt intake manifold to cylinder head.
Attention: Make sure that no parts get into the inlet channels, as this can cause severe engine damage.
Installation
Place the intake manifold against the cylinder head and tighten the fastening evenly in a crosswise pattern. Before installing, check all O-rings -arrow-, replace damaged O-rings with new ones.
Screw on intake manifold support.
Connect the connectors at the intake manifold for the intake air temperature sensor and the idle speed control valve.
Insert the fuel tank vent valve and fix the hose.
Attach the battery positive connector to the intake manifold and screw in the hexagon. Replace the cover.
Screw the guide tube of the oil level gauge to the intake manifold.
Connect the oil return hose to the guide tube of the engine oil level indicator and secure it with a clamp.
Install throttle valve.
Connect the fuel inlet and outlet hoses at the fuel distributor and secure them with new clamps. "Withdrawal".
Connect the crankcase ventilation pipe.
Connect connectors for oxygen sensors and VANOS solenoid valve.
Install the multi-socket connector for valve injectors.
Attach the vacuum hose from the brake booster to the intake manifold.
Install and screw down both plastic covers. Insert the bolt caps into place.
Screw on the oil filler cap.
Install fairing.
520d model only
Withdrawal
Remove fairing.
Release screws -1- and remove engine cover -2-.
Loosen clamp -arrow- and disconnect at EGR valve (exhaust gas recirculation valve) intake air pipeline.
Remove bolts -1- and remove engine cover.
Detach the hoses located in the area of the engine oil level indicator from the holders.
Unfasten the pipelines from the side lining at the drainage casing. Remove rubber trim -1- towards top. Loosen the swivel clips on the side trim -2- by turning them ¼ turn. Pull out the side trim towards the top.
Unscrew bolts -arrows- and remove cover on left side of engine.
Remove 4 bolts -arrows- securing EGR valve to intake manifold.
Note: The 4th bolt is not visible in the picture.
Loosen the rear bolt at the intake manifold. In Figure W-10355, a ratchet wrench is attached to the rear bolt.
Pull out the covers located between the intake manifold channels.
Remove bolts and nuts -1- and -2- for intake manifold. Remove the collector.
Installation
Replace all o-rings
Tighten intake manifold to cylinder head evenly in a diagonal pattern.
Further installation is carried out in the reverse order.
Install fairing.