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Throttle Housing Replacement
 
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Pelican Technical Article:

Throttle Housing Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$400

Talent:

***

Tools:

Set of sockets T-40 Torx socket, flathead and Phillips screwdriver

Applicable Models:

BMW 323Ci Coupe/Conv (1999-00)
BMW 323i Sedan/Wagon (1999-00)
BMW 325Ci Coupe/Conv (2001-06)
BMW 325i/xi Sedan/Wagon (2001-06)

Parts Required:

Throttle housing, throttle housing gasket

Hot Tip:

Work with a cool engine

Performance Gain:

Car will run well

Complementary Modification:

Inspect intake air ducts and replace if necessary. Replace air filter.

The digital motor electronics (DME) engine management system in BMW E46 vehicles with the 6-cylinder engine may be equipped with one of two different throttle systems:

  • M52 engine (1999-2000 models) is equipped with a conventional throttle cable connecting the accelerator pedal to the throttle housing.
  • M54 and M56 engine (2001-2005 models) are equipped with an electronic throttle (drive-by-wire). There is no throttle cable. Instead, potentiometers in the accelerator pedal module (PWG) communicate pedal position directly to the engine control module (ECM). Two separate signals, one signaling pedal position and the other indicating rate of pedal movement, communicate driver demand on the system. Based on pedal position and movement, the ECM communicates throttle opening to the throttle housing at the intake manifold. 

A faulty throttle housing can cause a number of problems for the engine, from a check engine light to a rough or surging idle. Before you condemn your throttle housing, be sure to inspect all the intake air ducts. They should be well-sealed and free from cracks or tears. Check the function of your crankcase breather valve and inspect all the breather hoses. If a breather hose cracks or fails, the air leak can cause a rough idle or engine stalling. On electronic throttle vehicles, inspect the throttle housing electrical connector condition; the pins have a tendency to lose tension. The best way to check pin tension is with a pin fit kit. However, this may not be available to you so you can visually inspect the pins and see if they are spread open or bent. 

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches. 

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you are working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

First, disconnect the negative (-) battery cable.
Figure 1

First, disconnect the negative (-) battery cable. See our Tech Article on battery replacement and removing for more info. Remove the air filter housing assembly fasteners (yellow arrows) and disconnect the air flow meter electrical connector (green arrow).

Loosen the air flow meter clamp (green arrow), then disconnect the duct from the air flow meter and remove the air filter housing from your engine compartment.
Figure 2

Loosen the air flow meter clamp (green arrow), then disconnect the duct from the air flow meter and remove the air filter housing from your engine compartment.

Working at the intake air duct, pull the vacuum hose connector out of the duct.
Figure 3

Working at the intake air duct, pull the vacuum hose connector out of the duct.

Working at the intake resonance valve, disconnect the electrical connector by squeezing the release tab and pulling it away from the valve (yellow arrow).
Figure 4

Working at the intake resonance valve, disconnect the electrical connector by squeezing the release tab and pulling it away from the valve (yellow arrow).

Next, remove the two T-40 Torx fasteners (green arrows).
Figure 5

Next, remove the two T-40 Torx fasteners (green arrows).

Remove the E46 resonance valve from the intake manifold.
Figure 6

Remove the E46 resonance valve from the intake manifold.

Next remove the E46 intake air ducts from your throttle housing.
Figure 7

Next remove the E46 intake air ducts from your throttle housing. There are two hose clamps to loosen, one at idle valve (yellow arrow) and the other at the throttle housing (green arrow). Reach below the duct with a 6mm nut driver (near engine mount) and loosen the clamps from below. Once loose, remove the duct from the engine.

Follow the engine oil dipstick tube down toward the engine mount.
Figure 8

Follow the engine oil dipstick tube down toward the engine mount. Remove the dipstick tube 13mm fastener (green arrow), then rotate the dipstick tube away from the throttle housing.

While working next to the throttle housing, remove the two 10mm nuts and bolt from the wiring harness junction (green arrows).
Figure 9

While working next to the throttle housing, remove the two 10mm nuts and bolt from the wiring harness junction (green arrows).

Next, disconnect the idle air valve electrical connector by squeezing the release tab and it pulling away from valve (green arrow).
Figure 10

Next, disconnect the idle air valve electrical connector by squeezing the release tab and it pulling away from valve (green arrow).

Pull the wiring harness junction from the intake manifold and lay aside.
Figure 11

Pull the wiring harness junction from the intake manifold and lay aside.

On early models with the M52 engine (MS 42.
Figure 12

On early models with the M52 engine (MS 42.0), disconnect the throttle housing cable by it pulling up and out of the rubber retainer (green arrow). Vehicles with the MS43 engine software do not have a throttle cable.

Remove the idle air valve T-40 Torx fasteners (green arrows).
Figure 13

Remove the idle air valve T-40 Torx fasteners (green arrows). On early models with the M52 engine (MS 42.0): remove the throttle cable mounting bracket from the engine.

Then pull the idle valve out of the intake manifold and remove.
Figure 14

Then pull the idle valve out of the intake manifold and remove. Depending on how long the valve has been in vehicle, it may be stuck to the rubber hose it mounts in. If this is the case, gently work the valve side to side as you pull it out.

On early models with the M52 engine (MS 42.
Figure 15

On early models with the M52 engine (MS 42.0): reach down next to the throttle housing and fully open the throttle using plastic the lug on side (yellow arrow). Disconnect the throttle cable by pulling the ball end down and out of throttle lever (green arrow).

On early models with the M52 engine (MS 42.
Figure 16

On early models with the M52 engine (MS 42.0): disconnect the throttle housing electrical connector (green arrow) by rotating it counterclockwise until it pulls away from the throttle housing.

Next, disconnect the throttle housing electrical connector (green arrow).
Figure 17

Next, disconnect the throttle housing electrical connector (green arrow). This photo shows late model MS43 engine software. To disconnect, squeeze the release tab and pull it off the throttle housing.

Remove the four 10mm throttle housing fasteners (yellow arrows) then the remove throttle housing from the engine.
Figure 18

Remove the four 10mm throttle housing fasteners (yellow arrows) then the remove throttle housing from the engine. To install the throttle housing, follow these removal directions in reverse.

Remember to replace the throttle housing gasket (green arrow).
Figure 19

Remember to replace the throttle housing gasket (green arrow).

On early models with the M52 engine (MS 42.
Figure 20

On early models with the M52 engine (MS 42.0): adjust the throttle cable by twisting the knurled section (yellow arrow).

Late models MS43 engine software: perform throttle adaptation as described below.
Be sure that all electrical connectors are properly seated.
Figure 21

You also have to adjust the cable at the full throttle position. You will need a scan tool that reads engine data stream, specifically throttle angle (green arrow).On vehicles with manual transmissions: Turn the ignition key to the ON position and press the accelerator pedal to the floor (full stop). Throttle angle should read 80-84 degrees.On vehicles with automatic transmissions: Turn the ignition key to the ON position and press the accelerator pedal until the pedal reaches the kickdown stop. Throttle angle should read 76-80 degrees. On vehicles with automatic transmissions: Turn the ignition key to the ON position and press the accelerator pedal past the pressure point of kickdown switch. Throttle angle should read 84-88 degrees. On vehicles with automatic transmissions, turn the ignition key to the ON position and press the accelerator pedal to the floor (full stop). Throttle angle should read 100%

To adjust, rotate adjuster (yellow arrow) located at the end of the throttle cable housing.
Figure 22

Be sure that all electrical connectors are properly seated. Listen for an audible click when connecting. On early models with M52 engine (MS 42.0), align the white arrows on the electrical connector and the throttle housing when installing (green arrows).

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Comments and Suggestions:
aston Comments: hi nick. now the code 5e19, or p1500 comes up at 1700rpm could this be a doggy throttle body?
November 28, 2016
  Followup from the Pelican Staff: COuld be the idle valve or a faulty throttle housing. if the idle valve sounds like it is hunting, replacing it. - Nick at Pelican Parts  
Seaesta Comments: I have the early model m52 with the ms42.0 cable throttle. The throttle Lever pictured in pic # 15 had broken, no longer able to hold the throttle cable ball. Can just the throttle lever be replaced? Or must I replace the throttle body. Thanks
June 27, 2016
  Followup from the Pelican Staff: I believe you will need the throttle body.

Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Lathe Comments: After doing this for the Cvv my car goes into limp mode as soon as I touch the accelerator. It's giving me an error code for the valve being mechanically stuck, yet I removed the boot to look and I can see the valve opening when I press the gas. Could this be my icv or did something go wrong when I adjusted the throttle cable?
April 10, 2016
  Followup from the Pelican Staff: I would assume the connector was damaged. Check the terminals for bends or damage. - Nick at Pelican Parts  
moparman33 Comments: On a 1998 M52, When installing the secondary throttle housing over the gasket on the throttle body, how tight should the two mounting bolts be? Should it seat all the way over the gasket or just enough to seal off the airgap?
February 24, 2016
  Followup from the Pelican Staff: The mounting surfaces should be sealed, I can't give a spec on the sealing amount. I don't think it exists.

I don’t have the torque info.

I would grab a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799 - Nick at Pelican Parts
 
BaliDawg Comments: Nick, your statement that "2001 - 2005 M54 engines have MS43" is incorrect. After 03/2003 E46 switched to MS45.1 on coupes and sedans Xi and M3 retained MS43 to end of production.
Just want to clarify for others.
December 23, 2015
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
The system electrical layout remains similar from 43 to 45, differences mainly in software. On the repair standpoint, not that important.
- Nick at Pelican Parts
 
Steve Comments: Hi have e90 318d and at constant 1500 revs the revs seem to increase and decrease slightly on their own, as if they are hunting, would cleaning the throttle body cure this problem? Many thanks
December 17, 2015
  Followup from the Pelican Staff: Unlikely. Late model BMWs should not have the throttle housing cleaned, as they have a special coating that can be removed. I would check for a vacuum leak.- Nick at Pelican Parts  
JLH Comments: I have 01 325I Auto/steptronic. You say I have MS43, If I am only replacing the Throttle Housing Gasket, do I need to complete step/figure 21? Is it safe to drive the car to a Bmw dealer to perform or do I have to have it towed? I do not have a Scan Tool.
September 22, 2015
  Followup from the Pelican Staff: If just the gasket, should be Ok without performing adaptation. - Nick at Pelican Parts  
JLH Comments: I need to replace Heater Inlet Pipe under intake Mani and CCV & all hoses on my 01 325I auto. Do I need to take the Throttle housing completely off to accomplish?
September 21, 2015
  Followup from the Pelican Staff: Yes, and the intake. The pipe bolts below it and nearly impossible to remove with the intake installed. - Nick at Pelican Parts  
JLH Comments: I have 01 325I sedan automatic. M54, How do I know if the MS4-43 applies to my engine? Or do I not have these. Thanks
September 21, 2015
  Followup from the Pelican Staff: 2001 - 2005 M54 engines have MS43. - Nick at Pelican Parts  
JLH Comments: How much/many steps do I have to do in this procedure to properly replace the CrankCase Valve? Any links to other steps I should be taking?
September 15, 2015
  Followup from the Pelican Staff: See this tech article:

http://www.pelicanparts.com/BMW/techarticles/BMW-3-Series-E46/12-ENGINE-Crankcase_Breather_Valve_Replacement/12-ENGINE-Crankcase_Breather_Valve_Replacement.htm - Nick at Pelican Parts
 
Aoei Comments: Your adaptation instructions is for the MS42 throttle... no cable at all for the MS43. MS43 adaptation procedure appears to be 10s ign. on not started and 10s. off before engine start.
February 26, 2015
  Followup from the Pelican Staff: Instructions for MS42 and MS43 cars are provided in separate steps. - Nick at Pelican Parts  
batesy Comments: Will it still hold in place?
December 30, 2014
  Followup from the Pelican Staff: No, you will have to repair it. - Nick at Pelican Parts  
Batesy Comments: Hi I am changing my accelerator pedal on my 325ci and the lug on the floor plate has snapped whilst removing my old one, will this cause a problem when fitting the new one?
December 30, 2014
  Followup from the Pelican Staff: Yes, you should repair the stud. Remove the old one and install new. Or drill a hole, weld a nut and attach it using a bolt. - Nick at Pelican Parts  
Eli Comments: im trying to find out if the error code i got from my peake scanner tool has to do anything with the intake boot? i read that most of the time if the intake boot has a small leak or a hairline crack it could trigger limp mode when flooring the throttle. is that true? cuz i cant seem to find any problem on it. the error code i got from my peake tool is 2882, 2883, and 28A2. hope you could help me with my problem. i dont know whats the common problem with e46 to go into limp mode. lastly i heard having both o2 sensors break down is not likely to happen so both error code 2882 and 2883 saying bank 1 and bank 2 could not mean to replace both precat o2 sensors right? or am i wrong? please explain or let me know what i should do.
September 28, 2014
  Followup from the Pelican Staff: These are fuel trim fault codes. It could be an air leak or a faulty sensor. I would check your fuel trim and see what direction the fuel trim is skewed. - Nick at Pelican Parts  

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Page last updated: Wed 12/7/2016 02:19:59 AM