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Air Intake Ducts Replacement
 
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Pelican Technical Article:

Air Intake Ducts Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$60

Talent:

**

Tools:

Set of sockets (10mm), wrenches, flathead screwdriver, 6mm nut driver

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:

Intake air ducts, hose clamps

Hot Tip:

Work with a cool engine

Performance Gain:

Car will run well

Complementary Modification:

Change engine air filter

When an intake air duct cracks or tears, engine drivability suffers. You may have a rough idle, hard start or a check engine light that is on with fuel trim faults. The air entering through the tear in the duct is unmeasured and the engine management system cannot calculate fuel injection based on it. Therefore the engine drivability suffers.

When replacing your E46 intake air ducts, replace them in pairs. If you are removing both and only one is cracked, it is still a good idea to replace both.

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.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

This photo shows intake air duct damage.
Figure 1

This photo shows intake air duct damage. The duct has dry rotted and cracked (green arrow). The vehicle duct was replaced and had fault codes for fuel trim bank 1 and bank 2, lean.

Remove the air filter housing assembly fasteners (yellow arrows) and disconnect the air flow meter electrical connector (green arrow).
Figure 2

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 the engine compartment.
Figure 3

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

While working at the intake air duct, pull the vacuum hose connector out of the duct.
Figure 4

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

While working at the intake resonance valve, disconnect the electrical connector (yellow arrow).
Figure 5

While working at the intake resonance valve, disconnect the electrical connector (yellow arrow).

Then remove the two T-40 Torx fasteners (green arrows).
Figure 6

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

Remove the resonance valve from the intake manifold.
Figure 7

Remove the resonance valve from the intake manifold.

Next remove the intake air ducts from throttle housing.
Figure 8

Next remove the intake air ducts from throttle housing. There are two hose clamps to loosen, one at the idle valve (yellow arrow), 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.

With duct removed from the vehicle, mark the orientation using a marker (yellow arrow).
Figure 9

With duct removed from the vehicle, mark the orientation using a marker (yellow arrow). This will help get the ducts back into the correct position when reinstalling. Loosen the hose clamps (green arrows) and separate the ducts.

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Comments and Suggestions:
Sith Comments: Will this generally remove the CEL after replacement or will I have to drive it a bit to trigger that the replacement was installed?
August 5, 2016
  Followup from the Pelican Staff: The fault will have to be cleared, or driven until the test is passed twice. - Nick at Pelican Parts  
rootue Comments: I have a 2001 325i and would like to know what the larger of the two hoses that attaches via the f-connector into the upper intake boot is and does. I understand the smaller hose that attaches to the f-connector into the upper intake boot comes from the pressure regulator on my fuel filter. Thanks.
January 23, 2016
  Followup from the Pelican Staff: I recall it going to the suction jet pump installed in the brake booster vacuum hose. - Nick at Pelican Parts  

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Page last updated: Sat 12/3/2016 02:20:39 AM