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BMW E39 Throttle Housing Removal
 

Pelican Technical Article:

BMW E39 Throttle Housing Removal

Kerry Jonsson

Time:

2 hours2 hrs

Tab:

$200

Talent:

****

Tools:

10mm, T30 Torx socket with ratchet,

Applicable Models:

BMW 530i Sedan (2001-03)
BMW 540i Sedan/Wagon (1997-03)

Hot Tip:

Due to previous service the fasteners may be different

Performance Gain:

Clean the throttle housing.

Complementary Modification:

Replace the throttle body sealing gasket.

When you accelerate what makes the car go faster? What increases the engine speed and drive the drivetrain down the road? When you step on the gas pedal you open the throttle body to let more air into the engine. On older carbureted engines the increase in airflow would draw more gas out of the carburetor and get the engine to accelerate. Modern engines use sensors to detect airflow and throttle position but a throttle body must still open and allow more air into the engine to accelerate.

This article will cover the removal of the throttle body without electronic control but the car does have ASC. Anti-Slip Control closes a throttle in front of the actual throttle body. This ASC throttle is normally open and is commanded to close if wheel slip is detected under acceleration. This chokes off the engine to reduce power and allow the tires to re-gain grip with the road.

You do not have to remove the entire air box and air intake tube but it will give you a little more room to work.

Throttle Body Removal Six Cylinder:
With a flathead screwdriver loosen the air intake hose clamp and remove the air intake duct
Figure 1

With a flathead screwdriver loosen the air intake hose clamp and remove the air intake duct

Squeeze the retaining clip on the ASC throttle position sensor and pull the connector away from the sensor.
Figure 2

Squeeze the retaining clip on the ASC throttle position sensor and pull the connector away from the sensor.

Twist the ASC throttle linkage until the ASC throttle cable lines up with the opening on the linkage (red arrow) and pull the cable out of the linkage by lifting it upwards.
Figure 3

Twist the ASC throttle linkage until the ASC throttle cable lines up with the opening on the linkage (red arrow) and pull the cable out of the linkage by lifting it upwards.

Remove the two 5mm Allen head fasteners (green arrows) that secure the ASC throttle body to the main throttle body.
Figure 4

Remove the two 5mm Allen head fasteners (green arrows) that secure the ASC throttle body to the main throttle body.

Pull the ASC throttle body away from the main throttle body.
Figure 5

Pull the ASC throttle body away from the main throttle body.

With a 10mm socket remove the four fasteners (yellow and green arrows) recessed inside the throttle body.
Figure 6

With a 10mm socket remove the four fasteners (yellow and green arrows) recessed inside the throttle body. One bolt is hidden behind the throttle body (green arrow).

Squeeze the retaining clip on the throttle position sensor for the main throttle body and pull the connector away from the sensor.
Figure 7

Squeeze the retaining clip on the throttle position sensor for the main throttle body and pull the connector away from the sensor.

Pull the throttle body away from the intake manifold.
Figure 8

Pull the throttle body away from the intake manifold. In our case someone has coated the intake manifold with black silicone in an obvious attempt to seal any cracks in the manifold.

Position the throttle body so you have access to the throttle cables under the unit.
Figure 9

Position the throttle body so you have access to the throttle cables under the unit. Twist open the black throttle linkage of the cable and pull the cable end (green arrow) out of the linkage.

Twist open the second black plastic throttle body and pull the cable end (green arrow) out of the linkage.
Figure 10

Twist open the second black plastic throttle body and pull the cable end (green arrow) out of the linkage.

Pull the cable (green arrow) out of the rubber mount in the bracket and squeeze the rubber mount through the opening (yellow arrow) in the bracket.
Figure 11

Pull the cable (green arrow) out of the rubber mount in the bracket and squeeze the rubber mount through the opening (yellow arrow) in the bracket. Do the same procedure for both throttle cables.

If you have a pair of hose clamp pliers use them to crimp the two coolant lines going to the base of the throttle body.
Figure 12

If you have a pair of hose clamp pliers use them to crimp the two coolant lines going to the base of the throttle body.

Use a flat head screwdriver to loosen the two clamps that hold the two small coolant lines to the throttle body and pull off the two hoses.
Figure 13

Use a flat head screwdriver to loosen the two clamps that hold the two small coolant lines to the throttle body and pull off the two hoses. You can now remove the throttle body from the car.

Throttle Body Removal Eight Cylinder:
Squeeze the connector for the idle speed motor and unplug it.
Figure 14

Squeeze the connector for the idle speed motor and unplug it.

Pull the idle speed motor and hoses out of the throttle body assembly in the direction of the blue arrow and move it out of the way.
Figure 15

Pull the idle speed motor and hoses out of the throttle body assembly in the direction of the blue arrow and move it out of the way.

Squeeze the connector for the ASC throttle position sensor (green arrow) and pull the connector in the direction of the blue arrow.
Figure 16

Squeeze the connector for the ASC throttle position sensor (green arrow) and pull the connector in the direction of the blue arrow. This connector uses the old style Bosch connector while has a recessed spring clip that we have removed to make it easier for the connector to come off. You can use a pick to pry off the spring clip off.

Remove the T30 fastener (green arrow) under the ASC throttle body.
Figure 17

Remove the T30 fastener (green arrow) under the ASC throttle body.

Remove the two T30 Torx fasteners (green arrows) that hold the ASC throttle body onto the main throttle body and then pull the ASC throttle body off of the engine.
Figure 18

Remove the two T30 Torx fasteners (green arrows) that hold the ASC throttle body onto the main throttle body and then pull the ASC throttle body off of the engine.

Use a pair of pliers to squeeze the throttle cable retaining tab and push it downward in the direction of the blue arrow.
Figure 19

Use a pair of pliers to squeeze the throttle cable retaining tab and push it downward in the direction of the blue arrow.

Remove the throttle cable from the linkage by sliding it between the gap (green arrow) Do this same procedure on the second throttle cable (yellow arrow).
Figure 20

Remove the throttle cable from the linkage by sliding it between the gap (green arrow) Do this same procedure on the second throttle cable (yellow arrow).

Squeeze the retaining clip on the throttle position sensor (green arrow) and pull the connector towards you to remove the connector from the throttle body.
Figure 21

Squeeze the retaining clip on the throttle position sensor (green arrow) and pull the connector towards you to remove the connector from the throttle body.

Remove the six T30 Torx fasteners (green arrows) that hold the throttle body onto the intake manifold.
Figure 22

Remove the six T30 Torx fasteners (green arrows) that hold the throttle body onto the intake manifold. Here the fasteners were removed and replaced with 10mm bolts, but they are usually shallow T30 Torx Plus or Ribe style. Make sure you have your tool properly seated in the fastener before you try to loosen it because these fasteners are very easy to strip. You may want to have six replacements when you perform this repair. Pull the throttle body out of the engine.

Use a pick to remove the throttle body to intake manifold gasket.
Figure 23

Use a pick to remove the throttle body to intake manifold gasket. Installation is the reverse of the removal steps. Fit the throttle body to the intake manifold then plug in the throttle position sensor in. Install the throttle cables then install the ASC throttle housing. Install the ASC throttle position plug and the ISC motor. Install the air intake hoses and move the throttle several times with the key off and make sure it does not stick open at any point.

Comments and Suggestions:
smitty Comments: im confused my peake code reader says code 76 tps 1 so i tried finding this sensor to no avail car is a 2002 530i i assume its m54 engine the cars symptoms are like a bad tps only other code was a misfire cyl.1 any help on your part would be helpful
October 29, 2017
  Followup from the Pelican Staff: TPS is internal to the throttle housing. - Nick at Pelican Parts  
Rob Comments: again .. sorry WOULDNT start ...
September 30, 2017
  Followup from the Pelican Staff: Got it. - Nick at Pelican Parts  
Rob Comments: Hi
I should've mentioned in the previous comment , that the car/engine drove /ran
normally for several months while the whistling sound was going on UNTIL
the day it would start again.
Thanks
Rob
September 30, 2017
  Followup from the Pelican Staff: Thanks for the info. - Nick at Pelican Parts  
Rob Comments: Hi , my E39 m62 engined 535i had begun emitting a low toned whistling sound when it warmed up after 10/15 mins of driving and once it started it was continuous from idle through to higher revs. However under load when accelerating it would stop ... the sound never got louder or increased or decreased in line with the engine revs ,
in neutral or park , the whistle continued all through the rev range...
When I tried to listen for its origin, its seemed to be coming from the throttle body /manifold , top of the engine area.
After driving for a few hrs, I hopped back in and it wouldn't fire up , the starter keeps turning the eng. over but it won't fire.
I can't help but think its related somehow, so was hoping you guys may have heard of this before ...
The car has 120,000 kms 80,000 ...I recently had all the timing gear done with parts I bought from you .
Hope you can offer some advice
Here in Australia , we imported both the 540 and the smaller 535 V8s
Thanks
Rob
September 30, 2017
  Followup from the Pelican Staff: Did it run before the timing component replacement, or was that an attempt at repairing issue? - Nick at Pelican Parts  
Drinkingsnake Comments: I'm French... Be indulgent , for my poor english language...!
Anyway,
the head of the six of my throtle body screws, seems to be torx one, but....

Impossible to unscrew, and so I strip them...

I was in the neccesity to cut them, with a kind of " dremel" , with a ciculary saw

So... is it possible and how ? to remove or to lift up, the intake manifold , without dismantle the fuel rail , or the electric boxes ?!?

Regards ,
Chris
December 12, 2016
  Followup from the Pelican Staff: Your best off trying to cut a flat slot in the head of the fastener. Then use a flathead screwdriver to remove it. - Nick at Pelican Parts  
eva Comments: hi ...question I replace the throttle body of a 2003 BMW 525i and the car now shows fail safe transmition on the control panel. What can I do to fix this
April 20, 2016
  Followup from the Pelican Staff: Check the fault codes to be sure it is related. You may need to code or program the DME. - Nick at Pelican Parts  
540IVincent Comments: Please note that the bolts used to attach both the throttle body to the intake manifold and the CCV/back cover on the 540I are NOT a T30 torx but a Ribe/Polydrive! I have read countless posts on the different forums where DIY'ers have stripped the heads of these bolts due to using the incorrect tool! I think it would be very helpful if someone at Pelican Parts could update the information regarding this! Hope this helps!
January 5, 2016
  Followup from the Pelican Staff: This is a good point. You can get a better grip using torx Plus socket, or Ribe style. I will have the note added. - Nick at Pelican Parts  

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Page last updated: Tue 12/12/2017 02:05:16 AM