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BMW E39 Intake Manifold Removal
 
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Pelican Technical Article:

BMW E39 Intake Manifold Removal

Kerry Jonsson

Time:

8 hours8 hrs

Tab:

$100

Tools:

T30 Torx, 11mm, 13mm, 19mm socket with ratchet, flathead screwdriver, pliers

Applicable Models:

BMW 528i Sedan/Wagon (1997-00)
BMW 540i Sedan/Wagon (1997-03)

Parts Required:

New manifold gasket

Hot Tip:

Stuff rags in the cylinder head intake manifold to prevent anything from falling in.

Performance Gain:

Better running engine

Complementary Modification:

Change fuel injector seals, PCV and throttle body gaskets

All an engine is, is a self-powered air pump. An air pump draws in air, compresses it and then expels the compressed air. Your engine does the same thing. It draws in air through your intake manifold. The intake manifold is one of the parts of your engine that contribute to the power output. Make the ports too small and airflow travels at high speed at low rpm but restricted at high rpm. If your intake manifold volume is too large then airflow will be slow at low rpm (low mid-range power and throttle response) but will make more horsepower at higher rpm. This is why modern intake manifolds have some sort of intake runner control to get the best of both worlds. In this tech article we are going to go over all of the steps to remove the intake manifold for the six and eight cylinder engines.

On the eight cylinder engine you will need to remove the upper engine cover. This is different with the six cylinder engine. You do not need to remove the fuel rail from the manifold but we have done so for photographic purposes, we have also removed the air-box, MAF and throttle body for photographic purposes. You do not have to remove the air-box, MAF and throttle body but you do have to separate the components so you can remove the intake manifold. Removing these components also gives you more room to work.

Intake Manifold Removal Six Cylinder Engine:
Working at the left side of the intake manifold just in front of the throttle body lift up on the EVAP Purge solenoid and remove it from the bracket on the intake manifold.
Figure 1

Working at the left side of the intake manifold just in front of the throttle body lift up on the EVAP Purge solenoid and remove it from the bracket on the intake manifold.

Locate the oil dipstick tube and move down the tube until you see its mount on the intake bracket.
Figure 2

Locate the oil dipstick tube and move down the tube until you see its mount on the intake bracket. Remove the 10mm fastener (green arrow) that mounts the oil dipstick tube to the intake bracket. You donÂ't have to but you can remove the two 10mm fasteners (yellow arrows) that mount the idle speed motor to the intake manifold bracket. You will eventually have to unplug the idle speed motor and removing it makes it easier.

We have chosen to remove the two 10mm fasteners and removing the idle speed motor by moving it down in the direction of the blue arrow.
Figure 3

We have chosen to remove the two 10mm fasteners and removing the idle speed motor by moving it down in the direction of the blue arrow.

Pull the idle speed motor out from underneath the intake manifold to expose the electrical connector.
Figure 4

Pull the idle speed motor out from underneath the intake manifold to expose the electrical connector. Push in on the connector retaining clip (green arrow) and pull the connector in the direction of the blue arrow.

Reach behind the bracket on the intake manifold below the throttle body and push on the electrical connector retaining clip (green arrow) and unplug it by pulling the connector in the direction of the blue arrow.
Figure 5

Reach behind the bracket on the intake manifold below the throttle body and push on the electrical connector retaining clip (green arrow) and unplug it by pulling the connector in the direction of the blue arrow.

Squeeze the locking tabs on the crankcase breather hose and remove it from the valve cover.
Figure 6

Squeeze the locking tabs on the crankcase breather hose and remove it from the valve cover.

Locate the thinner EVAP purge solenoid hose (green arrow) and remove it from the intake manifold.
Figure 7

Locate the thinner EVAP purge solenoid hose (green arrow) and remove it from the intake manifold. This is made easier by twisting back and forth while pulling it downward in the direction of the blue arrow.

Pull the throttle body cooling hose (green arrow) out of its holder on the intake manifold bracket.
Figure 8

Pull the throttle body cooling hose (green arrow) out of its holder on the intake manifold bracket.

Working at the top of the intake manifold remove the positive terminal cover.
Figure 9

Working at the top of the intake manifold remove the positive terminal cover.

With a 19mm socket remove the positive terminal bolt (green arrow) from the intake manifold.
Figure 10

With a 19mm socket remove the positive terminal bolt (green arrow) from the intake manifold. Be careful that this terminal does not contact ground. It is covered in plastic so it is difficult to do this. If you want you can disconnect the battery negative terminal to open the circuit completely to prevent a short circuit.

Working underneath the intake manifold behind the motor mount bracket remove the 13mm fastener (green arrow) that holds the rear lower intake manifold bracket to the engine block.
Figure 11

Working underneath the intake manifold behind the motor mount bracket remove the 13mm fastener (green arrow) that holds the rear lower intake manifold bracket to the engine block. Here the fastener is already removed.

Still working underneath the intake manifold in front of the motor mount bracket remove the 13mm fastener (green arrow) that mounts the front lower intake manifold bracket to the engine block.
Figure 12

Still working underneath the intake manifold in front of the motor mount bracket remove the 13mm fastener (green arrow) that mounts the front lower intake manifold bracket to the engine block.

Working at the top of the intake manifold again remove the seven 11mm intake manifold mounting bolts (green arrows).
Figure 13

Working at the top of the intake manifold again remove the seven 11mm intake manifold mounting bolts (green arrows).

Lift up on the intake manifold and look underneath.
Figure 14

Lift up on the intake manifold and look underneath. Remove the hose at the bottom of the crankcase breather valve (green arrow) from the breather valve (yellow arrow).

Remove the two small hoses (green arrows) under the intake manifold by the throttle body.
Figure 15

Remove the two small hoses (green arrows) under the intake manifold by the throttle body. Mark them so you know which one goes where during installation.

Peel out the old intake manifold rubber seal type gasket from the grooves in the intake manifold.
Figure 16

Peel out the old intake manifold rubber seal type gasket from the grooves in the intake manifold. Installation is the reverse of the removal steps. Install the two small hoses under the intake manifold. Install the intake manifold on the engine. While the intake is still loose install the battery terminal under the top of the intake manifold. Fit the breather hoses at the valve cover and the bottom crankcase breather valve. Install the EVAP canister purge hose, coolant hose and electrical connector for the air temperature sensor in their positions of the intake manifold. Tighten the fasteners both on top and underneath the intake that hold it to the engine block. Fit the idle speed motor, mount the oil dipstick tube and position the EVAP purge solenoid on its bracket. Install the other systems such as throttle body, fuel rail and air-box that you removed prior to doing the job. Intake manifold to cylinder head torque: (M8) 22 Nm (16 ft-lb) Tighten in alternating pattern. (M7) 15 Nm (11 ft-lb) Tighten in alternating pattern. (M6) 10 Nm (7.3 ft-lb)

Intake Manifold Removal Eight Cylinder: You will need to remove the engine cover to remove the intake manifold. You do not need to remove the air-box, throttle body or fuel rail to remove the intake manifold but you do need to remove the components that attach them to the engine if you are going to remove them with the intake manifold. See our tech articles on removing the air-box, throttle body and fuel rail to disconnect these components.
Working at the back of the intake manifold at the left side remove the hose clamps that hold on the large brake booster vacuum line and remove the hose from the intake manifold.
Figure 17

Working at the back of the intake manifold at the left side remove the hose clamps that hold on the large brake booster vacuum line and remove the hose from the intake manifold.

In the same corner of the intake manifold remove the clip (green arrow) that holds the crankcase breather pipe to the back of the intake manifold by lifting up on it.
Figure 18

In the same corner of the intake manifold remove the clip (green arrow) that holds the crankcase breather pipe to the back of the intake manifold by lifting up on it.

Remove the crankcase breather pipe (green arrow) from the intake manifold by pushing it forward in the direction of the blue arrow.
Figure 19

Remove the crankcase breather pipe (green arrow) from the intake manifold by pushing it forward in the direction of the blue arrow.

Looking underneath the intake manifold on the left side you will see the front of the crankcase breather pipe (green arrow) move forward in the direction of the blue arrow.
Figure 20

Looking underneath the intake manifold on the left side you will see the front of the crankcase breather pipe (green arrow) move forward in the direction of the blue arrow.

Remove the ten 11mm fasteners (green arrows) that hold the intake manifold to the car.
Figure 21

Remove the ten 11mm fasteners (green arrows) that hold the intake manifold to the car. You can now lift the intake manifold off of the engine. Peel out the old intake manifold rubber seal type gasket from the grooves in the intake manifold. Installation is the reverse of the removal steps. Install the intake manifold on the engine and tighten the fasteners. Install the crankcase breather pipe and fit the clip that holds it on. Install and tighten the hose clamps for the brake booster vacuum line. Fit the other components such as the fuel rail, throttle body and air-box if you removed them to take off the intake manifold. Intake manifold to cylinder head torque: (M8) 22 Nm (16 ft-lb) Tighten in alternating pattern. (M7) 15 Nm (11 ft-lb) Tighten in alternating pattern. (M6) 10 Nm (7.3 ft-lb)

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Comments and Suggestions:
Nana Comments: What is M6 M7 M8
October 2, 2016
  Followup from the Pelican Staff: Metric fastener sizes. 6mm, 7mm, 8mm - Nick at Pelican Parts  
Thrasher Comments: What intake manifold would I upgrade to from a stock 1999 528i. I have it out for other reasons what's my best upgrade with little cost and a lot of hp's.
September 15, 2016
  Followup from the Pelican Staff: Not sure there is an upgrade worth doing on the 528i. - Nick at Pelican Parts  
Sroor9001 Comments: Would you please give me a link to that article ??
January 20, 2016
  Followup from the Pelican Staff: All BMW article links begin here:
http://www.pelicanparts.com/BMW/techarticles/tech_main.htm

The intake article is here:

http://www.pelicanparts.com/BMW/techarticles/tech_main.htm - Nick at Pelican Parts
 
Sroor9001 Comments: Thanks for this write up but I want to know is it same like m54 engine BMW 525 2002 cause it seem this is 97 or 98 model am I right ??
January 17, 2016
  Followup from the Pelican Staff: Yes that is an earlier engine. Check out E46 article for the differences on the M54 engine. - Nick at Pelican Parts  

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Page last updated: Wed 12/7/2016 02:06:19 AM