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M54 6 Cylinder Engine Throttle Housing Replacement
 
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Pelican Technical Article:

M54 6 Cylinder Engine Throttle Housing Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$300

Talent:

*****

Tools:

Set of sockets T40 Torx socket, flathead, Phillips screwdrivers

Applicable Models:

BMW 525i Sedan (2004-05)
BMW 530i Sedan (2004-05)

Parts Required:

Throttle housing, throttle housing gasket, TPS, IACV, gaskets, O-rings

Hot Tip:

Work with a cool engine

Performance Gain:

Car will run well

Complementary Modification:

Inspect the intake air ducts and replace if necessary and replace air filter

The digital motor electronics (DME) engine management system in BMW E60 vehicles with the M54 6-cylinder engine is designed with a drive-by-wire throttle. There is no throttle cable connecting the accelerator pedal to the throttle housing. 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're 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.

Disconnect the negative (-) battery cable. See our tech article on battery connection notes.

Remove the DISA valve. See our tech article on DISA valve replacing.

Working at the intake air duct, squeeze the release collar (green arrows) and pull the hose connection off the duct in the direction of the yellow arrow.
Figure 1

Working at the intake air duct, squeeze the release collar (green arrows) and pull the hose connection off the duct in the direction of the yellow arrow. 

Next, remove the intake air ducts from the throttle housing.
Figure 2

Next, remove the intake air ducts from the throttle housing. There are two hose clamps to loosen. One clamp is located at the idle valve. The other hose clamp is located at the throttle housing. Start at the idle valve. Loosen the 6mm hose clamp (green arrow).

Then, pull the idle air control motor boot (green arrow) off the idle control motor.
Figure 3

Then, pull the idle air control motor boot (green arrow) off the idle control motor.

Next, remove the intake air duct from the throttle housing.
Figure 4

Next, remove the intake air duct from the throttle housing. Loosen the 6mm hose clamp (green arrow).

Then, pull the intake air duct off the throttle housing and remove it from the engine.
Figure 5

Then, pull the intake air duct off the throttle housing and remove it from the engine.

Working next to the throttle housing, remove the three 10mm nuts and bolts from the wiring harness junction.
Figure 6

Working next to the throttle housing, remove the three 10mm nuts and bolts from the wiring harness junction. The green arrow points to a hidden nut that the ratchet is on in the photo. The yellow arrows point to the other two nuts. The inset photo shows one out of sight nut on the bottom left.

Follow the engine oil dipstick tube down toward the engine mount.
Figure 7

Follow the engine oil dipstick tube down toward the engine mount. Remove the dipstick tube using a 13mm wrench (red arrow). Then rotate the dipstick tube away from the throttle housing. Next, disconnect the idle air valve electrical connector (yellow arrow). Then disconnect the throttle housing electrical connector by pressing the release tab (blue arrow) and pulling it off the housing. Remove the throttle housing wiring from the holder (green arrow) and move it aside. Pull the wiring harness junction from your intake manifold and lay it aside. Remove the idle air valve T40 Torx fasteners (purple arrows).

Then pull the idle valve out of the intake manifold and remove it.
Figure 8

Then pull the idle valve out of the intake manifold and remove it. Depending on how long the valve has been in the 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.

Remove the four 10mm throttle housing fasteners (green arrows).
Figure 9

Remove the four 10mm throttle housing fasteners (green arrows).

Then, remove the throttle housing from your engine.
Figure 10

Then, remove the throttle housing from your engine. To install the throttle housing is to do the reverse of the removal directions. Use the following notes: Remember to replace the throttle housing sealing O-ring (green arrow). Throttle housing adaptation for the MS 43 is as follows: Turn the ignition key to the ON position for 10 seconds, (do not start engine). Next turn the ignition key to the OFF position for 10 seconds. Start the engine.

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Page last updated: Fri 12/9/2016 02:23:43 AM