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Intake Air Ducts Replacement
 
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Pelican Technical Article:

Intake Air Ducts Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$60

Talent:

**

Tools:

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

Applicable Models:

X3 E83 (2004-06)
X3 E83 facelift (N/A-A)

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 E83 X3 (M54 engine) intake air ducts, replace them with high quality parts. I have seen some imitation boots dry rot and crack open in less than a year after replacing.

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 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. Questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

This tech article will show you how to replace the intake air housing (green arrow) and the intake air duct (red arrow).
Figure 1

This tech article will show you how to replace the intake air housing (green arrow) and the intake air duct (red arrow). The yellow arrow point to intake air duct damage. The duct has dry rotted and cracked (yellow arrow). The vehicle duct was replaced and had fault codes for fuel trim bank 1 and bank 2, lean. Start by removing the engine covers and cabin microfilter housing. See our tech article for those tasks.

Start by removing the four T25 Torx fasteners (red arrows) for the fresh air intake duct.
Figure 2

Start by removing the four T25 Torx fasteners (red arrows) for the fresh air intake duct. Next you will unclip the five air filter housing retaining clips. Lift them up and unhook from the lid of the intake air housing. Start with the two near the mass air flow sensor. Then release the front clips.

Once you release all the clips, lift the intake air duct (blue arrow) and pull it out of the air filter housing lid (red arrow).
Figure 3

Once you release all the clips, lift the intake air duct (blue arrow) and pull it out of the air filter housing lid (red arrow).

Loosen the air flow meter clamp (green arrow).
Figure 4

Loosen the air flow meter clamp (green arrow). Disconnect the air flow meter electrical connector by pulling it straight out. If it won't come out, lever the release tab open using a small flathead screwdriver.

Then disconnect the duct from the air flow meter.
Figure 5

Then disconnect the duct from the air flow meter.

Pull the wiring harness (yellow arrow) off the mount on the intake air housing (green arrow).
Figure 6

Pull the wiring harness (yellow arrow) off the mount on the intake air housing (green arrow).

Remove the two 10mm fasteners (red arrow) and remove the air filter housing from the engine compartment.
Figure 7

Remove the two 10mm fasteners (red arrow) and remove the air filter housing from the engine compartment.

While working at the intake air duct, pull the vacuum hose with the elbow connector out of the duct (red arrow).
Figure 8

While working at the intake air duct, pull the vacuum hose with the elbow connector out of the duct (red arrow).

While working at the intake resonance valve, disconnect the electrical connector (green arrow).
Figure 9

While working at the intake resonance valve, disconnect the electrical connector (green arrow). Then remove the two T40 Torx fasteners (red arrows).

Working at the left rear corner of the engine compartment, remove the weatherstrip by pulling it straight up (green arrow).
Figure 10

Working at the left rear corner of the engine compartment, remove the weatherstrip by pulling it straight up (green arrow). Then rotate the two plastic fasteners 90 degrees and remove (yellow arrows). Pull the hoses up and out of the plastic cover (red arrow).

Pull the cover away then up (red arrow) as you guide the hoses off toward the firewall (green arrow).
Figure 11

Pull the cover away then up (red arrow) as you guide the hoses off toward the firewall (green arrow).

Once the hoses are clear of the cover, lift the cover straight up (red arrow) and remove.
Figure 12

Once the hoses are clear of the cover, lift the cover straight up (red arrow) and remove.

Remove the DISA (resonance valve) out of the intake manifold.
Figure 13

Remove the DISA (resonance valve) out of the intake manifold. See our tech article on DISA removal for more info.

Next remove the intake air duct from idle valve and throttle housing.
Figure 14

Next remove the intake air duct from idle valve and throttle housing. There are two hose clamps to loosen, one at the idle valve (red arrow), and the other at the throttle housing. Use a 6mm nut driver (I prefer a flexible one) and loosen the clamp on the small hose. Then pull the hose off the idle valve (green arrow).

Next remove the intake air duct from throttle housing.
Figure 15

Next remove the intake air duct from throttle housing. Loosen the clamp (red arrow) almost all the way.

Once loose, remove the duct from the engine.
Figure 16

Once loose, remove the duct from the engine. Install the new duct in the same position as the old one, be sure it is evenly installed over the lip (red arrow) of the throttle housing. Then reassemble the intake air duct and air filter housing in reverse order of removal. Check that the ducts, hoses and the electrical harnesses are routed as they were before and check that the air ducts are properly sealed.

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Page last updated: Fri 12/9/2016 03:07:22 AM