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S54 Engine Intake Manifold Replacement
 
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Pelican Technical Article:

S54 Engine Intake Manifold Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$250

Talent:

*****

Tools:

Set of sockets (10mm, 13mm), screwdrivers, hose clamp pliers

Applicable Models:

BMW E46 M3 Coupe/Conv (2006)
BMW Z4 Coupe/Conv (2006-08)

Parts Required:

Intake manifold sealing boots, hose clamps

Hot Tip:

Work with a cool engine

Performance Gain:

Repair vacuum leaks from old gaskets

Complementary Modification:

Replace crankcase vent valve or coolant hoses

On the 6-cylinder S54 engine installed in BMW Z4 vehicles, the molded plastic intake manifold or intake plenum mounts between the six individual throttle bodies and the intake air housing. The manifold is designed for maximum volume required for the S54 engine. Depending on the model the S54 is installed in, it will vary slightly, due to engine compartment restrictions. The flow characteristics of the one-piece plastic shell are enhanced by internal funneling cones to direct the intake air to the throttle housings.

The plenum is attached to the throttle housings by rubber sleeves. A special tool (clamp pliers) is required to secure the one-time use clamps. BMW tool number 11 9 160. With that said, you can get away with a variety of different pliers. For example, some CV boot pliers work as well as some trim clip pliers.

The S54 uses six individual throttle housings operated by one electronic throttle actuator (EDR). For low engine speed (low load) and idling, intake air is provided by an idle control valve. The valve regulates airflow through an external air distribution pipe to the individual throttle housings.

If you have a hard-to-find vacuum leak, replace your intake manifold gaskets. If you find oil inside your intake manifold, replace the crankcase breather valve. Clean the inside of the intake manifold thoroughly, and be careful not to get any debris inside the cylinder head during the procedure. Removing the intake manifold will also give you easy access to the engine starter, knock sensors or coolant pipes and hoses.

BMW Z4 models with an S54 6-cylinder engine utilize a rubber boot to seal the intake manifold. Over time, the boots harden from heat or they swell from oil contamination.

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.

On the 6-cylinder S54 engine installed in BMW Z4 vehicles, the molded plastic intake manifold or intake plenum (red arrow) mounts between the six individual throttle bodies (blue arrows) and the intake air housing (red arrow).
Figure 1

On the 6-cylinder S54 engine installed in BMW Z4 vehicles, the molded plastic intake manifold or intake plenum (red arrow) mounts between the six individual throttle bodies (blue arrows) and the intake air housing (red arrow). The manifold is designed for maximum volume required for the S54 engine. Depending on the model the S54 is installed in, it will vary slightly, due to engine compartment restrictions. The flow characteristics of the one-piece plastic shell are enhanced by internal funneling cones to direct the intake air to the throttle housings.

Start by removing the intake air housing (red arrow) and duct (yellow arrow).
Figure 2

Start by removing the intake air housing (red arrow) and duct (yellow arrow). See our tech article on intake air housing and ducts replacing.

Working at the center top of the intake manifold, detach the breather hose (red arrow).
Figure 3

Working at the center top of the intake manifold, detach the breather hose (red arrow). Squeeze the collar and pull it straight off.

Loosen the firewall strut brace 16mm fastener (green arrow).
Figure 4

Loosen the firewall strut brace 16mm fastener (green arrow). Remove the strut tower strut brace fastener (red arrow). Lift and lay the strut brace aside (inset).

Working at the rear of the intake manifold, pull the solenoid (green arrow) out of the mounting bracket and lay it aside.
Figure 5

Working at the rear of the intake manifold, pull the solenoid (green arrow) out of the mounting bracket and lay it aside.

Working at the engine oil dipstick, remove the 10mm fastener (red arrow).
Figure 6

Working at the engine oil dipstick, remove the 10mm fastener (red arrow).

Next, the two lower manifold mount fasteners (red arrows) have to be removed.
Figure 7

Next, the two lower manifold mount fasteners (red arrows) have to be removed.

This photo shows the front lower mount.
Figure 8

This photo shows the front lower mount. Remove the 10mm fastener (red arrow). Repeat for the rear manifold mount as well.

Pull the dipstick tube (red arrow) sway from the intake manifold.
Figure 9

Pull the dipstick tube (red arrow) sway from the intake manifold.

Working at the bottom of the intake manifold, remove the solenoid (red arrow) from the mount by pushing it toward the firewall (green arrow).
Figure 10

Working at the bottom of the intake manifold, remove the solenoid (red arrow) from the mount by pushing it toward the firewall (green arrow).

Working at the bottom of the intake manifold, squeeze the crankcase vent hose (green arrow) collar and pull it off the intake manifold (inset).
Figure 11

Working at the bottom of the intake manifold, squeeze the crankcase vent hose (green arrow) collar and pull it off the intake manifold (inset).

Next, the crankcase breather drain (blue arrow) has to be detached from the oil pan.
Figure 12

Next, the crankcase breather drain (blue arrow) has to be detached from the oil pan. It is located right next to the steering shaft (green arrow). Squeeze the crankcase drain hose (red arrows) collar and pull it off the oil pan (yellow arrows).

The plenum is attached to the throttle housings by rubber sleeves.
Figure 13

The plenum is attached to the throttle housings by rubber sleeves. A special tool (clamp pliers) is required to secure the one-time use clamps (BMW tool number 11 9 160). With that said, you can get away with a variety of different pliers. For example some CV boot pliers work as well as some trim clip pliers. When removing the clamps (green arrow), use the pliers to pull the two parts indicated by red arrows together.

When removing the clamps (green arrow), use the pliers to pull the two parts indicated by red arrows together.
Figure 14

When removing the clamps (green arrow), use the pliers to pull the two parts indicated by red arrows together. I use KD Tools KD3729 pliers to get them off. You can also use CV axle pliers with pointed ends. Squeeze the clamp in the area indicated by the red arrows, until the clamp lifts slightly (green arrow), and then release. The clamp will pop free.

When unlocked, the clamp will pop free (red arrow).
Figure 15

When unlocked, the clamp will pop free (red arrow).

Working at the rear of the manifold, pull the vacuum hose (red arrow) out of the mount.
Figure 16

Working at the rear of the manifold, pull the vacuum hose (red arrow) out of the mount. Then remove the wiring harness (blue arrow) from the mount.

Next, remove the intake from the throttle housings.
Figure 17

Next, remove the intake from the throttle housings. Wiggle the manifold to free it. If necessary, use a gentle levering motion (red arrow) with a pry bar to free each boot. It doesn't take much force. Be careful not to break the plenum, a throttle body or the air rail.

Then, pull the manifold off the intake (red arrow).
Figure 18

Then, pull the manifold off the intake (red arrow). If you're replacing the rubber boots, remove the clamp (green arrow) for the manifold boot (green arrow). Use diagonal cutters to remove it.

To install: Install the manifold to the throttle housings with new clamps.
Figure 19

To install: Install the manifold to the throttle housings with new clamps. Then install the lower manifold mounts. Installing them first helps to get the manifold in the right position. Hold the manifold close to the throttle housings. Then use the pliers to clamp the boot clamps together (red arrows). Reinstall the remaining items in the reverse order of removal. Double check the wiring harness routing and hose connections. Once complete, let the engine idle for about 10 minutes. If you left something disconnected or an item is misrouted, it is best to find out before driving.


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Comments and Suggestions:
Wcedgar Comments: Do you have a step by step for removing intake so I can replace starter on my 01 325i?
September 13, 2016
  Followup from the Pelican Staff: http://www.pelicanparts.com/BMW/techarticles/BMW-3-Series-E46/24-FUEL-Intake_Manifold_Gasket_Replacement/24-FUEL-Intake_Manifold_Gasket_Replacement.htm - Nick at Pelican Parts  

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Page last updated: Fri 12/9/2016 02:57:13 AM