BMW 540i- Manuals

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 O-Ring, vent pipe front seal 11-61-1-745-195 1 3.05 O-Ring, ASC throttle body 13-54-1-747-475 1 2.75 Covering Cap, valley pan heat shield 13-71...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Loc-Tite or equivalent (I always use the blue stuff) various bolts/nuts (see text) A word about the prices I bought most of these parts "on...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Main Task Sub-Task TIS Procedure or Notes Disassembly Battery, etc. TIS 11 53 325 - Removing and Installing Coolant Manifold TIS 12 00 - Instru...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 On this page we'll attend to all the items which need to be disassembled to allow removal of the intake manifold and valley pan. Most of the re...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Disconnect battery positive lead. - make sure your seats/mirrors are in their #1 saved position so you can return them after reapplication of p...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Disconnect and remove flex line between MAF and ASC throttle body. - release hose clamps on both ends (A) - reach underneath and disconnect fle...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 intake manifold and two on fender well). Place removed hoses in a clean environment - ie., inside a large ziplock bag. Driver’s side electrical...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Accelerator Cables - move main throttle lever backward with one hand while disconnecting both accelerator and cruise control cable ends from le...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Passenger side electrical harness - remove valve cover plate (A) (the BMW plate) - same as driver’s side. - disconnect coils - same as driver’s...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Vacuum Control Plumbing - locate black pipe that runs front/back along upper driver’s side of intake manifold. Remove single 10mm bolt (A) hold...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Engine Vent Tube - PITA Alert! The vent tube is located under the intake manifold (dotted lines in photo), runs along the driver’s side head/bl...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Intake Manifold - Find the vacuum line that runs from the fuel tank breather valve (A) (pete's T) under throttle body and over to left-lower co...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 At this point, inspect the area around the valley pan - that black plate is a plastic heat shield which snaps to the pan. The retainer clips wi...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Valley Pan - Clean up as much gunk from the area around the valley pan and intake ports as possible. The intent is to avoid contaminating the r...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 VALLEY PAN INSTALLATION Valley Pan - Spend a bit more time cleaning up the area, keeping debris from entering the coolant in the block (and the...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Water Manifold - Clean and inspect the two water pipes. Pay particular attention to the ends where the o -ring seals will be positioned. Use ve...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 INTAKE MANIFOLD DISASSEMBLY AND SEAL/GASKET REPLACEMENT Vacuum Plumbing - Locate the black vacuum pipe/hose assembly which came away from the c...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Rear Manifold Cover - Remove vacuum hose (A) between fuel pipe and rear cover (leave attached to diaphragm on fuel pipe). Using a baggie and zi...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Engine Vent Pipe - The vent pipe runs up thru the center of the intake manifold, between the front and rear covers. It attaches to the rear cov...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Miscellaneous - Remove the front and rear seals from the Intake Manifold. - Remove o-ring from front of primary throttle body.

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 INTAKE MANIFOLD SUBASSEMBLY Vent Tube - Carefully install new o-ring into front of vent tube, apply light coat of lubricant to o-ring, then ins...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 NOTE: refer to previous photo for locations of these seals. - Working from the front of the intake manifold, reach into manifold and gently gra...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Intake Manifold Seals - Turn manifold assembly upside down and install four new seals into mating grooves, positioning each seal so that the se...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 both visually and by touch! - Carefully lower manifold onto engine block/heads. - Install ten new mounting spacers, repositioning manifold slig...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Vacuum Plumbing Installation - PITA Alert! Access is difficult for this step. Pre-adjust a small screw-type hose clamp and, using a pair of nee...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Passenger side electrical harness Installation - connect electrical connectors to main and secondary throttle position sensors (F). - connect e...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Fuel Lines - Remove baggies and zip ties from four fuel lines and from hose at left-rear of fuel pipe. Install fuel lines (on my motor the ends...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Idle Control Valve - Insert grey ICV bushing into throttle body. - Position ICV and rubber mounting clamp (C), carefully capturing mounting ear...

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm Recovered and published by BMW-Planet.com – May 2012 Connect battery positive lead. - After power is reapplied, turn key to RUN position but do not start engine. - Store current seat/mirror settin...