11 61 050 Removing and installing intake air manifold (S54)

Special tools required:

11 9 160

Necessary preliminary tasks:

Remove intake filter housing

M3 CSL only:

Remove raw air housing

NOTE: Instructions for disconnecting and connecting battery. (See 12 00 ... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY )

Disconnect negative battery lead.

Vehicles with SMG transmissions only:

Open electronics box cover
Detach relay (1) of hydraulic pump
Disconnect line between expansion tank and hydraulic unit from intake manifold

IMPORTANT: Reinstall relay (1) of hydraulic pump only after connecting line between expansion tank and hydraulic unit.

Fig 1: Identifying Relay

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E46 only:

Remove microfilter.

Fig 2: Locating Microfilter

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E46 only:

Open cable duct on lower section of microfilter housing and feed out cable(s).

Fig 3: Locating Cable Duct On Lower Section

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E46 only:

Release screws (1) and remove lower section of microfilter housing (2).

Fig 4: Release Screws (1) And Remove Lower Section Of Microfilter Housing (2)

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Press locks.

Remove hose for engine vent.

Fig 5: Locating Hose

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Gently raise lug (1) and slide holder upwards.

Feed out battery positive lead.

Fig 6: Pulling Slide Holder

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M3 CSL only:

Unlock lug (1) from holder.

Feed out battery positive lead (2).

Fig 7: Unlocking Lug (1) From Holder And Feeding Out Battery Positive Lead (2)

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Not applicable to M3 CSL:

Detach guide tube (1) for oil dipstick from in take air manifold.

Press locks on vacuum hose (2) and detach.

Fig 8: Identifying Vacuum Hose With Guide Tube

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Detach tank venting valve (1) from holder on intake air manifold.

Fig 9: Identifying Venting Valve

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Release support bracket at front and rear from intake air manifold.

Fig 10: Locating Support Bracket

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Press lock. Detach hose (1) from intake air manifold.

Fig 11: Identifying Intake Air Manifold Hose

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Disconnect hydraulic fluid connecting hose:

Press locks.

Detach connecting hose to hydraulic unit tank connection.

Fig 12: Locating Hydraulic Unit Tank Connection

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Place special tool 11 9 160 on lugs of clamp. (See ENGINE - SPECIAL TOOLS article)

Press clamp together until lock is opened.

Fig 13: Identifying Special Tool (11 9 160) On Lugs Of Clamp

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Installation:

Replace clamps.

Preassemble clamps in installation position.

Catch (1) must be secured in lug (2).

Fig 14: Ensure Catch (1) Is Secured In Lug (2)

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IMPORTANT:

Use only original clamps.

If hose clamps are used, there is the risk that the throttle control linkage will stop or jam and no longer return to the idle position.

Installation:

Push intake air manifold with hose clamps (1) preassembled in installation position onto throttle assembly.

Fig 15: Identifying Hose Clamps

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Installation:

Place special tool 11 9 160 on lugs of clamp. (See ENGINE - SPECIAL TOOLS article)

Press hose clamps together with special tool 11 9 160 until lock (1) engages. (See ENGINE - SPECIAL TOOLS article)

Fig 16: Identifying Special Tool (11 9 160) On Clamp

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Press locks and detach condensate return (1).

Fig 17: Identifying Condensate Return

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NOTE: For purposes of clarity, shown on removed engine.

IMPORTANT: A vacuum line (1) and a wiring harness (2) are clipped into place on the reverse side of the intake air manifold.

Raise intake air manifold slightly and detach from throttle assembly.

Feed out vacuum line (1) and wiring harness (2).

Remove in take air manifold.

Fig 18: Identifying Vacuum Line & Wiring Harness

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