11 61 051 Removing and installing intake manifold

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2008 MINI Cooper, 2007 MINI Cooper, 2006 MINI Cooper, 2005 MINI Cooper, and 2004 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

For Special Tool identification, see FUEL SYSTEM - SPECIAL TOOLS - COOPER (1.6L) R50/W10 .

Special Tools Required:

13 5 280

Disconnect battery; to do so, proceed in accordance with instructions for disconnecting and connecting battery. Refer to 12 00 DISCONNECTING AND CONNECTING BATTERY .

Remove air cleaner housing. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING .

Remove throttle assembly. Refer to 13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY .

Remove cover from fuel rail.

Detach line to brake booster from intake manifold.

Press ring downwards to expose line (1).

Detach crankcase ventilation valve from inspection hole cover

Fig 1: Identifying Crankcase Ventilation Valve

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Catch and dispose of escaping fuel.

Remove fuel line from fuel rail; disconnect quick-release coupling for this purpose.

Detach plug connector from intake air temperature/manifold air pressure sensor (TMAP).

Detach knock sensor plug from fuel rail wiring harness.

Disconnect tank vent link and unclip at fuel rail.

Disconnect vacuum line from intake manifold.

Remove retaining screws of fuel rail, then remove fuel injectors and fuel rail from manifold. Seal off fuel pressure regulator with special tool 13 5 280. Support fuel rail with a suitable piece of wire or manufactured rod.

Remove dipstick.

Fig 2: Sealing Off Fuel Pressure Regulator With Special Tool 13 5 280

Courtesy of BMW OF NORTH AMERICA, INC.

Release manifold screws (5-1) and remove manifold.

Unclip coolant line below manifold.

Installation:

Check gaskets on all cylinders and replace if necessary.

Tighten down bolts in sequence (1-5).

Tightening torque, 11 12 8AZ in ENGINE - TIGHTENING TORQUES- COOPER (1.6L) R50/W10 .

Fig 3: Locating Intake Manifold Retaining Screws

Courtesy of BMW OF NORTH AMERICA, INC.