Version from 9/98

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2003 BMW 540i, 2002 BMW 540i, 2001 BMW 540i, 2000 BMW 540i, and 1999 BMW 540i. However, it is still accessible from the selected car via links, so may be relevant.

Press sliding piece on vent pipe (1) forward until it is no longer fixed to cover.

Fig 1: Pressing Sliding Piece On Vent Pipe Forward

Courtesy of BMW OF NORTH AMERICA, INC.

Keep vent pipe (1) pressed forward and lay towards bottom.

Fig 1: Keeping Vent Pipe Pressed

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

Replace sealing ring (1) and coat with oil as anti-friction agent. Make sure sealing ring is correctly seated and is not crushed by vent pipe.

Feed vent pipe onto connection on cover.

Fig 1: Identifying Sealing Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten nuts (left and right). Remove decoupling elements and lift intake air manifold upwards to remove.

Fig 2: Removing Nuts And Decoupling Elements

Courtesy of BMW OF NORTH AMERICA, INC.

If necessary, remove vent pipe in intake air manifold:

Remove throttle valve.

Remove covers at front and rear from intake air manifold.

Fig 3: Removing Throttle Valve

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Vent pipe is located with a lug (1) and locked with a retaining lug (2) in intake air manifold.

Carefully press retaining lug (2) back and push vent pipe out of bore.

Remove vent pipe (1).

Installation

Replace seal.

Fig 4: Removing Vent Pipe

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

Insert vent pipe.

Check fixture (1) and lock (2) of vent pipe in intake air manifold.

Replace seals.

Install covers at front and rear.

Fig 5: Checking Fixture And Lock

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The intake air manifold is vibrationally separated from the cylinder head by decoupling elements and gaskets.

Nut
Decoupling element
Intake air manifold
Seal

Installation

Fig 6: Identifying Nut, Decoupling Element, Intake Air Manifold And Seal

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

Check seals and replace if necessary.

CAUTION: Ensure that seals are correctly seated.

Fig 7: Checking Seals

Courtesy of BMW OF NORTH AMERICA, INC.

Installation

Fit two decoupling elements on left and right with nuts and do not tighten (i.e. no preload).

Align intake air manifold.

Fit all other decoupling elements with nuts and tighten crosswise from inside to outside.

Tightening torque, refer to 11 61 1AZ in ENGINE - TIGHTENING TORQUES - 540i .

Fig 8: Fitting All Other Decoupling Elements With Nuts

Courtesy of BMW OF NORTH AMERICA, INC.