BMW M52 Intake Manifold Removal – 1995-2000 3,5,7,Z3 Series 6 Cyl.

BMW M52 Intake Manifold Reassembly Checklist

• Reattach the vacuum lines to the rear left corner of the intake manifold.
• Reattach the two fuel lines to the rear right corner of the intake manifold.
• Install the positive battery cable back through the intake manifold. It should be directed through the last opening in the manifold (between ports 5 and 6).
• Carefully lower the intake manifold back into place onto the cylinder head studs. Also verify that it is properly seated on its lower mount.
• Reconnect the electric vacuum control valve at the left rear corner of the manifold.
• Reconnect the intake manifold's vacuum line to the suction jet pump. Secure it with a "worm gear" style hose clamp.
• Reach down behind the intake manifold and reconnect the coolant temperature sensor into the cylinder head.
• Reconnect the PCV valve to the lower vent hose (dipstick return line).
• Reattach the positive battery cable to the top of the intake manifold using the plastic nut. There is no torque value for this nut...just make sure it is snug.
• Double check once again that the manifold is properly lined up on all of its mounting studs, including the lower one.
• Install the lower intake manifold mounting nut. Torque the nut to 47 Nm (34 ft-lb).
• Install the nine cylinder head mounting nuts. Torque the nuts to 15 Nm (11 ft-lb).
• If you are installing a new throttle body gasket, do it now.
• Install the electrical plug back into the throttle body.
• Mount the throttle body back onto the intake manifold. Torque its four mounting bolts to 13 Nm (10 ft-lb).
• Position the wiring harness in front of the intake manifold. Install its front mounting bolt. There is no torque value on this bolt, just make sure it is snug.
• Install the dipstick tube mounting bolt. Torque the bolt to 24 Nm (17 ft-lb).
• Reinstall the rear wiring harness nut. DO NOT FORGET THE GROUNDING STRAP. There is no torque value on this nut.
• Reinstall the intake boot back onto the throttle body. Make sure the intake boot is firmly seated on the throttle body...if it is not it can come loose and cause a vacuum leak. Tighten the throttle body hose clamp.
• Attach the throttle cable back to the idle control air bracket.
• Maneuver the idle control valve into position in front of its mounting hole in the intake manifold.
• Reinstall the electrical plug into the end of the idle control valve.
• Attach the intake boot to the idle control valve. Tighten the hose clamp.
• Install the idle control valve into the intake manifold. Press it in firmly with your hands to ensure it has a good seal.
• Install the two T40 idle control bracket mounting bolts.
• Install the wiring harness support bracket back onto the idle control valve bracket. Install the 10mm nut.
• Reinstall the DISA valve into the intake manifold. Install its two T40 mounting bolts.
• Install the DISA valve electrical plug.
• Plug the vacuum line back into the top of the intake boot.
• Replace the vacuum line back onto fuel tank vent valve.
• Plug the fuel tank vent valve's electrical connection back in.
• Reinstall the MAF sensor into the intake boot and tighten the hose clamp.
• Plug the MAF sensor's electrical connection back in.
• Reinstall the intake muffler and the intake snorkel.
• Plug the wiring harness back into the E-box
• Replace the E-box cover and tighten its T30 bolts
• Attach the positive battery cable to the engine compartment terminal. Tighten the 19mm nut.
• Plug the fuel injector wiring harness into the air temperature sensor on the top of the intake manifold.
• Install the fuel injector wiring harness back on the fuel injectors.
• Install the plug back in the solenoid valve.
• Install the crankcase breather line back into the valve cover
• Reattach the rear vacuum line to fuel rail.
• Reinstall the oxygen sensor clips and the oxygen sensor connections to the top of the intake manifold.
• Reinstall the left engine cover.