BMW E60 Intake Boot Replacement – 2004-2010 5 Series – M54 6 Cylinder



BMW E60 Intake Boot Replacement – 1 Hour
Basic level repair
Repair cost level 1

The BMW Repair Guide used this 2005 530i for the following article.



Repair Summary
The following article gives detailed instructions on replacing the one piece intake boot on a BMW E60 5 series car with the M54 six cylinder engine. Even though we have used a 2005 BMW E60 530i to perform this repair, this article can be applied to any BMW 3,5,X, or Z series vehicle with the M54 inline six cylinder engine with minor modifications.

A BMW E60 intake boot repair may be needed if your vehicle is displaying the SERVICE ENGINE SOON light on the dashboard, “Increased emissions!” warnings on the iDrive display, and engine code faults 2882, 2883 2986 and 2987 on your diagnostic scanner.

intake boot removal bmw e60 vacuum leak

One of our favorite vehicles here at the BMW Repair Guide is the E60 530i with the M54 engine. It’s a great car, and is still one of our most favorite designed BMWs ever. Unfortunately for us E60 lovers, the earlier ones were plagued with electrical issues that have taken their toll on their owners wallets over the past few years. Another issue that E60 owners are encountering is that many of the plastic engine parts, seals and gaskets are starting to age, causing them to become brittle and leak. As we wrote about in our article Rough Idle Repair – E60 530i, gaskets and plastic parts in the engine compartment are beginning to fail, wreaking havoc as they allow outside air to penetrate the closely metered flow en-route to the intake manifold.

At this point, we are going to stand up on our pulpit and pontificate the necessity of purchasing a smoke machine/leak detector for your garage. One of the biggest repair bugs BMW owners are dealing with these days are vacuum leaks in their vehicle’s intake system. The intake system is a spider web of plastic and rubber parts, so pinpointing where the leak is coming from can really only be done with a smoke testing machine. A visual inspection rarely will reveal the leaking part. We know…not what you wanted to hear at this point. But before you leave our article, please consider this: a trip to the dealership or independent shop to find and fix your intake system leak will cost more than buying a decent smoke machine and doing it yourself. We guarantee you that’s a fact. So why not buy your own so you have it for future home repairs? There are several “non-commercial” machines on the market that will get the job done: if you are interested in purchasing one, we have provided links below in the Tool and Supplies section.

intake boot leak detector smoke machine
The BMW Repair Guide uses the Vacutek EVAPro smoke tester at its facility.

That being said, one of the most common intake system leaks comes from the intake boot. The intake boot connects the air filter box to the throttle assembly, and is at the heart of  incoming air into the engine. The intake boot is mostly comprised of corrugated rubber and plastic that tends to crack over time. Unintentional “manhandling” of the intake boot while doing other repairs in the engine compartment can also cause stress fractures and loose connections. Do to its large size, it always seems to be in the way of some repair on the left side of the car.

A BMW E60 intake boot replacement is a simple job for the DIY mechanic. ***Please be aware that if you currently have dashboard and/or iDrive warning messages on, you may need to use a diagnostic scanner to clear them after the repair.

The BMW Repair Guide highly recommends the use of a diagnostic scanner to help identify and fix issues with your BMW automobile. A good BMW diagnostic scanner is inexpensive, easy to use, and helps take the “guess work” out of diagnosing repair issues with your vehicle. The investment in a diagnostic scanner will usually pay for itself after one repair. If you are interested in using the same diagnostic scanner we use, please click here.

This repair requires that you know which engine model you have in your BMW so you can order the correct parts. Not sure which engine model you have? The BMW Repair Guide uses to verify all of their engine numbers. Simply click on the link below, enter the last seven digits of your BMW’s serial number (VIN number), and your engine model will be displayed along with other information concerning your vehicle.

Get my BMW engine model number

Affiliate link disclosure – The BMW Repair Guide uses affiliate links in their site. For more information on affiliate links, please click here.

1. Intake boot (required) The following intake boot is for the BMW M54 six cylinder only. Not sure which engine you have? Use our engine finder tool at the beginning of this section.

BMW E60 530i with M54 engine

2. Hose clamps (optional) Not required, but highly recommended.  Reusing an old hose clamp that can suddenly fail just doesn’t make sense. Refresh your hose clamps for just a couple extra bucks. You will need two 83-93mm and one 28-33mm clamps.

3. Air filter (optional) Have you changed your engine air filter lately? Since you need to remove it for this repair, now is a great to do it. Keep your inline six cylinder breathing easy with a new filter.

All BMW E60 6 cylinder vehicles


Section 1 – BMW E60 intake boot removal

  1. Disconnect the Mass Air Flow (MAF) sensor from the air filter box.  Using a flat blade screwdriver (or an 8″” socket on a flexible socket spinner) loosen the clamp that holds the intake boot to the air filter e60 intake boot repair - unplug the MAF sensorbmw e60 intake boot repair - loosen the hose clamp connecting boot to airbox
  2. Unfasten the clips securing the plastic cover to the air box. Remove cover from e60 intake boot repair - unclip top of air box and remove
  3. Disconnect the vacuum line from the BMW E60 intake boot by squeezing the plastic ring and pulling it off of its fitting.Remove the vacuum line from the intake boot
  4. Disconnect the electrical connector from the DISA valve. The electrical connector has a metal spring clip on the back side…squeeze it in to release the e60 intake boot repair - disconnect the electrical connection from the DISA valve
  5. Using a T40 torx bit, remove the two bolts anchoring the DISA valve to the intake manifold. CAREFULLY pull the DISA valve out of the e60 intake boot repair - remove the DISA valve mounting boltsRemove the DISA valve from the engine
  6. Using a flat blade screwdriver OR a flexible spinner with 8mm socket, loosen both the Idle Control Valve hose clamp and the throttle body hose clamp. bmw e60 intake boot repair - loosen the idle control hose clampLoosen the throttle bode hose clamp
  7. You can now grasp the intake boot and remove it from the vehicle. PLEASE READ THE FOLLOWING NOTES CONCERNING REASSEMBLY BEFORE INSTALLING NEW BOOT.


***Important notes concerning BMW E60 intake boot reassembly***

It is very important that the new BMW E60 intake boot is correctly attached to the throttle body before you tighten the metal clamp. Doing this for the first time can be frustrating…many mechanics think they have the boot attached, only to have it fall off when they tighten the clamp down. There is a very easy trick to this.

First, there are two tabs on the throttle body that match up with the two slots on the intake boot. Make sure they are lined up when you install the boot to the e60 intake boot repair - match up the intake boot slots bmw e60 intake boot repair - match up the throttle body tabs

Then, while keeping the boot level and lined up, push firmly. You have to push the boot on until it “snaps” into place on the throttle body…and it takes a little bit of force. But once it snaps into place you will know because you will not be able to easily pull it back off. You can now tighten the metal e60 intake boot repair - push intake boot onto throttle body

At this point you can go ahead and reassemble the intake system following the above directions in reverse.

BMW E60 Intake Boot Repair Finished
If you have any questions or comments, please feel free to contact us. And congratulations for Doing It Yourself!