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.
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.
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.
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.
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.
- 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 box.
- Unfasten the clips securing the plastic cover to the air box. Remove cover from vehicle.
- Disconnect the vacuum line from the BMW E60 intake boot by squeezing the plastic ring and pulling it off of its fitting.
- 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 connector.
- 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 manifold.
- 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.
- 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 throttle.
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 clamp.
At this point you can go ahead and reassemble the intake system following the above directions in reverse.