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X3 E83 (2004 - 2010)
Talk about the E83 BMW X3 in this forum!

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  #1  
Old 04-20-2015, 12:54 PM
jlex jlex is offline
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X3 intake manifold question

I've been receiving intermittent SES lights on my 2005 X3 (3.0). Running lean.
I'll knock off the light, then it'll reappear about 500 miles later.
Did a smoke test last summer to find leakage around the intake manifold gaskets, so I plan to take the intake manifold off this summer & replace the gaskets.
Anyone removed their intake manifold? I have the new Bentley book, and it's pretty explanatory.
My question is do I need to remove the DISA valve and the throttle body in order to remove the manifold? Bentley doesn't say anything about removing the DISA, but does say to remove the throttle body. I'm going to order gaskets & don't know if I can get by without those additional gasket parts or not. I'm not replacing the manifold itself, just the gaskets.
Let me know if anyone has any handy tips...
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  #2  
Old 04-20-2015, 01:11 PM
jdowen2 jdowen2 is offline
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Follow this:http://www.pelicanparts.com/bmw/tech...e-Manifold.htm
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  #3  
Old 04-20-2015, 02:35 PM
oraclesd oraclesd is offline
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If you're having any issues with your starter i.e. sluggish starts, etc it would be a great time to replace it while you have the intake out.
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  #4  
Old 04-21-2015, 06:54 AM
jlex jlex is offline
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Thanks for the link.
No problems whatever with the starter... If it goes bad afterward, I'll shoot myself.
Same goes for the CCV valve which I am also not planning to replace
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  #5  
Old 04-21-2015, 07:34 AM
swampX3 swampX3 is online now
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disa checks

take the disa off .....2 fasteners and an elec connector.....check for the usual failure modes .....pin backing out etc

take the throttle body and idle control valve off .....clean and gummout
check for smooth operation of idle valve

swap the intake boot if not already done
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  #6  
Old 04-21-2015, 08:31 AM
jlex jlex is offline
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Quote:
Originally Posted by swampX3 View Post
take the disa off .....2 fasteners and an elec connector.....check for the usual failure modes .....pin backing out etc

take the throttle body and idle control valve off .....clean and gummout
check for smooth operation of idle valve

swap the intake boot if not already done
Yeah, good advice. I didn't think of doing any cleaning/inspecting of those componenets. Looks like I'll need gaskets for those things.
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  #7  
Old 04-21-2015, 09:55 AM
swampX3 swampX3 is online now
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a good go by kit for manifold work etc

https://www.fcpeuro.com/products/bmw...6f95-204150005


this is good cause it has the 6 o rings (Engine Air Distribution Piece O-Rings)

Last edited by swampX3; 04-21-2015 at 09:57 AM. Reason: add info on o rings
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  #8  
Old 04-21-2015, 10:24 AM
jlex jlex is offline
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Thanks, but isn't the air distribution piece left on the intake manifold when just replacing the manifold gasket? Not sure there's a need to replace the O rings on it if it's left alone...
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  #9  
Old 04-21-2015, 12:49 PM
swampX3 swampX3 is online now
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on or off ?

for the cost of a starbucks I would change the o rings....they get hard and crack and are mini leak paths....they get as hard as old dipstick O rings that make it hard for folks to pull it out to check oil levels on the dipstick engines.....another 75 cent o ring that makes a big difference
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  #10  
Old 04-21-2015, 01:07 PM
jlex jlex is offline
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That's a good suggestion.
Seems to be a slippery slope taking care of things "while I'm in there".
I've wondered why I practically dislocate my finger every time I check the oil. Will have to check the dipstick O ring... another good suggestion.
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  #11  
Old 04-21-2015, 01:15 PM
mrsanchez3 mrsanchez3 is offline
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Quote:
Originally Posted by jlex View Post
That's a good suggestion.
Seems to be a slippery slope taking care of things "while I'm in there".
I've wondered why I practically dislocate my finger every time I check the oil. Will have to check the dipstick O ring... another good suggestion.
That is so the truth... The current maintenance work I'm prepping started with me looking to replace the plugs. That has morphed into plugs, ignition coils, VCG and related seals, VANOS seals, VANOS oil line, CCV system. sheesh.
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  #12  
Old 04-21-2015, 01:27 PM
jlex jlex is offline
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Quote:
Originally Posted by mrsanchez3 View Post
That is so the truth... The current maintenance work I'm prepping started with me looking to replace the plugs. That has morphed into plugs, ignition coils, VCG and related seals, VANOS seals, VANOS oil line, CCV system. sheesh.
I hear ya... If these components were individually accessible, you could do one thing at a time. Problem with these cars is you have to pull a lot out of the way to reach your objective so to avoid that .....
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  #13  
Old 04-21-2015, 01:34 PM
swampX3 swampX3 is online now
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some good views

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  #14  
Old 04-21-2015, 02:00 PM
timarnold timarnold is offline
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Not to add on, but it's not a bad time to replace your Oil Filter Housing Gasket as well. It's very inexpensive (<$7) and with the intake manifold off a breeze to change.
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  #15  
Old 04-21-2015, 02:13 PM
swampX3 swampX3 is online now
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dipstick o rings

when the two o rings at the top of the dipstick swell and crack/deteriorate it can take a block and tackle to pull the stick out .....replace them for happy customers !.....the two o rings are in the picture in this fest post below.....he asks the question "does anyone ever replace these o rings "....it's a must !

https://www.google.com/url?sa=i&rct=...29737076198698

generic o ring part no info.....most sticks take two o rings

http://parts.bmwofsouthatlanta.com/p...431717666.html

Victor Reinz Oil Dipstick Seal - Upper
Retail Price:
$2.59
Sale Price:
$2.33
Quantity:

(13) In Stock
Part Number: W0133-1662180
Notes: 9.0 X 2.2
Position: Upper
Condition: New

Shipping Options:
Ground, Overnight, 2 Day
OEM

Last edited by swampX3; 04-21-2015 at 02:34 PM. Reason: add parts/links
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  #16  
Old 04-22-2015, 07:02 AM
jlex jlex is offline
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Quote:
Originally Posted by timarnold View Post
Not to add on, but it's not a bad time to replace your Oil Filter Housing Gasket as well. It's very inexpensive (<$7) and with the intake manifold off a breeze to change.
Thanks. Caught that last summer along w/ the valve cover gasket.
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  #17  
Old 04-23-2015, 10:18 AM
mrsanchez3 mrsanchez3 is offline
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Quote:
Originally Posted by swampX3 View Post
Great video. Thanks for sharing. I hadn't stumbled on this one before.
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  #18  
Old 04-23-2015, 06:57 PM
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sayemthree sayemthree is offline
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throttle body boot?
DISA valve gasket leak ?

when my throttle body boot leaked I could hear a sucking sound on acceleration. good time to inspect the DISA valve too.
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  #19  
Old 04-27-2015, 07:50 AM
jlex jlex is offline
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I'll replace the boot while I'm in there although the smoke test I did showed leakage around the bolt areas holding the intake manifold. I've ordered the DISA valve gasket so I can take a look at it before it has a chance to self-destruct.
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  #20  
Old 04-27-2015, 08:00 AM
jma1992 jma1992 is online now
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CCV bypass, using a catch can. Seems like a few E39 and few E53 owners have done it. Just a thought.
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  #21  
Old 04-27-2015, 08:15 AM
jlex jlex is offline
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Quote:
Originally Posted by jma1992 View Post
CCV bypass, using a catch can. Seems like a few E39 and few E53 owners have done it. Just a thought.
Totally in the dark on that solution
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  #22  
Old 04-27-2015, 09:03 AM
jma1992 jma1992 is online now
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Quote:
Originally Posted by jlex View Post
Totally in the dark on that solution
Same here lol.. Did some searching and came up with these threads.

http://www.bimmerfest.com/forums/sho...=601440&page=2

http://www.bimmerfest.com/forums/sho...d.php?t=822172

http://www.xoutpost.com/bmw-sav-foru...project-6.html


That boot is a PIA, do yourself a big favor and make sure the clamps are facing up or in a direction where they are easier to access. I replaced mine last fall.
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  #23  
Old 05-18-2015, 06:17 AM
jlex jlex is offline
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Followup:
I removed the intake manifold last weekend to replace the gasket. While I was in there, I also replaced the starter and the CCV system. At 108,000 miles, I figured the starter or CCV would start giving me trouble so...
Took the opportunity to inspect & clean the DISA & throttle body. Also cleaned up the IAC valve. New gaskets all around. I did the OFHG last year.
I was going to leave the fuel rail attached to the manifold, but absolutely couldn't access the joint to release the gas line... it's between the IM and the firewall, not beside the dipstick as shown in the Bentley manual. Ended up removing the fuel rail along w/ the harness to disengage it from the fuel system. Replaced the O rings on the injectors before reinstalling.
Only glitch I encountered was wrestling w/ the torx bolts holding the starter on and dropping an injector into the engine after the manifold was installed
Here are a few pix I took during the process. You can see where the old gasket was ripped up and allowing a vacuum leak. According to the Carfax report (I bot this car used a couple years ago) the IM had been replaced (cracked maybe?). Looks like the joker at the dealership was careless on reinstalling it as it appears the gasket was ripped on the engine stud. Get someone to help reposition the IM to make sure this doesn't happen to you.
I am posting a step by step process for anyone who wants to go thru the same process. It's a good checklist:

Intake Manifold Removal on 2005 X3 3.0 engine

disconnect battery
remove front plastic cowling (4 T30 torx bolts)
remove band clamp from air filter housing to air intake boot
remove 2 (10mm bolts) from base of air filter housing
disconnect (and label) wire from MAF sensor
uncouple wire harness from side of air filter housing
remove 4 coarse-threaded (T30) screws found under front cowling
lift air filter housing & front cowling out together
remove top brace over engine 4 (13mm) bolts
remove cabin filter
loosen 4 (T30) captive bolts from inside cabin air cleaner housing
unclip rubber wire support from bottom part of air cleaner housing
pull out cabin air filter housing
remove 2 plastic clips & pull weather-stripping from top of rt side bulkhead
pull vacuum hose out of brake booster
pull out bulkhead
remove plastic top plate covering injectors 2 (10mm) bolts & cover
remove & label electrical connector from DISA. Remove 2 (T40) bolts from DISA
disconnect vacuum line bracket 1 (T30) bolt
2 clamps holding air intake boot can now be reached. Remove both clamps & boot
disconnect and label all electrical connections coming off of distribution box
remove distribution box (1 10mm bolt & 2 10mm nuts)
pull box out of the way
remove 2 (T40) bolts from IAC bracket, then pull idle air control valve off
remove electrical connector & 4 long (10mm) bolts then remove throttle body
disconnect electrical connector at vanos
remove fuel rail: disconnect and label electrical connectors
pull out 2 metal brackets from fuel rail loom that hold O2 sensor connectors
pull out wire clips holding connectors to injectors, then push aside wire loom
release gas pressure from fuel rail using Schraeder valve
take off 4 (10mm) nuts holding fuel rail; pull injectors out of manifold along with fuel rail; set aside
remove 9 (11mm) manifold nuts
remove nut holding manifold bracket at bottom of manifold
disconnect dipstick hose at bottom of CCV valve
disconnect vacuum line from fuel tank sensor near power steering reservoir
release barrel switch from metal holder at bottom of intake manifold
disconnect vacuum line at right rear side of manifold
undo gas line bracket from underside of manifold (T30 bolt)
remove plastic bolt from top of manifold (12mm) holding red battery cable
lift off manifold

On reassembly, clean throttle body & DISA valve. Replace:
intake manifold gasket
IAC gasket
throttle body gasket
lower injector O rings
DISA valve gasket

Think about replacing:
CCV system
oil filter housing gasket
starter
alternator
radiator hoses


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