I have the same problem on a 2001 BMw 325Ci... According to the manual there is another nut underneath the manifold attached to a support bracket. This nut must be removed before the manifold can be removed, but it is difficult to see. I have not found it yet. I am guessing that like most of the bolts and connections in this generation of BMW's you will be working blind and by feel alone....
I am trying to get to the oil seperator / PCV valve... who would have put this where it is... I am for the first time questioning German design and engineering. I have the same problem on a 2001 BMw 325Ci... According to the manual there is another nut underneath the manifold attached to a support bracket. This nut must be removed before the manifold can be removed, but it is difficult to see. I have not found it yet. I am guessing that like most of the bolts and connections in this generation of BMW's you will be working blind and by feel alone....
I am trying to get to the oil seperator / PCV valve... who would have put this where it is... I am for the first time questioning German design and engineering.
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Removing the intake looks ******* the 750il m70 but its not. I took mine off and painted it glossy black with rustoelum. You will need to disconnect and remove your fuel injectors and wire harness. Then with a flat head lososen and remove both of your air filter housings then use a 10mm socket remove your throttles. Dont forget to disconnect the sensors in back of the intakes aswell. Use a 10 remove the intake bolts. The bottom bolts are tricky and hard to see you will need to remove the injector silencers which are the two small walls made of fiber and foil. They are located right between the intake and valve covers. A few screws at the top of the intake hold them in and can easily be removed. After that you will needa long extension to get to the bottom row of 10mm bolts. Use the openings you made by removing the silencers to get easy access to the bottom row. The bolts will fall after you unscrew them so i use a piecec of paper and jam it into my socket so the bolt eont come out. After you remove the bolts you can pull both intakes up at one time. Hoped this helped good luck
Upper intake manifold bolts : 89 in.lb. Lower intake manifold bolts : 89 in.lb. Thottle body bolts :89 in.lb. Front intake manifold support nut:89 in.lb. Upper intake support bracket nuts :53 in.lb. Reference:Service manualif you need further assistance please let me know and i will be glad to assist you further. If this has assisted you please feel free to rate the solution thanks -Midwest-tek
Very easy job but I don't think there is a diagram. You'll need to remove the wiper arms, then the black snaps that attach the front cowl just below the windshield, then remove all the 8mm bolts that hold the front cowl down at the back of the engine compartment...leave the wiper motor attached to it, just un-plug it, un-plug the washer hose and lift the cowl out. Now you can get at all the bolts and studs that hold the top half of the plenum, remove them and the throttle linkage, also the vacuum line at the back of the intake, also the EGR solenoid connector. Remove the top half of the plenum Now remove all the 8mm bolts that hold the lower half to the manifold and lift it out. When you re-install it, use new seals as they always leak even though they look good- this is the biggest cause of lean codes on this vehicle.
There is a support bar that runs from the middle of the block to the bottom of the intake. The manifold will not nove, even if you have all the bolts out When you put it back together, make sure to start all dolts for the support gracket abd then torque down the manifold. If you don;t do it like this, you will never be able to start the bolts in the support bracket
NOTE
The 3.8L (VIN K) non-supercharged engine uses a two-piece intake
manifold consisting of an upper air plenum which mounts the throttle
body and a lower intake manifold assembly which houses the fuel
injectors. The 3.8L (VIN 1) supercharged engine uses a similar lower
intake manifold. The supercharger serves as the upper manifold. Lower Manifold
NOTE
Two bolts which fasten the lower intake manifold to the cylinder
head are accessible only after the upper intake manifold is removed.
These bolts are located in the right front and left rear corners of the
lower intake manifold. Remove the upper intake manifold to service the
lower intake. The 3.8L (VIN 1) supercharged engine uses a manifold
similar to the 3.8L (VIN K), but the supercharger serves as the upper
manifold.
Disconnect the negative battery cable.
On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
Remove the upper intake manifold using the procedure above.
Remove the EGR outlet pipe from the intake manifold.
Detach the engine coolant temperature sensor wiring harness from the sensor.
Remove the lower intake manifold bolts and carefully lift off the manifold.
Clean all parts well with degreaser, especially the gasket seal
surfaces on the upper and lower manifold pieces and between the lower
manifold and the cylinder heads..
Install new gaskets to the cylinder heads and new seals to the
engine block. Carefully lower the manifold into place. Apply
thread-locking compound to the bolt threads. Make sure to install the
two hidden bolts in the lower intake manifold. Hand start all bolts,
then torque evenly to 11 ft. lbs. (15 Nm). Follow the toque sequence,
starting in the center, then working outwards in a circle.
Install the remaining components in the reverse order of the removal process.
Upper Intake Manifold (Plenum)
Disconnect the negative battery cable.
On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
Tag for identification, then remove the right side spark plug wires.
Disconnect the ignition wires from the fuel rail.
Remove the fuel rail. Please see Section 5.
Remove the cable bracket from the intake manifold.
Remove the throttle body.
NOTE
Two bolts which fasten the lower intake manifold to the cylinder
head are accessible are accessible only after the upper intake manifold
is removed. These bolts are located in the right front and left rear
corners of the lower intake manifold.
Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engine.
Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine To install:
Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
Install new gaskets to the cylinder heads and new seals to the
engine block. Carefully lower the manifold into place. Make sure to
install the two hidden bolts in the lower intake manifold. Hand start
all bolts, then torque evenly to 89 inch lbs. (10 Nm). Follow the
torque sequence, starting in the center, then working outwards in a
circle.
Install the remaining components in the reverse order of the removal process.
you can either go in from the bottom or the top.. top take intake off and starter is below againt firewall.. bolts holding it in are wedged between trans housing and firewall tight but you can manage.. remove and reinstall be careful of wires when i did it 2 snapped off and hard to replace them.. going from below you need to remove exhaust a small canister on a bracket and loosen the transmission and lower about 2 inches before being able to get to the starter to remove..
Hi the crank shaft sensor is located just above the front pulley at the front of the engine and is held in place be a 5mm hex bolt, undo this and remove the sensor then you will need to follow the wire that dissapears under the intake manifold and unplug the multiplug, replacement is the reverse, regards mark
Removing the intake is no prob. on these. Assuming this is a non turbo model, you remove the two bolts holding the egr tube flange at the back of the intake. You will have a couple wire clips you need to dissconect and small vacum hoses that will be easily noticable as you try to move the intake aside, but there is a row of small bolts at the front inbetween the intake rails holding the upper intake to the lower. Seperate the manifold by removing these bolts. it has rubber gaskets that stay right with the manifold you do not need to replace at reassembley. This will allow you to move it far enough to change the plugs. Hope this helps.
Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine
I have the same problem on a 2001 BMw 325Ci... According to the manual there is another nut underneath the manifold attached to a support bracket. This nut must be removed before the manifold can be removed, but it is difficult to see. I have not found it yet. I am guessing that like most of the bolts and connections in this generation of BMW's you will be working blind and by feel alone....
I am trying to get to the oil seperator / PCV valve... who would have put this where it is... I am for the first time questioning German design and engineering.
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