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The following article gives detailed instructions on replacing the throttle body gasket in a BMW M60 8 cylinder engine. Even though we have used a 1995 840i to perform this repair, this article can be applied to any vehicle with the M60/M62 V8 engine including 5, 7, 8 and X5 series vehicles with minor modifications to the repair steps.
A BMW M60 throttle body gasket replacement can fix vacuum leaks causing a rough idling engine.
The BMW M60 and M62 8 cylinder engines powered many different models throughout the 1990's and early 2000's, including the E31 8 series, E32/E38 7 series, E34/E39 5 series and the E35 X5. Other than the Nikasil issue that affected a few early M60 motors, they are generally regarded as very reliable engines. But as with all BMW motors that are increasing in age they are prone to deteriorating parts. As we constantly say here at the Repair Guide, "our vehicles were not built to last forever". Eventually many of the engine's parts will fail and need to be replaced.
One common area of failure in the M60/M62 8 cylinder engines is the gaskets that comprise the air intake system. The brutal heat conditions within the engine compartment take their toll on the rubber gaskets and seals, eventually causing them to become brittle and crack. Failing intake system gaskets suck unmetered air into the cylinders and can cause a variety of issues including rough idling engine, engine stalling, difficulty starting the engine, and error codes and dashboard lights.
The throttle body gasket on M60/M62 engines is a well-known source of vacuum leaks and is luckily one of the simpler ones to replace. Since the throttle body is located on the front of the intake manifold, removing it to replace the gasket is very straightforward with a limited amount of parts that need to be moved out of the way. A BMW M60 throttle body replacement takes about two hours to perform from start to finish and does not require any special tools other than the long reach (6") T30 Torx bit that can be purchased from our tool list below.
M60 Engine - All Models
1995 BMW 530i
3.0L V8 - Gas
1994 BMW 530i
3.0L V8 - Gas
1995 BMW 540i
4.0L V8 - Gas
1994 BMW 540i
4.0L V8 - Gas
1995 BMW 740i
4.0L V8 - Gas
1994 BMW 740i
4.0L V8 - Gas
1993 BMW 740i
4.0L V8 - Gas
1995 BMW 740iL
4.0L V8 - Gas
1994 BMW 740iL
4.0L V8 - Gas
1993 BMW 740iL
4.0L V8 - Gas
1996 BMW 840Ci
4.4L V8 - Gas
1995 BMW 840Ci
4.0L V8 - Gas
1994 BMW 840Ci
4.0L V8 - Gas
View the detailed parts diagram for this repair.
Includes detailed part diagrams, part numbers and links to purchase all of the required components needed to complete this repair.
Before starting this repair, you must have the following required parts.
All BMW M60 engines. BMW M62 engines with production date to 09/1998
This is the same factory throttle body gasket that would be installed at the dealership.
All BMW M60 and M62 V8 engines
This is the same factory secondary throttle o-ring that would be installed at the dealership.
All BMW M60 and M62 engines
Used as both a throttle body and crankcase vent mounting bolt on M60 and M62 8 cylinder engines. These T30 torx bolts are notorious for stripping due to a combination of soft metal and age. M6x25
Pre-cut 1 meter length of 8mm (id) x 13mm (od) fuel hose. Many uses in BMW vehicles including vacuum lines and fuel system.
BMW E30, E31, E32, E34, E38, and E39
10.5mm rubber stop plug. Many uses in BMW engines.
All BMW models with M60/M62 V8 engine
The air filter must clean 8000-9000 gallons of air for each gallon of gasoline burned inside the engine, without restricting the air intake. Air filter replacement at recommended intervals lets an engine breathe properly while protecting it from costly damage. Air filters should be inspected and replaced as needed at least once a year, more often if the vehicle is driven in heavily polluted or dusty conditions.
Section 1 - Removing the BMW M60 Throttle Body Gasket
Removing the throttle body gasket on your BMW M60/M62 8 cylinder engine is a straightforward procedure. It is important to note that space around the lower throttle body mounting bolts is extremely confined....the secondary throttle must be removed to access them. If you do not have a 6" T30 long bit socket in your toolbox, you will need to purchase one before starting this repair. Please see our tool list if you wish to order one.
Remove the four 10mm nuts anchoring the top engine cover. Remove cover from engine compartment.
Disconnect the idle control valve by pinching in the metal release clip and pulling the plug free.
Next, disconnect the throttle body.
Use a flatblade screwdriver to raise the metal locking clip on the throttle valve switch. Pull the plug free and gently stow out of the way.
Disconnect the mass air flow sensor's (MAF) electrical connection.
Use a flatblade screwdriver to release the seven metal clips that secure the lid on the intake muffler.
Loosen the hose clamp connecting the intake muffler to the intake boot. Remove the intake muffler from the vehicle.
Grasp the idle control valve and pull it free from the intake manifold. Disconnect the idle control valve hose from intake boot and remove from the vehicle.
Loosen the hose clamp that secures the intake boot to the secondary throttle housing (ASC+T unit). Remove the intake boot from the vehicle.
Next, remove the Bowden cable from the bottom of the secondary throttle housing by pushing the spring mechanism back to release the tension on the cable. With the tension released, grab the cable’s barrel fitting and pull it off of the spring mechanism as shown below. Using an inspection mirror helps in locating the barrel fitting. Stow the cable safely out of the way.
Disconnect the accelerator and cruise control Bowden cables from the throttle body by grasping their black plastic cable stops and pulling them free of the spring mechanism.
Use a T30 torx bit to remove the two throttle body mounting bolts anchoring the cable bracket. These bolts are notoriously prone to stripping. We suggest soaking them in PB Blaster first for 15 minutes before attempting to remove them. If you strip the heads, please see step 20 below for an easy way to extract them. If you need to order new bolts, please see our parts list.
Disconnect the plastic retaining clip anchoring the cable to the cover bracket. Lay the throttle cable bracket safely to the side away from the work area.
As discussed at the beginning of this section, it is nearly impossible to remove the lower throttle body mounting bolts without removing the secondary throttle body first...there just isn’t any short cuts around it. Access is very tight in this area of the engine, especially around the thermostat.
Start by removing the vacuum hose connecting the fuel tank vent valve to the throttle body. This hose must be removed to properly access the lower secondary throttle mounting bolts. This hose is a common source of vacuum leaks..now is a great time to replace it if yours is old and brittle. You can use a 12” piece of 8mm (5/16”) fuel hose to replace it from any auto-parts store, or you can order one from our parts list.
Remove the three secondary throttle mounting bolts using a long (6”) T30 torx bit. You will have to use a 6” torx bit….there is just not enough clearance to use a regular size bit to extract the bolts. If you do not have a set of 6” torx bits you can order them from our tool list.
Grasp the secondary throttle and remove it from the throttle housing. Note that there is an o-ring that seals it to the throttle body. This should also be replaced with the throttle body gasket (see our parts list to order).
The throttle body is anchored to the intake manifold by six T30 bolts. Two of them were removed in step 12 above. The other four will need to be removed now. Note that the throttle body bolts are notorious for stripping. We strongly recommend soaking them in Blaster PB for about 15 minutes before attempting to remove.
Use a 6” T30 torx bit to remove the remaining four throttle body bolts. Note that the bottom center bolt is very difficult to see...use an inspection mirror to locate it if necessary.
If you end up stripping one of the throttle body bolts (like we did), simply drill the bolt head with a ¼” drill bit until it snaps off. Please see our parts list to reorder new throttle body bolts.
When all the T30 bolts are removed, grasp the throttle body and remove it from the intake manifold.
Section 2 - Replacing the Gasket and Reinstalling the Throttle Body
Make sure to thoroughly clean both the throttle body and intake manifold so the new gasket properly seals. Now is also a great time to clean the inside of the intake manifold since you can reach your hand in with the throttle body removed.
Use a metal pick to remove the old throttle body gasket from the intake manifold.
Use CRC Brakleen to clean both the intake manifold and throttle body surfaces. Be sure to remove any excess oil and grime that could cause the new gasket not to seal correctly.
Soak a rag with CRC Brakleen and wipe down the inside of the intake manifold. You can see we removed quite a bit of sand and oil that was stuck to the bottom of ours.
Inspect the rubber stop plug that may be installed in your M60's throttle body. This rubber plug tends to dry out and crack with age causing a vacuum leak and a rough idling engine. Ours was so dried out we actually had to score it with a Dremel to get it off of the throttle body. Replace the stop plug with a fresh one (see our parts list to order a new stop plug or click here). Simply use a zip tie to hold it in place (you don't need to use a hose clamp).
Install the new throttle body gasket into the intake manifold.
Reinstall the throttle body and hand tighten its six mounting bolts. DO NOT forget the throttle cable bracket that attaches to the top left mounting bolts! Use a piece of masking tape to secure the bolts onto the T30 torx bit...this will keep them from falling off while installing.
Torque the throttle body bolts to 10 Nm (7.5 ft-lb).
Remove the old o-ring from the secondary throttle body and install a new one.
Reinstall the secondary throttle and hand tighten the three mounting bolts.
Torque the three mounting bolts to 10 Nm (7.5 ft-lb). Note that the lower mounting bolt can be difficult to get to with the torque wrench...work slowly and use patience so you don't strip its head.
Install the fuel tank vent valve vacuum hose. If you are installing a new hose like we are, use a fresh #4 hose clamp to secure it to the secondary throttle. Make sure to attach the other end to the fuel tank vent valve itself.
Reinstall the throttle cables and the secondary throttle cable.
Reinstall the rest of the intake system following Section 1 steps 1-9 in reverse.
Part # 13-71-1-702-002 - Rubber ring between rubber intake boot and secondary throttle housing tube. Fits: BMW E31 840Ci, BMW E32 740i, BMW E32 740iL, BMW E34 530i, BMW E34 540i, BMW E38 740i, BMW E38 740iL, BMW E39 540i
RaceChip developed the new XLR to increase responsiveness on the road. Their innovative throttle tuning system lets you tune your engine's reactions to your taste - choose from 7 separate stages (Eco+, Eco, Neutral, Sport, Sport+, Race, and Race+). Your engine's performance isn't affected by RaceChip XLR, but you can access it more immediately and directly. Experience significantly sharper responses for yourself - no waiting for the message to get through or frustrating "pauses for thought". And the best thing: installation is simple and requires no specialist knowledge. Try it now! The Brainbox: The Brainbox is the nerve center of XLR and controls the processes needed to optimize throttle response. The Brainbox's compact size (ca. 70 x 80 mm) allows it to be fitted easily in the footwell of your vehicle. As it is so flat, it does not restrict the driver's legroom at all. It can be fixed almost anywhere in the footwell, for example in existing slots or vents. The Controller: The XLR Controller allows you to choose between 7 stages: Eco+, Eco, Neutral, Sport, Sport+, Race and Race+. Each stage sharpens your car's throttle response a little more, until in Race+ it's like a thoroughbred sports car. You can mount the Controller anywhere in the car so that it's in the right place for how you want to use it. The size and design mean it fits right in with the rest of the interior and the other control elements. Fits: BMW E70, BMW E71, BMW F01, BMW F02, BMW F07, BMW F10, BMW F25, BMW Z4 sDrive30i, BMW Z4 sDrive35i, BMW Z4 sDrive28i, BMW Z4 sDrive35is, BMW G30, BMW F12, BMW F13, BMW F30, BMW E84, BMW F32, BMW F31, BMW F34, BMW F22, BMW F06, BMW F80, BMW F82, BMW F15, BMW F16, BMW F83, BMW F36, BMW F33, BMW F26, BMW F23, BMW F85, BMW F86, BMW G11, BMW F87, BMW F48, BMW F39, BMW G01, BMW G32, BMW G02
Part # 13-63-1-721-456 - Does your car surge when it is idling? If so, it is probably time to replace the throttle position switch. Fits: BMW E30 318i M42 1.8L, BMW E30 318is M42 1.8L, BMW E31 840Ci M60 4.0L, BMW E31 840Ci M62 4.4L, BMW E32 740i M60 4.0L, BMW E32 740iL M60 4.0L, BMW E34 530i M60 3.0L, BMW E34 525i M50 2.5L, BMW E34 540i M60 4.0L, BMW E36 318i M42 1.8L, BMW E36 318i M44 1.9L, BMW E36 318is M42 1.8L, BMW E36 318is M44 1.9L, BMW E36 325i M50 2.5L, BMW E36 325is M50 2.5L, BMW E36 M3 S50 3.0L, BMW E36 M3 S52 3.2L, BMW E36 318ic M42 1.8L, BMW E36 318ic M44 1.9L, BMW E36 318ti M42 1.8L, BMW E36 318ti M44 1.9L, BMW E36 323ic M52 2.5L, BMW E36 323is M52 2.5L, BMW E36 325ic M50 2.5L, BMW E36 328i M52 2.8L, BMW E36 328ic M52 2.8L, BMW E36 328is M52 2.8L, BMW E38 740i M60 4.0L, BMW E38 740i M62 4.4L, BMW E38 740iL M60 4.0L, BMW E38 740iL M62 4.4L, BMW E39 528i M52 2.8L, BMW E39 540i M62 4.4L, BMW Z3 1.9 M44 1.9L, BMW Z3 2.8 M52 2.8L, BMW Z3 M Coupe S52 3.2L, BMW Z3 M Roadster S52 3.2L
RaceChip developed the new XLR to increase responsiveness on the road. Their innovative throttle tuning system lets you tune your engine's reactions to your taste - choose from 7 separate stages (Eco+, Eco, Neutral, Sport, Sport+, Race, and Race+). Your engine's performance isn't affected by RaceChip XLR, but you can access it more immediately and directly. Experience significantly sharper responses for yourself - no waiting for the message to get through or frustrating "pauses for thought". And the best thing: installation is simple and requires no specialist knowledge. Try it now! The Brainbox: The Brainbox is the nerve center of XLR and controls the processes needed to optimize throttle response. The Brainbox's compact size (ca. 70 x 80 mm) allows it to be fitted easily in the footwell of your vehicle. As it is so flat, it does not restrict the driver's legroom at all. It can be fixed almost anywhere in the footwell, for example in existing slots or vents. The Controller: The XLR Controller allows you to choose between 7 stages: Eco+, Eco, Neutral, Sport, Sport+, Race and Race+. Each stage sharpens your car's throttle response a little more, until in Race+ it's like a thoroughbred sports car. You can mount the Controller anywhere in the car so that it's in the right place for how you want to use it. The size and design mean it fits right in with the rest of the interior and the other control elements. App Control: RaceChip is the first company to offer throttle tuning together with app control. The combination gives you the easiest ever way of controlling your vehicle's throttle response. RaceChip XLR connects directly with the RaceChip app on your smartphone via Bluetooth. If you already have a RaceChip chip tuning module in your car, XLR is the perfect add-on, and using them together is even easier - you can control both modules from the driver's smartphone using the same app. Fits: BMW E70, BMW E71, BMW F01, BMW F02, BMW F07, BMW F10, BMW F25, BMW Z4 sDrive30i, BMW Z4 sDrive35i, BMW Z4 sDrive28i, BMW Z4 sDrive35is, BMW G30, BMW F12, BMW F13, BMW F30, BMW E84, BMW F32, BMW F31, BMW F34, BMW F22, BMW F06, BMW F80, BMW F82, BMW F15, BMW F16, BMW F83, BMW F36, BMW F33, BMW F26, BMW F23, BMW F85, BMW F86, BMW G11, BMW F87, BMW F48, BMW F39, BMW G01, BMW G32, BMW G02
By using state of the art electronics, Sprint Booster allows crisp and instantaneous acceleration, eliminating all delays. A dash mounted selectable switch lets you choose between stock/moderate/aggressive acceleration modes at the touch of an LED button. Most cars of the 20th Century have replaced the more conventional throttle cable with an electronic control module that translates how hard the pedal is pushed into an electronic signal that the computer uses to accelerate the vehicle. The ETC (Electronic Throttle Cable) also known as the "Drive by Wire" system has the unfortunate downside of delayed response and subdued acceleration which can create problems in certain situations such as uphill starts, quick gear changes, and passing other vehicles. Installation is as simple as plugging it in between your accelerator pedal module and the harness. Once installed you'll instantly feel the difference the moment you step on the throttle. It can be removed just as easily if you ever want to return your car back to stock. Covered by a money-back guaranteed that allows you to feel the difference without any risk. *New to V3: 36 Acceleration Programs, Valet Mode, Pedal Lock Mode* Fits: BMW E46, BMW E82, BMW E88, BMW E90, BMW E91, BMW E92, BMW E93, BMW F30, BMW F32, BMW F31, BMW F34, BMW F22, BMW F36, BMW F33, BMW F23
If you're looking for the easiest way to add power and torque to your BMW, a Turner Performance Chip is answer to your prayers. Dyno-tuned by BMW tuning legend Jim Conforti, these chips are designed to make the most of high-octane (91+) pump gas and boost mid-range torque and high-RPM horsepower. To make the most of these improvements, fuel and spark maps are fine-tuned to make your BMW perform better than it did when it left the factory. There is no downside to installing a Turner Performance Chip - each chip is designed to safely improve performance, while maintaining driveability and improving responsiveness. All chips are shipped with detailed instructions and are typically installed in an hour by an enthusiast with hand tools. Turner Motorsport and Jim Conforti have over 20 years of experience with making your BMW come alive with software tuning. Unlike eBay chips, Turner Performance Chips use extensively tested, carefully designed fuel & spark maps designed to get the most performance out of your BMW without risking engine damage or reducing driveability. Since 1995, Jim Conforti has been using his expertise to fine tune the BMW driving experience by finding more power and torque and improving throttle response. With over 10,000 units sold, it's no surprise that Jim Conforti is widely regarded as the leader in BMW chip tuning. Don't be fooled by imitators - your BMW deserves the best. The M70 V12 is an awe-inspiring engine that produces smooth power, designed for use in BMW's flagship luxury cars. It's designed to be smooth, quiet, and non-intrusive, and as a result, it's often said to be underpowered. Jim Conforti was able to wake up the M70 and unlock the power potential of this great engine. More high-RPM horsepower, more mid-range torque, and more response from the electronic throttle are in the palm of your hand with the Turner Conforti Performance Chip. Horsepower Gain: +29 @ 5,500 RPM Torque Gain: +35 @ 3,600 RPM Installation instructions included. Turner is so confident you will be delighted by your new no-downside power, torque, and overall performance, that they offer a 30 day money back guarantee on this product, serviced by ECS Tuning. Fits: BMW E31 850Ci M70 5.0L
Part # 11-14-1-742-042 - Valley pan gaskets are a common failure on the M62 motors, Symptoms can include a smell of coolant regularly or a mysterious loss of coolant with no identifiable leaks. This kit contains the basics need to be replaced when doing a valley pan gasket. It is always a good idea to replace the accessory belts when ever they need to be removed to ensure proper tension and belt integrity. Kit includes Valley pan with gasket Valley pan securing hardware Valley pan heat shield Water pipe o-rings Water cross over gaskets Throttle body gasket Water pump with gasket Intake gaskets Accessory belt A/C belt Fits: BMW M62 4.6L, BMW E31 840Ci M62 4.4L, BMW E38 740i M62 4.4L, BMW E38 740iL M62 4.4L, BMW E39 540i M62 4.4L, BMW E53 X5 M62 4.4L
Part # 11-14-1-742-042 - Valley pan gaskets are a common failure on the M62 motors, Symptoms can include a smell of coolant regularly or a mysterious loss of coolant with no identifiable leaks. This kit contains the basics need to be replaced when doing a valley pan gasket. It is always a good idea to replace the accessory belts when ever they need to be removed to ensure proper tension and belt integrity. Kit includes Valley pan with gasket Valley pan securing hardware Valley pan heat shield Water pipe o-rings Water cross over gaskets Throttle body gasket Water pump with gasket Intake gaskets Accessory belt A/C belt Fits: BMW E31 840Ci M62 4.4L, BMW E38 740i M62 4.4L, BMW E38 740iL M62 4.4L, BMW E39 540i M62 4.4L
Part # 13-64-1-731-357 - A vehicle with dirty injectors may host a wide variety of symptoms. From stalling, hesitation, misfiring, and a rough idle, to the wide open throttle woes. If your vehicle is suffering from these symptoms, the fuel injectors may be the cause. ECS Tuning recommends replacing all six injectors at once to ensure proper and accurate fuel delivery. Fits: BMW E30 325, BMW E30 325e, BMW E30 325es, BMW E30 325i, BMW E30 325is, BMW E30 325ix, BMW E31 850Ci, BMW E31 850CSi, BMW E32 750iL, BMW E34 525i, BMW E38 750iL
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