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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.
See all vehicles this article applies to
E60 5 Series M5
E60 5 Series 523Li
E60 5 Series 550i
E60 5 Series 545i
E60 5 Series 540i
E60 5 Series 535d
E60 5 Series 530xi
E60 5 Series 530xd
E60 5 Series 530Li
E60 5 Series 530i
E60 5 Series 530d
E60 5 Series 525i
E60 5 Series 525xi
E60 5 Series 525Li
E60 5 Series 525d
E60 5 Series 523i
E60 5 Series 520i
E60 5 Series 520d
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 owner's 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 on 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 is 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. Due 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 a dashboard and/or iDrive warning messages on, you may need to use a diagnostic scan tool to clear them after the repair.
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.
BMW E60 530i with M54 engine
This is the rubber intake boot that the mass air meter clamps to. If your boot has rotted or deteriorated, it will cause a rough idle and poor performance. Restore performance & driveability with this Original BMW replacement intake boot from ECS Tuning.
Commonly used in many different models.
28mm-33mm. Clamps are like bolts and nuts, as you can never have enough of them. If you do work on your vehicle in your home, you are going to need clamps often. If you need one clamp, why not get a few to ensure that you are always prepared.
Fits all BMW vehicles
83mm-93mm. Clamps are like bolts and nuts, as you can never have enough of them. If you do work on your vehicle in your home, you are going to need clamps often. If you need one clamp, why not get a few to ensure that you are always prepared.
All BMW E60 6 cylinder vehicles
Often overlooked, a clean air filter can make a noticeable difference in performance and fuel economy in your vehicle. When a vehicle's air filter is not properly serviced, it restricts air flow into the engine which directly translates to less horsepower to the wheels. This Part Fits the Following Vehicles: All BMW E60 6 cylinder vehicles
Section 1 - BMW E60 Intake Boot Removal
- 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 airbox. 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.
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.BMW E60 Intake Boot Repair Finished
