Pdf downloadread and download 2002 bmw z3 repair manual free ebooks in pdf bmw forums2000 bmw z3 repair manual publishers on amazoncom freeThe BMW Z3 Service Manual: 1996-2002 is a comprehensive source of service information and technical specifications available for the BMW Z3 Roadster.

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The BMW Repair Guide used this 2003 325ci for the following article. To see other repairs on our site using this actual car, please click on the image below!If your E46 3 series is starting to idle rough and is showing signs of poor acceleration and performance, you may be ready for a BMW E46 intake manifold gasket replacement. The intake manifold gaskets become hard and brittle with age causing a vacuum leak, allowing excess unmonitored air to enter the engine which can cause a host of issues on a BMW M54 engine.As our wonderful BMW E46’rs slowly creep up on their 20th year anniversary (yepyou read that right20 years!), parts are going to start failing. The parts most prone to failure are those associated with the air intake system. Cannot access serial port windows 7 firewall.

It’s pretty simplemost are made out of plastic or rubber, and the extreme engine heat over time leaves them brittle, cracked, or completely broken. It seems as though every BMW E46 we bring into the BMW Repair Guide these day needs a complete air intake restorationincluding pipes, hoses, valves and gaskets.This article focuses on replacing your BMW E46 intake manifold gaskets. Although there may be other leaks associated with your air intake system, the intake manifold gaskets are the best place to start.

Let’s face it.whether they are the culprit or not behind your rough running engine, they need to be replaced. One of the biggest repair bugs BMW owners are dealing with these days are vacuum leaks in the 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. I knownot what you wanted to hear at this point. But before you leave my 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.

I guarantee you that’s a fact. So why not buy your own so you have it for future DIYer repairs?

There are several “non-commercial” machines on the market that will get the job done: the and the being two of the more reasonably priced ones. The BMW Repair Guide uses the EVAPro by Vacutec in its repair shop.Replacing the BMW E46 intake manifold gaskets on the M54 engine is not that technically difficult.

It just involves the removal of a lot of parts, so it’s important to follow a strict inventory plan so you don’t lose anything. As you will see in the following article, marking and identifying wire harnesses and connections is important in this repairthere are a lot of them, and marking them during disassembly makes putting the car back together extremely easier. There is nothing more frustrating than wasting an hour trying to figure out where a wire connection goes, or “burying” a connection under a bunch of installed parts.When replacing your BWW E46 intake manifold gaskets, we strongly urge you to replace your DISA valve o-ring, and throttle body gasket as well. Since both parts must be removed to perform this repair, it is good practice to replace their gaskets during reassembly to avoid any vacuum leaks. Both are critical for proper idling, and are inexpensive and easy to replace. Procedure. Remove the right side engine cover using a pick and a 10mm nut driver as shown below.

Remove the cabin air filter cover by unsecuring the 3 twist screws that mount it to the filter housing. Using a torx T30 bit remove the three screws securing the filter housing to the fire wall.

Remove the filter housing from the vehicle. Using a T30 torx bit, loosen the two bolts securing the metal bulkhead cover (the bolts are attached to the cover and should not be able to be completely removed).

Remove the bulkhead cover from the car. The next step in the BMW E46 intake manifold gasket repair is to remove the air box from the engine compartment. Use a 10mm nut driver or socket wrench to remove the two air box mounting bolts on the left side (driver’s side) of engine compartment. Disconnect the Mass Air Flow (MAF) sensor. Using a flat blade screwdriver, loosen the hose clamp connecting the air intake boot to the air box.

Remove the air box from the engine compartment. Remove the vacuum line from the intake boot. Remove the DISA valve electrical connector. The release spring is on the back side of the connector. You will need to remove the DISA valve to get clearance for intake boot removal. Using a T40 torx bit, remove the two screws anchoring the DISA valve to the intake manifold. Grasp the DISA valve and carefully remove.

Using a flat blade screwdriver, loosen the hose clamp anchoring the top hose of the intake boot to the idle control valve. Pull the top hose off of the idle control valve being careful not to bend or tear it (there is a screw below it we need to get to in the next step). Using a flat blade screwdriver, loosen the hose clamp anchoring the intake boot to the throttle body. Pull the intake boot off of the throttle body and remove from vehicle.

You will notice from the photo below we damaged our intake boot during removal. This boot had 140,000 miles on it and ripped apart during removal. If this happens to you,. Disconnect electrical connection to the throttle body. You may need the help of a flat blade screwdriver to get it loose.

Bmw Z3 Specs

Now it is time to remove the engine wiring harness from the BMW E46 intake manifold. Start by removing the top two T40 torx bolts. Next move down the wiring harness and remove the 10mm bolt using a nut driver or socket and wrench. Next, the bottom throttle body mounting bolt must be removed. Use a 10mm socket wrench with extension. Finally, remove the 10mm bolt anchoring the engine wiring harness to the idle control valve.

Gently pull the wiring harness away from the intake manifold so the manifold can be removed without pinching any wires. Remove the electrical connector from the idle air control valve and mark with tape. Remove the fuel tank venting valve by grasping its rubber mount and pulling straight out off of its mounting plate. Remove the engine vent hose (crankcase breather hose) from cylinder head cover by squeezing sides of spring clip and pulling loose. Be careful with this hoseit is plastic and can easily crack or break off. Disconnect the VANOS solenoid electrical connector and label. There is an electrical connection on the back of the intake manifold that will need to be disconnected.

It is reachable with your handsuse a flashlight and our images below to locate and disconnect. Make sure to label with tapethis is a common connection that many mechanics forget to reconnect (because of its obscure location). Remove the oxygen sensor connections from their clips on top of the intake manifold. Tuck gently out of the way behind manifold. Using a 10mm socket, remove the last three mounting bolts from the throttle body (one of them has already been removed in step 17). Remove throttle body from vehicle.

You can now gain access to the lower BMW E46 intake manifold mounting bolt. Using a 16mm socket with extension, remove the lower manifold mounting bolt. Remove the dipstick ventilation hose from the bottom of the PCV valve. The hose runs from the PCV valve to the bottom of the oil dipstickif you dont remove it, it will break off and require replacement. You can see from the images below, ours was already broken off. If you break yours during disassembly,.

Using an 11mm socket, remove the nine intake manifold mounting nuts. Note that the nut closest to the fire wall is difficult to get toit is hidden behind wiring.

Use patience when trying to remove. One of the biggest pains when doing a DIY repair is losing nuts and bolts when removing them with a socket wrench.

Nothing is more irritating than dropping a bolt into the engine bay, never to find it again! To avoid losing nuts and bolts, especially those in awkward positions, insert a piece of tape in the socket. The tape will securely hold the nut or bolt while extracting it, avoiding an unnecessary trip to the hardware store to try and replace it. Grasp the intake manifold with both hands and remove from the threaded head studs. It may be necessary to GENTLY tap the BMW E46 intake manifold with a rubber mallet to loosen its seal on the engine head. There is one last electrical connection that can only be accessed when the BMW E46 intake manifold is partially removed.

It runs from the intake manifold to the engine block on the fire wall side of the manifold. You may need to use a flat blade screwdriver to pry the connection loose while squeezing the release clip (see images below). Gently prop up the intake manifold so the rubber gaskets can be removed.

Be careful when moving the manifold so as to avoid breaking any vacuum pipes. Use a metal pick to remove the rubber intake manifold gaskets. Avoid using a screwdriver or any tool which may scratch or damage the manifold. Vacuum off the cylinder head making sure to get all of the loose debris. Also vacuum out the valve ports in case debris has fallen in. Use a soft brush and rag to thoroughly clean the engine head and the BMW E46 intake manifold. This is a very important step to insure the gasket creates an airtight seal.Throttle body and DISA valve gasket replacementUse a metal pick to remove the DISA valve gasket (o-ring) and the throttle body gasket.

Replace with new parts.ReassemblyBMW E46 intake manifold reassembly – Follow the above steps in reverse. Make sure the new rubber gaskets are properly seated in the intake manifold before reinstalling. Pay particular attention when mounting the intake manifold back on the engine; the threaded head studs can snag the rubber gaskets, pulling them out of alignment.Make sure to use the following torque values when tightening down the intake manifold nuts and throttle body bolts.Intake manifold nuts – 15 Nm (11 ft-lb)Throttle body bolts – 13 Nm (10 ft-lb)Repair finishedIf you have any questions or comments, please feel free to. And congratulations for Doing It Yourself!

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