BMW 540i Specifications download pdf (Page 35)

Originally developed and published here by unknown author: http://members.cox.net/rlacm/IntakeIndex.htm

Recovered and published by BMW-Planet.com – May 2012

NOTE: refer to previous photo for locations of these seals.

- Working from the front of the intake manifold, reach into manifold and gently grasp rear

half of vent pipe. Push pipe backward (telescoping it slightly) onto rear cover seal, ensuring

pipe is completely seated at each end.

Primary Throttle Body

- Install new seal into front face of intake manifold - ensure seal is properly seated.

- Install primary throttle body to intake manifold using new bolts as necessary, tightening in

a star pattern (6x T-30 bolts) (C).

Secondary Throttle Body

- Install new o-ring onto front of primary throttle body: lightly lubricate.

- Install secondary throttle body (3x T-30 Torx bolts) (B).

- Dork Alert! Failure to complete this step will really piss you off later. Position black vacuum

control pipe onto manifold using front bracket and single nut (don’t tighten). Locate hose at

front (connected to T network) which was removed from nipple at lower-right corner of

primary throttle body. Reconnect to nipple (A) using new screw-type hose clamp,

positioning screw so that it faces up on right side of nipple.

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BMW 540i Specifications Page 35