Removing the intake plenum

Preliminary work 

• Refer to DISCONNECTING ALL BATTERY GROUND LEADS .
• Refer to BRINGING FRONT COMPARTMENT LID IN THE SERVICE POSITION .
• Refer to REMOVING THE ACOUSTIC COVER .
• Refer to REMOVING THE SEAL FOR THE HOOD REAR .
• Refer to REMOVING ACOUSTIC COVER AT REAR .
• Refer to REMOVING THE DME CONTROL UNIT (540i 2017-2020) , or REMOVING THE DME CONTROL UNIT (540i 2021-2022, 540i xDrive 2021-2022) .
• Refer to REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) (540i 2017-2020) , or REMOVING THE INTEGRATED POWER SUPPLY MODULE (PDM) (540i 2021-2022, 540i xDrive 2021-2022) .
• Refer to REMOVING CONTROL UNIT BRACKET (540i 2017-2020) , or REMOVING THE CONTROL UNIT HOLDER (540i 2021-2022\, 540i xDrive 2021-2022) .
• Refer to REMOVING THE COVER ON LEFT AND RIGHT IN THE ENGINE COMPARTMENT AT THE TOP .
• Refer to REMOVING BOTH FRONT-END STRUTS .
• Refer to REMOVING FRONT CROSS CONNECTION .
• Refer to REMOVING THE REAR TOP CROSS CONNECTION .
• Refer to REMOVING THE FAN COWL .
• Refer to REMOVING THE FRONT UNDERBODY PROTECTION OR FRONT THRUST FIELD .
• Refer to REMOVING THE UNDERBODY PROTECTION OF THE STEERING GEAR AND THRUST FIELD RESPECTIVELY .
• Refer to DRAINING THE COOLANT FROM THE LOW-TEMPERATURE COOLING SYSTEM .
• Refer to CONNECTING THE COOLANT LINES FOR THE LOW-TEMPERATURE COOLANT CIRCUIT .
• Refer to REMOVING TANK VENT VALVE .

• Loosen screw (1).
• Guide tank ventilation line (2) out of clamp (3) and remove it.

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• Unlock and release the plug connections (1).
• Unlock the locks (2).
• Guide tank ventilation line (3) out of clamp (4) and remove it.

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• Unlock the locks (1).
• Feed the tank ventilation line (2) out and set it aside.

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• Unlock the locks (1).
• Feed out the wiring harness section (2) for the sensor system 2  and set it aside.

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• Loosen screws (1).
• Feed out charge air line (2) and place to one side.

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• Unlock and release plug connection (1).
• Loosen clamp (2).
• Thread off coolant line (3) and place to the side.
• Loosen screw (4).

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• Unlock and release plug connection (1).

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• Unlock the locks (arrows).
• Feed out the wiring harness section (1) for the injectors and ignition coils and put to one side.

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• Guide tank ventilation line (1) out of clamp (2) and place it aside.

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• Feed out the wiring harness section (1) for the injectors and ignition coils of the cylinder head cover (2) and put to one side.

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• Loosen screw (1).

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• Unlock and loosen coolant line (1).
• Catch and dispose of escaping coolant.

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• Loosen screws in the order (7) to (1).
• Slightly lift intake plenum (A) in arrow direction  .
  Fig 1: Intake Plenum Screws Loosening Sequence

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  NOTE: TECHNICAL INFORMATION 
  The tension rod screws and mounting bolts from the connecting neck on the intake plenum are not  allowed to be opened.
• Do not  release screws in the marked area  on the intake plenum (1).

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  NOTE: TECHNICAL INFORMATION 
  Additional coolant can leakage. Make sure that no coolant enters the intake port of the cylinder head.
• Unlock and release the coolant line (1) under the intake plenum (2).
• Catch and dispose of escaping coolant.
• Feed out the intake plenum (2) and remove it.

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• Empty the remaining coolant (2) from the intake plenum (1).

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  NOTE: TECHNICAL INFORMATION 
  The tension rod screws and mounting bolts from the connecting neck on the intake plenum are not  allowed to be opened.
• Do not  release screws in the marked area  on the intake plenum (1).

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