BMW E46 Upper and lower intake boot removal/DISA inspection doityourself

[danewilson77]

Upper and lower intake boot removal/DISA inspection.

Note 1. You do not need to remove the lower intake boot to inspect DISA. The lower intake boot is the PITA you speak of. With that said.....perform through step 6 (do not throw away upper intake boot, and then pull disa out. You may need to "squeeze/bend" the lower intake boot to allow for room to facilitate removal. Should take 20 minutes tops.

Note 2. Another good tool to have for this job is a 6mm offset box end wrench. Pic below. You might not have to cut the lower intake boot with the wrench below and the flex drive....but I highly recommend just buying new ones as they probably need changing anyways. This wrench is one that I have had for 20 years (note the rust), and I don't even know where you get something like that. Maybe online.

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/IMG_20110306_124420.jpg

How I do it. The below is for removal of upper and lower intake boot.

1. Go buy upper and lower intake boots.
2. Disconnect intake at MAF sensor to upper intake boot connection....by loosening hose clamp.
3. Unplug MAF sensor.
4. Slide out and remove intake cover
5. Remove 2 10mm bolts securing intake filter housing. Pull filter out...see aside....unclip aft hose....and remove housing.
6. Remove upper intake boot and inspect. Throw in garbage.
7. Cut lower intake boot about 2-3" from where it enters throttle body and icv.
8. Use a flex drive with extension to get at lil hose clamp for icv, and larger hose clamp for throttle body.

The below is for DISA removal

1. Perform through step 6, above, but do not throw upper intake boot away...unless it is intended to be replaced.
2. Unplug DISA by reving clip type plug.
3. Remove two torx screws (I do not remember size off the top of my head.
4. Slightly compress lower intake boot, and shimmy out DISA valve.
5. Inspect for proper gasket sealing surface (orange area - round).
6. Inspect for proper butterfly valve operation. This is a spring perated valve. Additionally check for play at securing pin.

NOTE 3. Should you ever need to replace Upper or lower intake boot, "F" type fitting on upper intake boot, or DISA.....the part numbers are indicated in the below drawing's/pictures. All part numbers below are for a 2/2004, 330i ZHP. Should be the same for a majority of E46's.

Upper intake boot

PC. 3 in drawing at below link.
http://www.realoem.com/bmw/showparts.do?model=EV53&mospid=47725&btnr=13_0905&hg=13&fg=15

"F" type fitting
http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/CellPhone366.jpg

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/CellPhone367.jpg

Lower intake boot
PC.6 in drawing at below link
http://www.realoem.com/bmw/showparts.do?model=EV53&mospid=47725&btnr=13_0905&hg=13&fg=15

DISA
PC. 7 in drawing at below link. Also not ICV (PC. 8) should be cleaned with carb cleaner at this time, if removing the lower intake boot.
http://www.realoem.com/bmw/showparts.do?model=EV53&mospid=47725&btnr=11_2879&hg=11&fg=40

[Oli77]

Got your back Dane ;)

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/IMG_20110306_124420.jpg

[danewilson77]

What happened..lol

Sent from my Droid using Tapatalk

[Oli77]

You had not posted the pic of the tool in this thread. I say the other thread on it, copied the image and pasted it here for you.

[danewilson77]

Ahh...right. Thanks Oli....

http://i1015.photobucket.com/albums/af278/nicee46/Funny/mmmmmmmmmmm85626.jpg

[Oli77]

Fine, be that way... here is what you look like Mr. Wilson.


Sitting by the phone, probably talking to Jim Conforti about your busted DME






http://3.bp.blogspot.com/_ccGXesYV-eA/TBq0EC-2iqI/AAAAAAAAB58/Mbu4-4H3cDw/s1600/sl.jpg

[danewilson77]

Nice....I like that dude.

Sent from my Droid using Tapatalk

[mimalmo]

What are the steps of the DISA inspection you mention in the title?

Also, part numbers would be helpful.

[danewilson77]

What are the steps of the DISA inspection you mention in the title?

Also, part numbers would be helpful.

Adding now Eli. Thanks for keeping me honest.

[llll1l1ll]

Reviving an old thread:

Anybody know what the size range of the Torx bolts are on the DISA valve? I am replacing mine and need to know so I don't make eight trips to Sears.

[danewilson77]

T-40

[llll1l1ll]

Nice! Thanks, DW.

[quikryptonite]

What is the best stuff to clean the DISA with?

[danewilson77]

What is the best stuff to clean the DISA with?

I use carb cleaner.

Sent from Williamsburg, VA USA

[Lanister]

Dane, would you suggest the following to be replaced along with upper and lower intake boots?

The Intake Book Connecting ring (13541438760). It's rather inexpensive but still good to know if it should be on the list of parts to get for the intake boot swap.

http://www.ecstuning.com/ES34024/

[wsmeyer]

Just saw this thread, here's how I got my lower boot off:

http://www.zhpmafia.com/forums/attachment.php?attachmentid=10203&d=1377914627

From the top with long needle-nose pliers with a 45 degree tip. Super easy and reinstalled with the hose clamp screw on the top facing forward.

[BCS_ZHP]

That's cheating right there, you have to bust your knuckles, curse and only get 1/64th of a turn on the rachet for the true DIY experience, JK.

[Lanister]

Dane, would you suggest the following to be replaced along with upper and lower intake boots?

The Intake Book Connecting ring (13541438760). It's rather inexpensive but still good to know if it should be on the list of parts to get for the intake boot swap.

http://www.ecstuning.com/ES34024/

Mr. Dane and the famillia, would you have any input on this?

[kayger12]

Mr. Dane and the famillia, would you have any input on this?

I don't see any reason to replace it. I've never read of one becoming brittle or presenting a problem.

When I did the lower boot in my 325 it had over 100k on it and the ring looked perfect.

[Eugene]

The clamp screw for my lower intake hose is on the bottom and I had an extremely hard time getting to the screw, so I left the old lower intake hose on. Any tips on how to possibly remove it?

[Oli77]

Some have cut the old boot away to get access to the ring clamp.

[GeorgeH]

I'll try to describe, but may be hard to visualize, might try and see if I can snap some pics thought.

I removed the DISA valve and upper intake hose. Then I use a 6mm socket on a 18" flexible driver. When they are on the bottom and aimed at the rear of the car I go from the intake around the back side of the engine and loosed the clamp. When I install the lower hose I aim the clam straight up on the back side and tighten the throttle body clamp. Then I aim the idle valve straight up on the back side and tighten it. Once those are on then I reinstall the DISA valve.

[kayger12]

I use a 1/4" drive mini-ratchet with a flex socket.

https://www.sears.com/craftsman-8mm-socket-6-pt/p-00943194000P (https://www.sears.com/craftsman-8mm-socket-6-pt/p-00943194000P)

[Xceler8]

Good thread, I will be attempting the DISA replacement this afternoon. Car is throwing a vacuum leak engine code and a smoke test revealed that some was from the DISA. Hopefully this fixes the issue as I need the car inspected to get my Texas Plates.