E34 M5 ITB Service and Synchronization DIY (lots of pics)

[shogun]

written by jint45 Location: Toronto Car: E34 M5 Euro , on Bimmerforums.com

Decided to pull this job on my M5 a couple days ago and documented it as much as I could. This job requires a couple of special tools which I will list and other things that need to be done prior to doing this job in order to do it correctly.


E34 M5 Throttle body balancing, adjustment and synchronization.
Engine: S38B36


PRIOR to adjustment:
All 24 valves must be adjusted to spec (0.28 to 0.33mm)
All ignition components in full working order ( Cap and rotor, coil, spark plugs, wires and crank position sensor)
All vacuum lines under the Intake Plenum must be fresh, can't have vacuum leaks.
All vacuum related rubber o-rings must be replaced.


Tools Needed
Carbtune tool www.carbtune.com
Vernier Calliper
Feeler gauges
10mm socket
8mm socket
7mm socket
Screw drivers


Parts needed
Brass screw o-rings 17211742635 x6
Throttle body to plenum o-rings 11611305124 x6
Vacuum hose, 1-2 meters of it.


Procedure


Remove the intake plenum and replace every vacuum line in your sight
http://i39.tinypic.com/1rvztt.jpg
Remove the TB shocks using an 8mm socket or wrench
http://i43.tinypic.com/1ys9qu.jpg
This is what they look like
http://i44.tinypic.com/9s8qav.jpg
Adjust the shock according to BMW specs
http://i41.tinypic.com/11h9ni0.jpg
Use a vernier calliper to adjust to 98mm
Clean up the little shocks, use a drill with a wire brush bit, treat with oil after cleaning them.
http://i39.tinypic.com/nysnbd.jpg
Next step is to adjust the ITB throttle valves
http://i42.tinypic.com/309q420.jpg
Adjust by BMW spec (top 21.7mm, bottom 22.7mm)
http://i42.tinypic.com/4hcxv6.jpg
http://i39.tinypic.com/9855jd.jpg
Assemble everything back, use new o-rings between the ITBs and and Intake plenum tubbing (sorry forgot to take pics of that) O-rings p/n#: 11611305124. Assemble all the ITB components back.


Now start removing the brass screws, use 7mm socket
http://i39.tinypic.com/309t3wj.jpg
Remove all of them, be careful, if they haven't been out of the in a while, you can strip or break one, they are made from brass, very soft material.
http://i42.tinypic.com/30lmmmo.jpg
This is what they look like out
http://i40.tinypic.com/2zznuco.jpg
Clean out the holes as much as you can
http://i43.tinypic.com/j8k3lv.jpg
I used a pick and 600 grit sand paper
http://i41.tinypic.com/2vtryp2.jpg
Remove old o-rings
http://i42.tinypic.com/50gl6t.jpg
Clean up the brass screws using a drill and a wire brush bit.
http://i40.tinypic.com/302t2f7.jpg
New O-rings
http://i44.tinypic.com/9hj81y.jpg
Install new o-rings
http://i43.tinypic.com/6o24ph.jpg
Screw them back into the ITB's
http://i40.tinypic.com/55ggzk.jpg
Tighten to the end and do ONE full turn back (360 degrees)
http://i40.tinypic.com/34t6gzd.jpg
Now I'm going to replace the spark plugs and the ignition coil (mine were due)
After this I will start balacing the ITB's.

NEW coil
http://i39.tinypic.com/2zxt3dg.jpg
New spark plugs
http://i40.tinypic.com/3581j7m.jpg
http://i43.tinypic.com/21jdems.jpg
Old vs. New
http://i41.tinypic.com/99jos7.jpg
Set spark plug gap
http://i44.tinypic.com/9pop5d.jpg
Tighten the spark plugs to 22nm +/-3


Now the Balancing starts


Connect carbtune vacuum lines to the ITB ports, you can only do 4 ITBs at a time with this tool, so leave the other two plugs in on CYL 5 and 6. After, just move two vacuum lines to cylinders 5 and 6 and plug cyl 1 and 2. Use cyl 3 and 4 for reference.

http://i43.tinypic.com/binn1l.jpg
Make sure the tool stands vertically.

http://i41.tinypic.com/33wsksn.jpg
ENGINE MUST BE IN OPERATING TEMPERATURE, YOU CANNOT DO THIS ON A COLD ENGINE


Start the engine and observe your carbtune. Use a 7mm socket to adjust. Tighten in increase vacuum, loosen to decrease vacuum. BMW says they should all be around 22.7 inHg. I wouldn't worry about that too much, make sure the readings are more less on the same line and the idle is from 850-950rpm. This is how it works, the higher your vacuum is, the lower you idle speed will be, the lower your vacuum is, the higher the idle speed will be.
http://i41.tinypic.com/23m6iro.jpg
And DONE.

written by jint45 Location:Toronto Car:E34 M5 Euro , on Bimmerforums.com

[genphreak]

... I knew it wasn't that hard to do, esp. now the balancing tools are around at >$100!

Original link with inline pics... am I the only one who is not seeing them? All I see is the raw URIs, eg http://i39.tinypic.com/1rvztt.jpg.