Before I Give Away This BMW... Intake/Cooling System Overhaul

In this episode of my BMW E46 giveaway build, I tackle one of the most critical jobs on any BMW — a complete cooling system overhaul and intake manifold refresh.

I start by removing the intake manifold, resealing it with new gaskets, installing a new DISA valve, replacing all vacuum lines and caps, and performing the Pilot O2 mod to help reduce oil consumption. While I’m in there, I also install a brand new CCV (breather / cyclonic oil separator), then smoke test the system for leaks after reinstallation.

On the cooling side, I replace every single component — both hard water pipes under the intake manifold, all heater hoses, radiator hoses, the radiator, automatic transmission thermostat, expansion tank and cap, coolant temperature sensors, thermostat, and a high-performance water pump. I finish it off with a pressure test to make sure the system is perfect before the giveaway.

If you’re working on your own BMW cooling system or intake refresh, this video will walk you through the entire process step-by-step. Whether you own an E46 or another BMW chassis, these are the upgrades and maintenance steps you need to keep your car reliable for years to come.

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PARTS USED:
https://www.fcpeuro.com/products/bmw-cooling-system-hose-kit-11531436408kit
https://www.fcpeuro.com/products/bmw-thermostat-vemo-17111437362
https://www.fcpeuro.com/products/bmw-aluminum-water-pump-pulley-kit-rein-pkw0002
https://www.fcpeuro.com/products/bmw-water-pump-emp-stewart-888010330
https://www.fcpeuro.com/products/bmw-thermostat-assembly-11537509227b
https://www.fcpeuro.com/products/bmw-engine-coolant-expansion-tank-nissens-996155
https://www.fcpeuro.com/products/bmw-comprehensive-breather-system-kit-11617501566kt2
https://www.fcpeuro.com/products/bmw-fuel-injection-air-flow-meter-boot-13541705209
https://www.fcpeuro.com/products/80-piece-vacuum-cap-assortment-wilmar-w5232
https://www.fcpeuro.com/products/bmw-radiator-auto-trans-e46-60782a
https://www.fcpeuro.com/products/bmw-expansion-tank-retainer-e46-17111436251-1
https://www.fcpeuro.com/products/bmw-vacuum-valve-febi-11617545382
https://www.fcpeuro.com/products/bmw-brake-booster-vaccum-hose-e46-34336751108
https://www.fcpeuro.com/products/bmw-brake-booster-check-valve-34331160183
https://www.fcpeuro.com/products/bmw-intake-manifold-gasket-set-corteco-11611436631
https://www.fcpeuro.com/products/bmw-vacuum-hose-silicone-black-silicone-crp-11747797175

TOOLS USED:
Fluid Extractor
https://amzn.to/3BN8bLH
Vevor 5K Lb. Car Lift
https://amzn.to/49zMiv9
Red Sotch Brite
https://amzn.to/3w5K6N7
3/8" Torque Wrench
https://amzn.to/45uM7jJ
Cooling System Pressure Tester:
https://amzn.to/48UhhCj
Inspection Mirror Set
https://amzn.to/49hOIOM
Sil-Glyde
https://amzn.to/4mdxicW
Silicone Spray
https://amzn.to/4mdxicW
Magnetic 11mm socket
https://amzn.to/4liq3Pt4
Metal Bore Drill Brush
https://amzn.to/4mdJ3QG
Ventus Smoke Machine
https://amzn.to/3J2LVRM
Bladder Adapter
https://amzn.to/45oMqNm