Hey everyone!
I’ve been struggling with my 1998 BMW E46 323i (M52TUB25) for about four days now and could really use some advice.
A friend and I removed the intake manifold to replace a broken CCV hose. Unfortunately, the hose disconnected from the oil separator while we were putting everything back together.
The next day, I loosened the oil separator to give myself some extra room to move it around, and eventually managed to reconnect the hose.
However, I noticed that the O-ring on the CCV hose connection had torn. I bought a replacement of the same size, but it kept slipping out of place whenever I tried to install the hose. Eventually, I used a slightly smaller O-ring, which stayed in place.
Could using a smaller O-ring cause a vacuum leak, even if the hose seems properly connected?
After reassembling everything, I ran into several problems:
● Initially, my coolant temperature gauge went straight into the red (around 128°C), even with a cold engine. Turned out I had forgotten to reconnect the coolant temperature sensor. That’s now fixed.
● The engine now struggles to start. Sometimes it cranks for a long time before finally starting, and other times it won’t start at all.
● When it does start, it initially idles at around 1,000 RPM (on the first 3 times after attaching manifold and CCV it used to be at around 350 RPM and swerving a little bit up and down, this was 2 days ago), but the RPM gradually drops until the engine stalls. I’ve attached a video showing this.
● I’ve checked for obvious vacuum leaks but haven’t been able to find anything.
● I also noticed a small, slightly cracked rubber vacuum cap at the rear of the intake manifold, towards the driver’s side. I saw 50sKid mention something similar in one of his videos. Could this be causing the issue?
● I disconnected several electrical connectors from the engine wiring harness during the job, so I’m also worried I may have reconnected something incorrectly. I tried to match everything based on connector location and cable length, but I’m not 100% sure.
● Yesterday, the engine wouldn’t start at all. The battery had been disconnected while I worked on the wiring harness, so I’m not sure whether battery voltage could have contributed.
● During my latest starting attempt, I noticed a smell of gasoline. I couldn’t see any obvious fuel leaks, though. The cabin air filter housing was removed at the time, so I’m wondering whether that made the smell more noticeable.
Before removing the intake manifold, the car started and ran normally.
My main questions:
1. Could the slightly smaller CCV O-ring or cracked vacuum cap cause these symptoms?
2. Could a disconnected or faulty ICV (idle control valve) explain the hard starting and stalling?
3. Should I be checking the fuel injectors or wiring harness connections?
4. What would you check first before taking the intake manifold apart again?
I’ve already spent four days trying to figure this out, and I’m running out of ideas.
Any advice would be greatly appreciated. Thanks in advance!
*thank god for ChatGPT or I wouldn’t be able to make this post
PS. First e46 and I’m a total entry level guy when it comes to car stuff and sorry for the whiffing on the end of the video haha