[lmsvvavr]

Here before the cleaning process...

The ports were quite blocked, full of crap....

To clean the ports I have used kwempe sugestion, Thank you kwempe! It worked very well...
Using a srew driver I have scrapped the ports walls right till the bottom.
I have then bent a screw deriver to be able to clean the "chamber" right at the bottom...

Here, using a cloth soaked in thinner, I have cleaning the ports to remove all the dirty...
I have repeated this process many times, (I have lost the count), till the cloth came back clean.
I do believe some dirty is around the valve, but it should came out as soon as I start the engine...

Here is the result, compare with the one before, and I think you can spot the difference! lol...

The overall looking of the engine also looks much better!

 

[kwempe]

Blimey that does show dedication, those ports look lovely!

 

[lmsvvavr]

Unfortunately, I was not able to take photos of the entire process of reassembling the parts, my battery went flat...:frown
Sorry to all that was following this thread...
But I do have the start of it, , first:

Engine cleaned and all new sealings in place...

Ready to be tightened...

Done!

And is all I have... The rest of it was basicaly the removal but in reverse... lol
I have replaced all filters including the micro ones, also a new vortex type breather...
I went for a road test... WAUUUUUUUUUUUUUU... it looks a totaly diferent car... more powerfull, and my MPG which was around 15 :eek , just went up a few miles later to about 30, despite the fact that the road test has been carried out in "Spot mode".... if you know what I mean... lol

 

[lmsvvavr]

Blimey that does show dedication, those ports look lovely!

LOL
Thats the way I work, or I do it properly, or I simple do not do it!
That is the way it should be anyway... (in my opinion)...

 

[kwempe]

Nice to see the new, genuine E60, cast iron manifold too. Shame it has taken so long for BMW to produce a replacement for the tin foil one! :thumbsup

 

[delganybmw]

E61 525D with the same problem

Just spent the weekend changing the manifold...couldn´t have done it without the pics...thanks

 

[daviebrown]

Any one need a cast iron manifold,

BMW E53 X5 3.0d CAST IRON EXHAUST MANIFOLD ... E46 E60 330d 530d | eBay

 

[Dynosaur]

But I do have the start of it, , first:

Engine cleaned and all new sealings in place...


Ready to be tightened...


Done!


And is all I have... The rest of it was basicaly the removal but in reverse... lol

Looks like you got the same casting as me.
From a Polish Ebayer perchance ?
Shame BMW haven't upgraded the stainless steel joke to cast iron.
Guess Poland will keep laughing all the while Germany doesn't <cue WWII joke>.

 

[lmsvvavr]

Looks like you got the same casting as me.
From a Polish Ebayer perchance ?
Shame BMW haven't upgraded the stainless steel joke to cast iron.
Guess Poland will keep laughing all the while Germany doesn't <cue WWII joke>.

Hi
Not really, it was a UK seller, and a genuine BMW cast iron manifold!

 

[Dynosaur]

Hi
Not really, it was a UK seller, and a genuine BMW cast iron manifold!

Excellent.
Did it make it quieter ?

 

[Dynosaur]

Anybody wanting an E60 (not E39) cast iron unit - can get a new one from Ebay Germany (translated) : -

Google Translate

... or you may save a few beans by going direct to ebay.pl

 

[1Animal1]

Just had a good read of this (in antisipation of MORE work!) - Excellent thread Kwempe and nice additionals Mjom.

Chuffed to bits I dont have tio do it but if I did, i'd be a hell of a lot more confident about it....

 

[bhzmac1]

A very detailed amount of information feeling a little less disheartened about attempting to resolve mine...

I have recently purchased a e60 530d and have the suspected exhaust manifold leak, fumes in cabin black soot on the pipes above the turbo and a lack of power below 2k. However I can not see any smoke on start up, what else is worth checking that could cause these issues before I tackle this job, or is it a clearly a leaking manifold?

Also in terms of seeking a cast iron replacement am I looking to source from E39 530d and 525d E46 330d and the old shape X5 3.0d's?

 

[Dynosaur]

A very detailed amount of information feeling a little less disheartened about attempting to resolve mine...

I have recently purchased a e60 530d and have the suspected exhaust manifold leak, fumes in cabin black soot on the pipes above the turbo and a lack of power below 2k. However I can not see any smoke on start up, what else is worth checking that could cause these issues before I tackle this job, or is it a clearly a leaking manifold?

Also in terms of seeking a cast iron replacement am I looking to source from E39 530d and 525d E46 330d and the old shape X5 3.0d's?

Yes, that's the right one.
Mine doesn't smoke at start-up but it has all the other symptoms and there are unusual raspberrying and whining noises as revs rise/fall under load.
I'd stake my house on your's leaking.

 

[bhzmac1]

OK its a job on the to do list. I think I would be happier attempting MJOJOM under car method, no issues with taking off the intake manifold but don't want to get to the injectors and find I have issues. Anyone attempted the under car method and experienced any particular issues apart from a bad back and a load of crap in the eye?:mad

 

[Dynosaur]

As it so happens, I'm in the middle of doing mine as we speak - up and under, Aussie-rules style.
Will let you know the in and outs (or maybe that should be the ups and downs) of it - hopefully tonight rather than tomorrow.

 

[bhzmac1]

As it so happens, I'm in the middle of doing mine as we speak - up and under, Aussie-rules style.
Will let you know the in and outs (or maybe that should be the ups and downs) of it - hopefully tonight rather than tomorrow.

Yes be good see how you get on. .... Just waiting for a guy at work to bring his fibre optic inspection camera down so we can have a proper look round the manifold area.

Where did you source your replacement manifold from?

 

[Dynosaur]

Where did you source your replacement manifold from?

From Ebay, but I paid £299 for it.
It was one of these : - NEW EXHAUST MANIFOLD BMW E60 E65 X5 3.0d 2.5d M57 M57N 325d 330d 525d 530d e61 | eBay
Cast buy a Polish company, made for the E60 - no top-end performance hit, which you do get with the E39 cast manifold.

There's none left on eBay UK, but if you Google translate "NEW EXHAUST MANIFOLD BMW E60 E65 X5 3.0d 2.5d M57 M57N 325d 330d 525d 530d e61" into Polish and enter it on ebay.pl, you may save a few jelly beans.
Depends on your time and money supply.

 

[Dynosaur]

OK, nearing end of removal.
Of note : - make sure you have a good selection of extensions, U/J's and adaptors.
Read the WHOLE of this thread before embarking on the job - there are some good pointers in it.

- Wheelarch liner off - just 8mm (one 10mm) hex-head screws ... lots of them - and some push-pin faux-rivets.

- Both front undertrays and stiffening plate off - all straightforward.

- Top cover and air filter off.

- Cat off : - there are three lines to it, ensure you disconnect all before dropping it.
To remove the square pressure sensor, depress the plastic tab just forward of the middle and tap it forward ... it'll slide out.
The turbo end's just two nuts. The back end is just a pipe (with two slot cuts) within a pipe .... but I had to use a Gator Grip to remove the rusty clamp-nut - and GG's aren't long reach, so if your nut doesn't come off with wire brushing and WD, then it's a Dremel job to cut the stud short enough for the GG to fit over the nut ... but easy enough.
The cat's back-end pipe splits pretty easy with WD and screwdriver-bashing with a mallet.

I'm currently undoing the manifold nuts - so that pretty much looks like it.

More later.

 

[Dynosaur]

OK, manifold's off.
Only other thing to add was to loosen the EGR valve to allow clearance for manifold removal.

But guess what.
No sign of manifold leakage.
Very strange, given acrid exhaust fumes in car.
Maybe I have a leak downstream of the turbo ?

Anyway, on reflection, I suspect that it might be possible to remove the manifold without removing the cat.
The manifold bolts are all pretty readily accessible from the top (with some 3/8" drive deep sockets).
And BTW, you'll need a 12-point 3/8-drive 12mm socket to remove the manifold/turbo bolts (they're not hex-head) because the shoulder on a 1/2" drive socket precludes access to the single bolt nearest the head.

If you were to loosen the cat's two support braces and the turbo mounting bolts, you'd probably have enough slack to manouvre the manifold without difficulty.
Certainly worth trying before removing the cat.

Be sure to use duct tape to cover the turbo apertures - it's the last place you want any kind of crud or worse, a stray nut.

Reassembly tomorrow.
I'm going to jubilee the turbo inlet and crankcase breather hoses to eliminate induction leaks as the cause of my sub-2krpm lack of boost.
Failing all that, I guess I'm looking at a screwed electronic actuator or coked up vanes, ie - a new turbo and bye-bye ££££.