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  #1  
Old 07-13-2018, 06:57 PM
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Damn... (3.0d exhaust manifold crack) - Fixed (with pictures!)

I guess it was inevitable...



Exhaust manifold, where the manifold joins the turbo (turbine).

New X8R cast iron part ordered and on the way. Replacing it looks to be a fun task!

I'll try to replace it without removing the valve cover. Removing the valve cover requires removing the entire inlet tract and injectors etc.



Trouble is, the rocker cover includes the frame for the air filter element, so it totally obscures the exhaust manifold. This is a task that will need to be performed virtually blind...



As we say down-under... Bugger...
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2005 BMW X5 3.0d (b 02/05)
2001 BMW F650GS Dakar (b 06/01)

Last edited by wpoll; 09-22-2018 at 04:45 AM.
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  #2  
Old 07-13-2018, 08:10 PM
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Ahhh, I feel your pain!! I was messing around trying to get at it all the other week to inspect, looks to be a friggin nightmare! I was pondering whether you could cut the air filter housing part of rocker cover off, to help with access.. but that might be making a big mistake! :p also, looked like you’ll need thin wall sockets/spanners to get at turbo bolts, I tried a normal spanner and it was too thick.. I guess if you can get exhaust out of the way, remove turbo bolts through the top, should be able to get at the manifold bolts, and slide out underneath. (Potentially leaving turbo more or less in place)

Good luck, have fun! And be sure to take lots of pics and do a write up on it please!
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Old 07-13-2018, 11:55 PM
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Whistle

Yeah, it's like a barrel full of monkeys in there...

I intend to remove the turbo outlet (to the intercooler), the turbo inlet, the washer bottle, all the air filter housings that can be pulled, the cabin air intake ducting etc. (just like when replacing the air filter element).

The A/C lines will be right in the way so I'll just have to work around them. Being an OB/GYN might help.... if I was one. Good thing I have a great range of socket extensions and universal joints (wiggles) on hand...

I will leave the turbo in place, along with the exhaust. I'm hoping I can even leave the lower alloy reinforcing plate in place (unless I drop something!). Removing either the valve cover or the reinforcing plate, exhaust and turbo hugely increases the amount of work required and I've seen YouTube videos from folk who have managed this task in this manner. It should even be possible to remove the manifold out the top once the studs are free.

What would be a deal breaker is a seized or broken stud. The general condition of the entire car is very good so I'm hoping I don't go there. I'll certainly get penetrating fluid on the studs etc. overnight in an effort to avoid "issues".

I'll be sure to photograph and write up the process...
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Old 07-14-2018, 06:09 AM
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Good luck Wayne, you've kindly handed out plenty of assistance to others on this forum, I hope in return the replacement goes without too many hassles for you. Just in case though, I'd get a bigger jar.
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Old 07-14-2018, 04:09 PM
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Thumbs up

Haha, yeah, might need that! Thanks Neil..!

Apologies for expletive above but it sums up task of removing the valve cover rather nicely.

While I enjoy working on my vehicles and the X5 in particular, I enjoy driving it more, and I'm keen to sort it and move on. I guess this task will up there with wheel bearings (but will require less tool purchases!) or the OFHG on the M54. And maybe not as bad as the dreaded alternator bracket gasket on the V8s. Putting it in context helps!!

This puts a delay on my plans to sort the rear sub-frame bushes. I recently purchased the sub-frame bush tools (used only once). Fortunately, I think the bushes are ok - I was going to replace them based on age/mileage. A task for later in the year now - while my swear jar is filling fast, the X5 maint. jar is emptying faster!!!
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Last edited by wpoll; 07-15-2018 at 06:56 AM.
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Old 07-15-2018, 02:17 AM
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What prompted you to check the manifold for cracks? Was there any noises or loss of power etc? And I might have to hit you up to borrow your subframe tool when the time comes to do mine
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Old 07-15-2018, 03:06 AM
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Quote:
Originally Posted by Ohsoslow View Post
What prompted you to check the manifold for cracks? Was there any noises or loss of power etc? And I might have to hit you up to borrow your subframe tool when the time comes to do mine
Nothing in the car's performance led me to check - it's running well. A little noisier than when I got 3 it years ago perhaps but hard to tell, as the cracks open up very slowly over time.

I did notice a little "soot" on the turbo outlet pipe but it turned out to be more dirt (stuck to oil) than soot when I cleaned it off. That got me to thinking it was time to grab the GiraffeCam and check it out. Glad I did, as I've caught it before any real symptoms have appeared.

At 59 quid, the X8R manifold (kit) is a no-brainer. Works out to be around NZ$200 inc. shipping. Another NZ$40 for the turbo outlet pipe gasket (which needs replacing anyway).

Here's the subframe bush tool I got (from TradeMe) - https://www.kommentools.com/products...g-tool-set-e53. This tool has already sorted one E53 in Chch, so I think it is destined to be a well-used bit of kit around the country!
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Old 07-16-2018, 05:11 AM
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So after spending way too much time Googling this issue, I finally found someone that has done this without taking the valve cover off - but they did remove the entire turbo and came in from underneath.

BMWxMAX from Russia has a very good series of blogs documenting all manner of maint tasks and mods.

https://www.drive2.com/r/bmw/1289884/

One of his blogs shows the entire manifold replacement...

https://www.drive2.com/l/467740493866860758/

So here's the thing... looking at his images and at my car, I really do reckon that it IS possible to replace the manifold without removing either the turbo or the valve cover.

So, borrowing a couple of BMWxMAX's photos, here's the above view, with all the covers off and the washer bottle removed: -



I will take mine to this point but also remove the vacuum reservoir, the turbo compressor outlet pipe (fat silver pipe at lower centre) and of course, the turbo inlet pipework (fat black pipe at lower right-of-centre). But that A/C pipe is going to get sworn at a fair bit...

And here's what it looks like from underneath: -



Old manifold is in place in the first image, new manifold in place in the last one.

This shows that even with the turbo removed, you cannot easily see or get to the top manifold bolts.

But more importantly, you can see the clearance from above, past the air filter housing. Plenty of room for tools and hands.

There is no argument - it will be easier to do this with either the valve cover or the turbo removed but given the extra work required (not to mention the extra cost in gaskets etc.) I'm not going down either path unless I have to.

A good magnetic mirror and light source are going to be a must however ....

Thanks to BMWxMAX for all the inspiration!
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Old 07-16-2018, 05:47 AM
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Once again, good luck with that. Hope the cast is true and everything lines up. Capturing the manifold in place using the studs you can see will give your seemingly necessary three arms a rest, before getting nuts on those obscured top studs. Holding the nuts in the socket with some butyl putty or similar might avoid them falling to places you can't reach.
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  #10  
Old 07-16-2018, 06:20 AM
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I'll be replacing all the studs too...a sucker for punishment, me.
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2005 BMW X5 3.0d (b 02/05)
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Last edited by wpoll; 07-16-2018 at 04:12 PM.
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