Exhaust manifold options

[Bigb]

Hi there, I bought my x5 a couple of weeks back knowing the manifold was cracked as I could smell it on start up and I could hear it on the test drive, agreed a few quid off because of this. I have just had a look tonight and there is indeed a fairly big split in it where the turbo bolts up. I'm going for a cast one and was wondering if anyone has tried any of the ebay ones? Any you could link and recommend? Going to slap a bit gungum on the crack and get one ordered up asap. Looking forward to this eating a weekend changing this over

[Horizon]

Yes EBay ones are good, several members have replaced the original sheet metal ones for the EBay cast iron ones with great results.
Use the search button on the forum to find previous posts

[Bigb]

I have searched, I seen the cast ones seem to be the way to go but there are a few on ebay, just want to know a decent one to buy that someone can recommend. Thanks again bryan

[Horizon]

http://xdrivers.co.uk/forum/index.php/t ... #msg103096

[Bigb]

Thanks

[X5-D-Sport]

Big B...
When you tighten the manifold up to the head, tighten it progressively & leave an hour, then nip up again & leave a couple of times....
I've known the bolting lugs to crack of you do too much too soon without letting the gasket settle.

Regards
Grant B

[Bigb]

Thanks for that, I'm going to tackle the job next weekend,doesn't look too bad a job, just time consuming.

[X5-D-Sport]

Agreed - its not difficult - just a long winded Balls-Ache job.

You would be well advised to remove the center bulkhead panel that is in front of the wiper motor & cabin filter.. just a couple of bolts - 1 of which holds the engine bay jump-start connection.

When you strip the top end of the engine.... NOTE WELL...

get a dozen re-seal-able bags for bolts/screws as sets as they are removed...
AND
remember, all the bits will fall off easily. If they don't there are more hidden bolts n screws...

While you are doing this job, it is also a good idea to swap out the cam cover gasket & the inlet manifold ring gaskets too... not expensive, but worth getting as IT WILL leak on induction, or oil other wise when re-assembled.

[Bigb]

Thanks again, I will renew the gaskets, going to do the ccv and I also have a thermostat to go in too as the temp gauge stays quite cool.loads to do lol

[Bigb]

Got the manifold off tonight,took me a good 3 hours to get to this stage, very involved job, my garage has neat piles of 3.0d engine sitting everywhere haha, injectors came out very easy which I was worried about so happy with that.my manifold has 1 huge split and about 4 small cracks so I should feel a bit more grunt when the cast item is fitted. Pleased to find my turbo is in good order too. Just got to build it back together now.

[X5-D-Sport]

Well done chap,

It's nice when they fire up nicely again.

Note, the injector pillars are FRAGILE, as are the tinsy bolts they use.... they only need nipping gentle hand tight up with a 1/4 drive socket, or will tear out or shear off.

If you get any strange knocking noises when re-starting, it will be an injector a tad loose & need just a little more bolt/nut torque.... easier this way than shearing the bolts off....

[Bigb]

Cheers again, I'm usually the worlds worst for giving nuts and bolts a bit too much grunt so will take care when bolting them back in. Waiting for a rocker cover gasket arriving so hopefully get on a bit more tomorrow

[X5-D-Sport]

NOTE WELL:

Each injector has a chunky copper washer, ensure you don't lose these.

And re nipping the Injector nuts... take your time doing these...
Wind the nuts down by hand using a 1/4 drive extension bar & the small socket AND NO WRENCH INITIALLY - got Gods-Sake don't use a 1/2 inch socket drive on these little fellas.

Nip all the nuts down by hand using just the 1/4 drive extension & socket. when they are all nipped & seated evenly... then apply a tiny bit of torque with a tiny 1/4 drive ratchet, & only pull ratchet with fingers expended holding the ratchet.
If you twist them down with a fist wrapped around the ratchet you will be guaranteed to tear them out of their mounts/shear off/strip nut threads etc.

They can always be nipped up a bit more & a bit more, where as drilling & helicoils are a sodding balls-ache.

Have fun Sir.

[Bigb]

I fitted the new manifold tonight, tightened the nuts a little more each time, once I got the last one nipped up, the first one I started on felt loose, just done this a few times until all were tight. I only had a 1/4 inch 10mm deep setup so couldn't really over tighten these anyway. I did notice little cracking noises as I went round them on every port, must have been the gaskets crushing.i fitted a new thermostat too, very easy to get to when everything is stripped down. I got my rocker gasket today, do I need to apply instant gasket to any part of this like the corners? Thanks again bryan

[Bigb]

All up and running again, not too tricky a job but very time consuming,glad to see my temp gauge sitting where it should now too after fitting the new thermostat.