Cracked Exhaust Manifold.

[Nige]

Noticed an exhaust fume smell in the X5. Removed the air filter top housing to get a better look


Using a small mirror, I was able to see the manifold has cracked


Rang Russ of DMWorx for some advice. "I did one of those yesterday Nige, book says 3.5 hours..." That`ll be a bit longer for me then . He was a huge help, explained I`ve have to remove the inlet manifold, injectors and other gubbins. A lot to remove but just be methodical.

We need the car over the weekend, so I`ll put it back for now, then start next week. Its not a cast manifold so at least I can save £200+ by welding it up myself.

I`ve had to put it all back together as we need the car over the weekend, but I`ll be tackling it next week and will post more photos then

[CondorX5]

Happened to my Range Rover just before I bought my first X, it was a right pain getting to it, luckily got a good second hand unit from the breakers. Luckily you can still drive it like that - good luck with the job, its tedious!

[g60renshaw]

Handy to know they are tubular so can be welded if mine ever goes. Could you hear it blowing?

[Nige]

[quote=""g60renshaw""]Handy to know they are tubular so can be welded if mine ever goes. Could you hear it blowing?[/quote]

Nope, not at all. Just smelled fume inside the cabin, opened the bonnet and traced it to somewhere under the airfilter.

[Nige]

Well, THAT was an interesting afternoon

Just about to remove inlet manifold


removed


removed the injectors


ta da


removed lots of fekking bolts


behind here is a 5mm torx headed screw. B#!*&rd thing


Once done, I could remove the rocker cover and FINALLY see the exhaust manifold


The top nuts were easy to access, the ones underneath, less so....


Removed


Oh, look, more cracks


wonder if it`ll weld ? Yep, it will


Will do the rest tomorrow and rebuild it all. Took me as long to get to this stage as the BMW book of lies says it will take to do the full job.

I need to speed up

[x555]

Looks like that's a bit of a mission there Nige.....thanks for taking the time to take and post photo's mate ...not always easy with some oily jobs

[Nige]

[quote=""x555""]not always easy with some oily jobs [/quote]
You`re not kidding

I`ve hopefully taken enough photos to post a `how-to` later

[g60renshaw]

Excellent write up. How too would be very good, just in case.

Jay

[lezmtaylor]

Nice one Nige.
Lez

[Nige]

A couple of the ports had cracked quite badly.


So I welded all the way around the flange. (the lower weld in the middle is intentional, its where the bolt head sits)


Before


After


New gaskets and manifold bolts (2 short, so reusing 2 old ones)


The Manifold and Rocker cover are now back on the car, tomorrow I`ll get it finished. Didn`t pick up the gaskets until mid afternoon so knew I wouldn`t finish it today.

[deepblonde]

This looks like quite a difficult job,(at least for me!)
But I can smell exhaust , and think it's coming from the exhaust manifold as well. I'm thinking of changing the stainless steel manifold , which seems to be prone to cracking all over the place, to a cast iron exhaust manifold. Anyone had any experience doing that?

[Horizon]

http://xdrivers.co.uk/forum/https://xdr ... n#msg12991