BMW E60 M57 530D exhaust manifold removal and replacement DIY guide.
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  1. #1
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    BMW E60 M57 530D exhaust manifold removal and replacement DIY guide.

    BMW E60 M57 530D exhaust manifold removal and replacement guide.

    This is a fairly big job with lots of pictures so not for the faint hearted. Do not attempt this unless you're competent. I accept no responsibility for mistakes, damage to you, your property or your car from following this guide.
    The old manifold was being replaced due to it cracking, as shown here.


    Let's begin then.
    Remove the engine cover, 5mm Allen key.


    The primary air filter cover.


    The bolt and the pipe for the air filter.


    Slide the plastic cover towards the left side of the car.(Passenger)


    Remove the rubber trim.


    Remove the pollen filters and the bonnet alarm switch plug.


    Remove the bulkhead trim covers. (2x T20 screws. Twist the 10mm's 90).


    Trims removed.


    Strut top trim covers.


    Strut brace(4x T40).


    Engine rear cover.


    Air filter secondary cover and air filter.


    Sensor plugs.


    Remove the plastic trim piece the wiring is attached to along with the square pressure sensor.
    Depress the plastic tab just forward of the middle and slide it forward.(Not shown in these pictures)




    Now from underneath.
    Remove undershields.


    Aggregate plate.(16mm)


    2x DPF braces(removed already in this picture)(13mm), the exhaust sleeve(16mm) after the DPF and then the DPF itself.(2X 16mm).


    Remove the turbo actuator plug from below the vehicle.


    Pull out clip and pull off turbo pipe from intercooler.


    Remove 10mm turbo pipe securing bolt.


    Twist the turbo pipe flange clockwise and remove the pipe.


    Pull off the rubber breather pipe.


    Remove the main turbo air feed pipe.


    Remove the rubber bungs from the bottom of the air filter housing then the turbo bolt's cover, situated just above the exhaust manifold.


    This picture shows where the clip is, pull the clip down and slide the cover out.


    Remove the turbo oil feed pipe and the return pipe.


    One way of getting at the feed.


    Slacken the turbo bolts and remove the turbo carefully.


    EGR bolts. These need removing.


    Removing lower EGR bolt.


    Remove the 3 EGR cooler Allen key bolts(6mm).


    Old exhaust manifold.


    Remove the exhaust manifold nuts(11mm)


    Comparison. Old stainless steel exhaust manifold VS New cast iron exhaust manifold.


    New manifold fitted.


    Now put it all back together.

    Some info on the exhaust manifold. The part number that was fitted was Part number 11627811449, as found on these vehicles. RealOEM.com * Part Cross-reference

    This engine is a M57N2 engine (306D3), this was a 530d.

    By all accounts part number 11622248166 can be used to replace your cracked manifold, as found on these vehicles.

    E38 730d

    E39 525d Saloon
    E39 525d Touring
    E39 530d Touring
    E39 530d Saloon

    E46 330d Touring
    E46 330d Saloon
    E46 330xd Touring
    E46 330xd Saloon

    E53 X5 3.0d SUV

    So second hand will suffice. It is the cast iron manifold.
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  2. The Following 6 Users Say Thank You to Ronnie For This Useful Post:

    cforehead (20-06-2013),chr15gb (04-01-2015),jinsta (29-04-2014),Kevin Whittaker (20-06-2013),simonsays (20-06-2013),Spirit (20-06-2013)

  3. #2
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    This is so good I almost want to go and buy an E60 to try it out. Tell me, is that an ugly and uninspiring exhaust manifold, or is it just me?
    2006 E91 330i M Sport click
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    Ronnie (20-06-2013)

  5. #3
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    Quote Originally Posted by cforehead View Post
    This is so good I almost want to go and buy an E60 to try it out. Tell me, is that an ugly and uninspiring exhaust manifold, or is it just me?
    It is an ugly and uninspiring manifold,

    Surprisingly I enjoyed doing this job, it was quite straight forward.
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  6. #4
    Got that WMD right here.
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    Thaaaaat's and exhaust manifold

    2006 E91 330i M Sport click
    2006 E87 130i M Sport SOLD click
    2009 E70 Xdrive30d M Sport SOLD
    2008 E92 335d M Sport SOLD
    click
    2002 E46 330 Clubsport SOLD click
    1994 Peugeot 106 Rallye click

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    Ronnie (20-06-2013)

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    Great guide Ronnie, I assume the stainless manifolds found on all M57N engines are prone to this issue?
    so E46, X5, E60/E61 (525d/530d), E65 (730d) & E83 (X3) are affected ???

  9. #6
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    Quote Originally Posted by simonsays View Post
    Great guide Ronnie, I assume the stainless manifolds found on all M57N engines are prone to this issue?
    so E46, X5, E60/E61 (525d/530d), E65 (730d) & E83 (X3) are affected ???
    Cheers Simon,

    Part number 11627811449, as found on these vehicles. RealOEM.com * Part Cross-reference

    Was a M57N2 engine. 530d
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  11. #7
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    Quote Originally Posted by Ronnie View Post
    Part number 11627811449, as found on these vehicles. RealOEM.com * Part Cross-reference

    Was a M57N2 engine. 530d
    Bummer cos it does happen on the M57N too

    Sent to the UKs fastest growing BMW Forum.

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    Ronnie (20-06-2013)

  13. #8
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    You have a guide now then.
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    Pics fixed.
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  17. #10

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    Hi Ronnie, just registered to the Forum having studied your manifold guide in detail. I think my '05 E61 525d is going to need a new manifold very soon. I've actually got most of the top of the engine exposed at the moment. I've been losing coolant recently and I was replacing a radiator hose that showed a failure on a pressure tester and got carried away with the dismantling! (wanted to remove swirl flaps and clean & replace intake pressure sensor and pressure converter filter as my car has never gone like it should.

    The car has also been smoking from under the bonnet when stopped in traffic. I was hoping that it might turn out to be steam from the coolant leak but now I've got the air filter out I can see that it and everything else on that side of the engine is completely covered in black soot. Unfortunately although I've got everything removed inc. inlet manifold I'm going to have to reassemble and move the car into the garage over the pit if I'm going to get access to the exhaust manifold. (It's currently on loose gravel and there is no way I can push the car from where it is and there's another non running car over the pit at the moment).

    Any way that is a long winded explanation before a very simple question. Looking at your first picture of your cracked manifold I can see the bolts holding the turbo on and wondered what kind of socket is needed to undo them and where you can get one from. I can't even see the turbo on mine from the top but will try your mirror trick tomorrow. I'd like to remove the airbox / rocker cover and go in that way but I really don't want to disturb the fuel system etc. It would be good to get the turbo off and have a look at it as I suspect that the actuator is not working unless if I'm lucky it was just one of the sensors above. Either way I've got to reassemble & see if there is any improvement to performance before I start again from underneath.

    I'd appreciate any thoughts from anyone and the socket info. Thanks...

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    Ronnie (05-09-2013)

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