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°).
Strut top trim covers.
Strut brace(4x T40).
Engine rear cover.
Air filter secondary cover and air filter.
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.
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.
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.