Coolant pipe rupture

[WolfieBase]

There is nothing novel here. The primary coolant pipe on my son's F30 330D ruptured, necessitating a week's wait for service at the local independent garage. I chose to do the task for him, as a retired engineer with 30 years of experience in vehicle maintenance prior to transitioning to a desk position, subsequently receiving training in electric cars before concluding that it was sufficient.
The removal of the intake manifold is a complex task that I would not advise doing unless you possess proficient hand dexterity and much familiarity with contemporary automobiles.
Detach the engine cover

Detach the air filter and its housing.
Detachment of the battery
Detach the wire from the alternator, oil pressure switch, air conditioning compressor, manifold absolute pressure sensor, throttle valve, and swirl flap actuator; furthermore, detach the cable ducting from the manifold.
Attempt to relocate the soundproofing from the rear of the engine (which I damaged) and detach the fuel line bracket from the manifold.
Remove the bolts securing the EGR intake elbow to the throttle body, inlet manifold, and EGR valve, then detach the elbow while extracting the EGR along with the sensor.
Remove the seven bolts securing the manifold (the bulkhead end need a universal joint or equivalent tool). I subsequently detached the wire from the vacuum valve and the ECU located at the base of the manifold. Although it may be advisable to do this, I clipped the vacuum valve and unscrewed the ECU; still, the process is intricate and difficult to reassemble due to limited space for my hands.
We replaced the manifold with an aftermarket version; the quality was satisfactory and it fit appropriately. One fastening hole required deeper drilling, the previous one was severely coked, and one or two flaps were loose. Approximately five hours in total, which I believe might be reduced by half in the future. I do not plan to be a next time!

[Doncaster34]

Excellent composition; thank you for sharing.

[WolfieBase]

Thank you. In the past, five hours sufficed to replace a cylinder head on a six-cylinder Jaguar. Alternatively, remove an engine off a Volvo and disassemble it entirely!

[blueWING007]

Incredible, all that effort only to substitute a coolant pipe.

[trikey]

The coolant flange/pipe from the cylinder head is prone to failure, often splitting along the side nearest the oil filter.
Unless the intake must be removed, I typically just loosen it and elevate it enough to reach the upper E8 bolt.

[WolfieBase]

Have you tested this on the six-cylinder engine? I found it really difficult to transport even after everything was disassembled.
It evidently varies every vehicle; nevertheless, after 11-12 years, it is probable that the manifold need a decoke at a minimum. The elbow from the throttle body was likely somewhat undersized, and the engine now exhibits a notably responsive performance, particularly in the midrange where the turbocharger is operating vigorously. We also discovered detached swirl flaps, which, if dislodged, may enter the intake ports or cause more severe issues.
BMW is not the only manufacturer using plastic coolant pipes; nonetheless, while examining this particular component, I am astonished by their durability. An aluminium component would certainly last throughout the vehicle's lifespan; the decision ultimately hinges on cost. In retrospect, Volkswagen's transition around 35 years ago prompts the question, "Was that a prudent choice?" I propose replacing the pipe if your automobile is

Exceeding ten years in age may lead to possible harm from overheating; it is advisable to clean the manifold and inspect the flaps concurrently.

[trikey]

I have completed such tasks on both 4 and 6 cylinder engines; however, I have mostly performed them for individuals who just requested the resolution of coolant leaks rather than the cleaning of the manifold. Were it my decision, I would extract the manifold and clean it simultaneously.