530d - Broken Swirl flap = Broken Engine
05-24-2008, 04:57 AM
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Hello everybody,
Yesterday was a very bad day. I went to work with my car as usual, but after 20 meters I heard a cracking sound from the engine. I had no more power.
Called the road assistance to tow me to the garage. In the afternoon the mechanic called me to give me the verdict. A swirl flap from the intake manifold broke and was sucked into the engine. He told me it would cost me +/-10000 EUROS for a new engine since the warranty expired.
The other option he gave me, is to replace the piston, cylinder head, intake manifold, etc. + work for approximately 6000 EUROS.
He said it is a well known problem.
I called some other BMW dealers and they told me the same thing. I checked the E60 forums and found all about it. http://forums.e60.net/index.php?showtopic=46764&st=0
Now I'm wondering why BMW didn't recall all the affected models, when they knew this is a case of bad engineering. I haven't contacted BMW Belgium yet, but do you think they would repay me (even just a part of) the damages, since it is such a common problem?
My current engine has only done 65k km.
What is the best thing I can do?
1. Buy a new engine
2. Replace the broken parts
3. Buy a used engine (probably +100k or +150k km)
Yesterday was a very bad day. I went to work with my car as usual, but after 20 meters I heard a cracking sound from the engine. I had no more power.
Called the road assistance to tow me to the garage. In the afternoon the mechanic called me to give me the verdict. A swirl flap from the intake manifold broke and was sucked into the engine. He told me it would cost me +/-10000 EUROS for a new engine since the warranty expired.
The other option he gave me, is to replace the piston, cylinder head, intake manifold, etc. + work for approximately 6000 EUROS.
He said it is a well known problem.
I called some other BMW dealers and they told me the same thing. I checked the E60 forums and found all about it. http://forums.e60.net/index.php?showtopic=46764&st=0
Now I'm wondering why BMW didn't recall all the affected models, when they knew this is a case of bad engineering. I haven't contacted BMW Belgium yet, but do you think they would repay me (even just a part of) the damages, since it is such a common problem?
My current engine has only done 65k km.
What is the best thing I can do?
1. Buy a new engine
2. Replace the broken parts
3. Buy a used engine (probably +100k or +150k km)
05-24-2008, 05:57 AM
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I would expect a new engine supplied and fitted by BMW at no cost to you at all. Be polite but very firm when you speak to them. You should not have to pay for such a huge repair due to such a small componant failing. 
05-24-2008, 06:15 AM
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Originally Posted by RobyO' post='587474' date='May 24 2008, 01:57 PM
Hello everybody,
Yesterday was a very bad day. I went to work with my car as usual, but after 20 meters I heard a cracking sound from the engine. I had no more power.
Called the road assistance to tow me to the garage. In the afternoon the mechanic called me to give me the verdict. A swirl flap from the intake manifold broke and was sucked into the engine. He told me it would cost me +/-10000 EUROS for a new engine since the warranty expired.
The other option he gave me, is to replace the piston, cylinder head, intake manifold, etc. + work for approximately 6000 EUROS.
He said it is a well known problem.
I called some other BMW dealers and they told me the same thing. I checked the E60 forums and found all about it. http://forums.e60.net/index.php?showtopic=46764&st=0
Now I'm wondering why BMW didn't recall all the affected models, when they knew this is a case of bad engineering. I haven't contacted BMW Belgium yet, but do you think they would repay me (even just a part of) the damages, since it is such a common problem?
My current engine has only done 65k km.
What is the best thing I can do?
1. Buy a new engine
2. Replace the broken parts
3. Buy a used engine (probably +100k or +150k km)
Yesterday was a very bad day. I went to work with my car as usual, but after 20 meters I heard a cracking sound from the engine. I had no more power.
Called the road assistance to tow me to the garage. In the afternoon the mechanic called me to give me the verdict. A swirl flap from the intake manifold broke and was sucked into the engine. He told me it would cost me +/-10000 EUROS for a new engine since the warranty expired.
The other option he gave me, is to replace the piston, cylinder head, intake manifold, etc. + work for approximately 6000 EUROS.
He said it is a well known problem.
I called some other BMW dealers and they told me the same thing. I checked the E60 forums and found all about it. http://forums.e60.net/index.php?showtopic=46764&st=0
Now I'm wondering why BMW didn't recall all the affected models, when they knew this is a case of bad engineering. I haven't contacted BMW Belgium yet, but do you think they would repay me (even just a part of) the damages, since it is such a common problem?
My current engine has only done 65k km.
What is the best thing I can do?
1. Buy a new engine
2. Replace the broken parts
3. Buy a used engine (probably +100k or +150k km)
?10000 is alot of dough, it defo would not hurt to have a go and see what happens. Good luck. It would not hurt to get legal advice from a lawyer who is an automobile law specialist either
05-24-2008, 06:40 AM
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Originally Posted by Nitrodaze' post='587490' date='May 24 2008, 04:15 PM
I have a feeling that if you approach BMW Belgium with a request for a replacement engine they may oblige you with a new engine. The reason being that this has been a known problem for a while now and they have chosen not to top recall. From a legal perspective, this very fact will place them in a very weak position in a litigation (provided you can provide concrete proof) hence they would rather change it than have a law suit which may serve to open up a floodgate of claims from those who have suffered this fate but did not realise that it was due to manufacturing fault. Manufacturers are liable for manufacturing defects even beyond warrantee period provided you have not tempered with the engine in any way that is contrary to BMW's recommendations (i.e.mods like flashing of ECM or installation of speed enhancing devices etc).
?10000 is alot of dough, it defo would not hurt to have a go and see what happens. Good luck. It would not hurt to get legal advice from a lawyer who is an automobile law specialist either
?10000 is alot of dough, it defo would not hurt to have a go and see what happens. Good luck. It would not hurt to get legal advice from a lawyer who is an automobile law specialist either
I haven't tuned the car in any way and the car always had regular maintenance at the BMW dealer. I will get legal advice through my insurance company and see what they can do.
I will post further info.
05-24-2008, 01:27 PM
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Originally Posted by RobyO' post='587474' date='May 24 2008, 03:57 PM
Hello everybody,
Yesterday was a very bad day. I went to work with my car as usual, but after 20 meters I heard a cracking sound from the engine. I had no more power.
Called the road assistance to tow me to the garage. In the afternoon the mechanic called me to give me the verdict. A swirl flap from the intake manifold broke and was sucked into the engine. He told me it would cost me +/-10000 EUROS for a new engine since the warranty expired.
The other option he gave me, is to replace the piston, cylinder head, intake manifold, etc. + work for approximately 6000 EUROS.
He said it is a well known problem.
I called some other BMW dealers and they told me the same thing. I checked the E60 forums and found all about it. http://forums.e60.net/index.php?showtopic=46764&st=0
Now I'm wondering why BMW didn't recall all the affected models, when they knew this is a case of bad engineering. I haven't contacted BMW Belgium yet, but do you think they would repay me (even just a part of) the damages, since it is such a common problem?
My current engine has only done 65k km.
What is the best thing I can do?
1. Buy a new engine
2. Replace the broken parts
3. Buy a used engine (probably +100k or +150k km)
Yesterday was a very bad day. I went to work with my car as usual, but after 20 meters I heard a cracking sound from the engine. I had no more power.
Called the road assistance to tow me to the garage. In the afternoon the mechanic called me to give me the verdict. A swirl flap from the intake manifold broke and was sucked into the engine. He told me it would cost me +/-10000 EUROS for a new engine since the warranty expired.
The other option he gave me, is to replace the piston, cylinder head, intake manifold, etc. + work for approximately 6000 EUROS.
He said it is a well known problem.
I called some other BMW dealers and they told me the same thing. I checked the E60 forums and found all about it. http://forums.e60.net/index.php?showtopic=46764&st=0
Now I'm wondering why BMW didn't recall all the affected models, when they knew this is a case of bad engineering. I haven't contacted BMW Belgium yet, but do you think they would repay me (even just a part of) the damages, since it is such a common problem?
My current engine has only done 65k km.
What is the best thing I can do?
1. Buy a new engine
2. Replace the broken parts
3. Buy a used engine (probably +100k or +150k km)
I've been a bit worried about this case too, so I recently took my intake manifold out and cleaned the swirl flaps: Cleaning the intake manifold
However, I still have those bas...ds in there
Today I read a post from a Finnish forum, where someone had the swirl flaps removed by a BMW service for 45?
. That's new to me!
I hope you get your ride fixed. My suggest is a new engine. I think you'd be happier with that.
And of course, welcome to the forum!
05-24-2008, 01:46 PM
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Real sorry to hear about the trouble you're having. Definitely be firm with the dealer and with BMW directly on this. I've read about the swirl flaps more often than I care to be comfortable about on here. Could you also share the details of your car with us?
05-25-2008, 01:23 AM
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Originally Posted by Anzafin' post='587672' date='May 24 2008, 11:27 PM
I am so sorry to hear that.
I've been a bit worried about this case too, so I recently took my intake manifold out and cleaned the swirl flaps: Cleaning the intake manifold
However, I still have those bas...ds in there
Today I read a post from a Finnish forum, where someone had the swirl flaps removed by a BMW service for 45? .
That's new to me!
I hope you get your ride fixed. My suggest is a new engine. I think you'd be happier with that.
And of course, welcome to the forum!
I've been a bit worried about this case too, so I recently took my intake manifold out and cleaned the swirl flaps: Cleaning the intake manifold
However, I still have those bas...ds in there
Today I read a post from a Finnish forum, where someone had the swirl flaps removed by a BMW service for 45?
. That's new to me!
I hope you get your ride fixed. My suggest is a new engine. I think you'd be happier with that.
And of course, welcome to the forum!
I read your DIY about cleaning the swirl flaps, but this was too late of course.
The dealer told me BMW have modified the new intake manifold by strengthening the swirl flap axles.
05-25-2008, 01:25 AM
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Originally Posted by MacSid' post='587684' date='May 24 2008, 11:46 PM
Real sorry to hear about the trouble you're having. Definitely be firm with the dealer and with BMW directly on this. I've read about the swirl flaps more often than I care to be comfortable about on here. Could you also share the details of your car with us?
I will contact BMW tomorrow morning and will post the details of this saga.
05-27-2008, 11:05 AM
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Hi all,
Having read these stories I obviously got a little nervous about the '03 530d I just bought. It has about 100k (kilometers) on it and I would HATE for this to happen to me.. I have called my local BMW dealer and explained what I've learned from the forum so far. They looked into it, and when they got back to me they told me they HAD heard of the problem but they had only rarely seen it happen. They also told me it usually happens at very high mileages (over 200k kilometers).
I asked them if they could take preventitive measures (i.e. take the flaps out) but they advised against it and stated the engine wouldn't run properly without the flaps. Also they said taking the flaps out is not an easy job.
I'm left VERY curious if anyone had since learned anything about this (potential) issue.. Anyone?
Having read these stories I obviously got a little nervous about the '03 530d I just bought. It has about 100k (kilometers) on it and I would HATE for this to happen to me.. I have called my local BMW dealer and explained what I've learned from the forum so far. They looked into it, and when they got back to me they told me they HAD heard of the problem but they had only rarely seen it happen. They also told me it usually happens at very high mileages (over 200k kilometers).
I asked them if they could take preventitive measures (i.e. take the flaps out) but they advised against it and stated the engine wouldn't run properly without the flaps. Also they said taking the flaps out is not an easy job.
I'm left VERY curious if anyone had since learned anything about this (potential) issue.. Anyone?