530d exhaust manilfold cracked
03-24-2009, 05:50 AM
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Originally Posted by Rob Hall' post='825291' date='Mar 24 2009, 10:43 AM
interesting, have called dealer for a price on a new manifold and they tell me that bmw central spares are supplying 50 manifolds per month, so looks like a design issue !!
How much did the dealer quote for the part, i've been able to smell fumes lately and suspect the same may have happened.
Dom
03-24-2009, 12:56 PM
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Originally Posted by Phantom Mark' post='825324' date='Mar 24 2009, 12:25 PM
great.........
Maybe it will be free then ?
Maybe it will be free then ?
Considering the top half of the engine was already taken apart to find the prob, i would have to put back together, take the car in and loose a few days, which im sure would end up costing more than sorting it myself, which i dont have time for. Also they couldnt tell me if the new manifold was a revised design or not so considering i have the facilities to repair seemed like the best option.
car is over 100k miles now.
was surprised by the cost of a new manifold at ?330 was expecting double that.
Tis a bit of a major gaining working room to remove the manifold but have done so today and repaired the manifold, quite an easy repair ( if it lasts, fingers crossed )
will post more pics tomorrow.
03-24-2009, 05:51 PM
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Originally Posted by Rob Hall' post='825291' date='Mar 24 2009, 06:43 PM
interesting, have called dealer for a price on a new manifold and they tell me that bmw central spares are supplying 50 manifolds per month, so looks like a design issue !!
03-25-2009, 02:14 AM
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access to the manifold
manifold removed
extent of parts removal to gain access
manifold repaired, tig welded the crack then welded a stainless steel plate over the whole area to reinforce.
hopefully will last as many miles as a new one !
manifold removed
extent of parts removal to gain access
manifold repaired, tig welded the crack then welded a stainless steel plate over the whole area to reinforce.
hopefully will last as many miles as a new one !
03-25-2009, 03:09 AM
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Originally Posted by Phantom Mark' post='826117' date='Mar 25 2009, 10:55 AM
Damn your brave Rob, good job mate, well done, oh, and good luck !!
Thanks,, was a lot of work but has only cost my time. The car does feel great again, so the crack must have been having an effect on noise and performance.
03-25-2009, 05:32 AM
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My Ride: 530d M Sport. It has Heads Up Display...need I say more...
What a major head ache. At least it has only cost you the time to do it. Nice job though. Would be interested to know if this was just on earlier cars hence updated part along with the swirl flaps issue.
05-14-2009, 01:00 AM
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My Ride: 2004 E61 530D fully loaded. 63000 miles at 14/05/09.
Full dealer service history on a 5 year service deal from new.
[
attachment=1021
80:[attachment=102177:IMG_0617.JPG]
Hi Rob,
I have just had the manifold replaced on my E61 530d. I was offered 40% of the part price by BMW on condition that they kept the old manifold. I refused the offer and paid full price because I wanted to see the part. Two BMW technicians from different dealerships have told me that they have changed several manifolds on 3 ltr diesels. One of them said he had changed so many that he assumed that there was a recall (which there isn't).
I have the manifold here and annex some pictures that show that there is clearly a flaw in manufacturing /design. the cracks are all on press lines where the parts were formed. They are clearly down to stress (metal fatigue) caused by heat. my car has only done 63000 miles but is out of warranty. it has been serviced by BMW and has a service deal until August this year. The total cost of replacement was ?634.08!!!
The problem could be a safety hazard, you dont want hot exhaust gases blasting around in the engine bay.
attachment=102180:[attachment=102177:IMG_0617.JPG]
Originally Posted by Rob Hall' post='824439' date='Mar 23 2009, 09:41 AM
Ive had exhaust fumes coming thru the air con for the last couple of weeks unless i have recirc on so decided to have a dig and find the cause. Was hoping for something simple but have found the manifold to be cracked just above the turbo. A pain to get at and see but heres a pic from the reflection of a mirror. Ive circled the crack although not easy to see. looks like a major job to take it off !! although it looks like it could be welded once off. Anyone else ever experience this ? not looking forward to this job and could easily have done without it.
Attachment 74843
Attachment 74843
I have just had the manifold replaced on my E61 530d. I was offered 40% of the part price by BMW on condition that they kept the old manifold. I refused the offer and paid full price because I wanted to see the part. Two BMW technicians from different dealerships have told me that they have changed several manifolds on 3 ltr diesels. One of them said he had changed so many that he assumed that there was a recall (which there isn't).
I have the manifold here and annex some pictures that show that there is clearly a flaw in manufacturing /design. the cracks are all on press lines where the parts were formed. They are clearly down to stress (metal fatigue) caused by heat. my car has only done 63000 miles but is out of warranty. it has been serviced by BMW and has a service deal until August this year. The total cost of replacement was ?634.08!!!
The problem could be a safety hazard, you dont want hot exhaust gases blasting around in the engine bay.
05-14-2009, 02:03 AM
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Holy Moly !!!
Thats some serious cracking !!!
Is it possible to spot this via inspection from above without stripping things back, ive often wondered if my car sounds a little loud on tickoever actually.....
I've got 85k on the clock here.
( No matter, Robs first post shows you can use a mirror )
Thats some serious cracking !!!
Is it possible to spot this via inspection from above without stripping things back, ive often wondered if my car sounds a little loud on tickoever actually.....
I've got 85k on the clock here.
( No matter, Robs first post shows you can use a mirror )