Anzafin

I just noticed this thread and now reporting in!
I haven't experienced the cracked exhaust manifold, but when my car had gone its first 20.000kms (12400mls), the dealer had called it in to change the turbo and exhaust manifold. The car was on its first owner back then, and he told me that there wasn't any faults or issues going on, the dealer just wanted to do it.
So I don't know if there has been some recall for these kind of issues .

Bob525D

Correct me if i am wrong but, arent the exhaust gases lethal to inhale on a diesel. Bearing in mind that these are the gases before they have gone through the DPF and CAT. This should be a recall for health and safety alone, at the very least a visual inspection should be done.

Mike Hawk

I had the collector come clean off the flange that mated up to the cats on OLDBMW* @ around 95k miles

Good thing I'm handy w/ a wrench and have a bro-in-law that welds for a living

* '97 M3/4/5

Rob Hall

When i asked the dealer for a price on a new manifold, they were supplying around 50 a month so id say its a serious problem. Without knowing if there had been any design improvement i couldnt see the point in having a new one so opted to repair myself, thinking after 100+k miles the metal will be nicely stress relieved and done all the settling down its going to do, the repair was easy but getting to it is a considerable pain, i did wonder at 1 point if it would have been easier to take the engine out
Ive done a good few miles on it now and all is well, in fact the engine just seems to get better with age

Rob Hall

mine has the updated flaps so doesnt look like it.

hibberd

I had mine replaced last summer, it was so bad that I had to drive with the windows open or else I wasnt feeling well. Its a poor design causing the problem> Mine was done under warranty so luckily didnt cost anything..

Ceeray

What are the other symptoms of this kind of problem?
Increased consumption?

It might be worth a while to check out that from my car too, if it could be seen without major dismantling.

hibberd

Easiest way to know if you have it is if you can smell the exhaust gas smeel when your standing next to the car..mine has a DPF and datalyst so normal there is no diesel exhaust smell when next toi the car or standing still..

pauld30

very interesting article, great photos, looks like a lot of work to get too it, but aleast you know its done properly cause you did it youself. better than paying an oil monkey ?125 per hour labour. how many miles had your car done ? still got your swirl flaps ? does seem like a design fault. cheers Paul how long did it take you approx. ?

Robbage

Hi having read this i have taken a look at my 525d 100k miles. And guess what a hairline crack although nothing like as bad as you have photographed here.

But no blowing exhaust noise, no exhaust smell in the car. Now it won't get better im sure, and if i hadn't read this thread i would not even know about it... But i have. So is there any point in creating work and expense now for what is not really an evident problem in terms of symptons, or should i just sit tight for now, as if it does not get any worse, it appears not to be an issue in my case?