Rob Hall

As you say, can only get worse. For me if i knew the crack was there id have to plan around getting it sorted asap.

Robbage

Thanks!

Ps do you tig weld for a living as that repair looks seriously professional standard?

jasonprice07

Hi all
I'm in the process of checking the manifold as I've got exhuast fumes entering the cabin.
I've removed the air filter and assembly but cant figure out how to remove the plastic part which holds a couple of electical connectors below the air filter.
I think one is the pressure sensor from the DPF. This is blocking my view of the manifold
I cant see any bolts holding it in place, seems like plastic tabs but I don't want to pull too hard and break it.

Can any one help?

Thanks

Jason

jasonprice07

Took the turbo outlet to intercooler pipe off instead.
Manifold looked ok, no cracks, must be leaking from somewhere else.

Jason

Rob Hall

For reference the repaired manifold has cracked again in several new places, although the previous repaired area is fine.

Have circled the visible cracks, the flange to manifold is also cracking but is barely visible, think you can see soot around the flange on the 2nd pic.





Have now fitted a new manifold as the material is obviously unstable after a certain amount of useage. The new 1 looks identical in design so just hope the material has been improved.
.
.
.
.
and yes ive bitten the bullet and removed the swirl flaps although worthy of comment, they were the supposed upgraded 4.5 flaps and there were no signs of distress. I used Anzafins trusty self tap screw method

Anzafin

Sorry to hear about your exhaust manifold. Maybe a good choice to go for new one this time though...
And nice to hear about your intake manifold ... That you removed the flaps. I don't consider the 4.5mm flap axel to be the secure solution, as there have been issues with them too.


- Antti -

nelu

First excuse my English, I’m new in this forum and I found here practical and useful information. A little history: I changed my economical E39 520d M packet 2003 for a 2004 E60 525d steptronic two weeks ago. When I bought the car, I smell some exhaust gas under the bonnet, but I think is a minor problem that can be quick fixed. I think it’s from the flexy joint on the exhaust. But after one week I smell exhaust gas in the cabin... I’ve checked information about that and I found the nicest photos made by Rob Hall (thanks!). Many thanks also for this forum and for the information posted here! I start to investigate and I found the exhaust manifold cracked, see picture.
It’s an expensive experience with a lot of work and I will do myself this job. First I think that a WIG welding of a patch can fix the cracks in the manifold, but the new post made by Rob Hall (very very sorry to here about the new cracks) makes me think about this.
Sure it’s a design problem found at a lot of cars: the cracks are in the deformed and stressed area combined with the thermal efforts, the torque movement of the engine transmitted to the heavy turbo and the primary catalytic converter combined with vibration and maybe resonance of the hot stream exhaust gases causes the cracks.
I found a new manifold at about 500Euro at a BMW dealer (haven’t bought yet – thinking at 2-nd hand manifold or a welding solution). But I bought all the gaskets, nuts and the 3 turbo bolts – to fit all new attachments parts.
May I ask, can I reuse the red silicon gasket under the cylinder head cover, and if the injectors which are to be removed I must replaced some gasket related to the injectors?

With this big job I will clean and check the intake manifold (swirl flaps – another serious problem), EGR, MAF, etc... I hope to improve the MPG which is now at 18 – 20 MPG too high…
I remember about my frugal E39 520d (about 38 – 40 MPG) – it’s not like a smooth 6 cylinder but a strong car without a problem.

Robbage

Hi im getting to the point of needing to do mine. Getting the fowl smells in car and noise is on the increase..

Bit wary of getting my local welder to do this as it appears to be highly risky, still £30 vs £300 i guess it depends how bad it looks on removing it.

Quick q to Rob Hall esp, why was it necessary to remove the cam cover, its not immediately clear to me how this helps? Could you elaborate at all on access requirements to remove the manifold please?

Thanks

jsmi

Hello 5-Series fans. I too have exhaust fume smells in the cabin when my 2004 530D (E60) is stationary. BMW have diagnosed a cracked manifold and called it "very unusual". They want GBP 839 to replace. I told them I had seen this issue many times on various forums which points to a part that is not up to the task, and asked them to contact BMW GB for some contribution.

I'm out of warranty and the last service was not done by a main dealer. I don't know how much this affected my request, but it was turned down flat. Another BMW specialist garage have quoted me GBP 550, so it's going there on Monday (I don't have the time/skill/patience to try it myself).

The reason for the post is to ask whether I should deal with the swirl flaps in some way whilst the engine cover/manifold is off. Any advice welcome!

Jeff

Rob Hall

Theres a good few hours labour to replace so 550 quid is a good price, with the manifold at over 300 plus gaskets.

If your pro flap removal then definately worth doing while the bits are removed, Anzafins method is a very economical/ effective and neat approach with material costs of a few self tappers, or replacement plugs can be purchased to replace the assemblies. I opted for the self tapper approach.
What ever You might think of the flaps you cannot argue that once they are removed it does relieve a 'what if' concern at the back of your mind !