I had the same problem it was a gasket gone just under the turbo.
If you shine a light down towards the turbo and get someone to start the car
up you should see a few exhaust fumes rising if it is leaking from there.

 

My money is on a cracket exhaust manifold did 4 this year already get it sorted the first car I came across with this issue destroyed the turbo as parts of the manifold broke off and disapeared into it

 

How many miles have you up Stephen? Hopefully it's just a gasket like John had on his.
The fecking exhaust manifold cracked on mine, you could smell fumes in the cabin when car was stationary. Do a bit of google searching on that and you'll see it's quite common on all the E60 Diesels around the 100K mark. Part is about 400 quid and it's quite labour intensive to get it swapped so fingers crossed it's not!

Beemerchris sorted mine out!

 

Ill have to check all that

I still have bmw warranty so i should be ok
There's only 90k klms on the car now so not high miliage , and it has full bmw history
Ill have a poke arround tomorrow

Ps: I have noticed the turbo whistling slightly under load ??

 

+1 on crack in the manifold

 

Its going up to M&G on monday afternoon

Noticed a little oil at the lower intercooler pipe and engine light has come on
Not good at all

 

Its going up to M&G on monday afternoon

Noticed a little oil at the lower intercooler pipe and engine exhaust light has come on
Not good at all

It's a relief if you have the warranty and good decision have it thoroughly checked.

 

My E60 530d is showing symptoms of a cracked manifold.

Can someone give a rough guide on how much it'll cost to fix this. Any indies recommended? Will BMW provide a goodwill contribution for repairs?

Cheers

 

I did 3 this year already (including caze's who posted above) It's a while ago so I would have to check parts prices with BMW. In general it's a big enough job (about 1 full day) as the rocker cover, fuel rail and lines,loom, maf etc have to come of the car to get to it. You also need the gaskets for the manifold and the rocker cover to do this.
If you pm me you reg and the last 7 digit's of your vin plus the mileage and service history I can try with BMW to see if they are willing to any goodwill. I don't wanna put your hopes up so as the only time I saw them doing anything on this was on a car that still had warranty on it.
While this isn't good do not delay to get this fixed as many cars have the older heatshield between the manifold and the airfilter/rocker cover and in that case the hot gases will melt a whole into the rocker cover, which in the worst case can melt it and cause a fire

HTH

 

Chris,

for some reason I can't send a PM to you. Have sent a txt msg to your mobile and just wondering if youve received it?

 

Only got the msg with the car details from you.
Tried to sent you a pm but YOUR inbox is full so you have to dlete some of your msg's

 

old thread i no,but i think iv the same problem,i get fumes into the car on startup. and can see bits of smoke comin from round the front of the car,
no lights on dash or that. how much is it do fix the problem?roughly

 

wer fixing one of these at the min call out and ill find out wat its working out at

 

Just get your manifoild repaired dont buy a new 1.

 

Cant be welded properly as it's a stainless steel double wall design

 

Question Beemerchris,

I've an 04 530D E60, same thing, fumes in the cabin when stationery.
As I changed the air filter today, I noticed lots of soot / shite under the air filter box. There's also oil on the flanges aswell. And !!! MPG is only 29.4 ...

A buddy of mine has the same car with 140k miles on it and he's getting 38-40mpg, mine has only 58k miles with full history. He rewelded his manifold along a broken weld point.
Also, I checked the breather filter on the rocker cover - gauze type, hadn't a new one so just washed it in petrol, dried it and put it back in.

What am I looking at, a manifold ? would that cause the oil leak down there ?
Good thread here http://www.bimmerforums.co.uk/forum/f15/2004-e60-530d-changed-my-exhaust-manifold-pics-t86668/
Had anyone ever fitted the E39 530d manifold ?

Cheers, B4T

 

I would replace the breather filter insert all together. Cost only around 25€
Not sure if the oil on the flanges is related and all depends on the amount of oil in the turbo to intercooler flange and how much oil acumulated in the intercooler already. If it's alot get the turbo checked too.
Never heard of the usage of a e39 on an e60 manifold before reading trough your link tho it seems to be a good idea to save a few quit.

Oh Chris but it can got my old 03 530d 1 done and a mates

Yes Sir but these are the cast iron types .....

 

Fair play for the reply BC

I will fit the vortex filter in a week or so when I get it.
I'll probably buy the swirl flaps from PMW and get the filter from them too, thats what I did with the 320D. My starter is lazy too so I'll change that in the same work.
The oil is on the flange below the air box - intercooler pipe I think.
After the air filter change, the MPG improved slightly but on another note, the cabin heater is crap in the car which makes me think that the thermostats are knackered.
I bought the car from BMW in Cahir, Tipp as a trade sale. It has a full BM service history, some UK, mainly Morrisons BMW. Would I have any case for a new manifold ? Only 58K miles on her. No warranty given !

Did you notice that the link poster had his egr thermostat pipe blanked off.
Any benefit to trying this ?
Its a great car and it came with a years tax on it which was a real bonus but I have to improve the mpg.
My car has straight out exhaust tips, does that mean it has a DPF or not ?
I had a tuning box on my last few cars which definately improve mpg, I'd fit one to this if it has no DPF. My 320D used to cover tailgaters in smoke when under hard throttle with the box fitted, sort of - if you need power, here's more fuel, if you dont need it, cut it back. It did work and I'd like to use the same box again, the company will reprogram it again for me for only €15.00 plus postage.

Anyway, appreciate the reply, I like my BMW's but they have their troubles !!!!

 

Check the engine temperature using the hidden menu . Thermostat failure is very common on them .Both EGR and main thermostats were gone in mine .Very little heat from the heater and engine temp was 55 degs. EGR thermostat replaced and temp came up to 70 deg. Car should run around 90 deg so main thermo was gone as well. Low engine temp is the reason for the low mpg.

 

Is it menu 7 ?
I can get into the hidden menu, put in my added up number and test my dash, etc but I can't get into the menu for temp ?
Any chance of a break down of how to activate the thing ?

What else would you be doing out there today anyway

 

I'm not near the car at the moment but from memory when you get to menu 19 it says locks on ,you put in your code it then steps you back to the beginning showing 1.00 . Hold in the button until it shows 1.--. Then press the button again and the 1 changes up 2,3,4, until you reach 7 and shows the temp . Below is a C+P from the site I followed explaining it a bit better.


To change top level menu’s press the button for 2 seconds until
the last two digits turn to underscores (XX.__) then release
the button and quickly press the button repeatedly to increment
through the top level menu’s, e.g.:
(press button 2 seconds)
01.__
(press button)
02.__
(press button)
03.__
etc
Once you arrive at the menu you want to go into just wait a few
seconds and the two underscores will be replaced by double
zeroes (XX.00) and every subsequent press of the button will
cycle you through the selected menu’s sub menu:
04.__ (wait few seconds)
04.00
(

 

The webasto heater can fume when running.

 

ok so this is getting worse on mine! fumes are becoming stronger in car,and on cold start the idle is quite lumpy and smokey round the exhaust side of the engine bay for a minute or so then it becomes prity normal then

am thinking i have either a cracked manifold or someting egr related as it looks quite sutty too.and wouldnt you no am broke at the minute too.

 

Right, I'm broke ... but !!!

PMW in UK are sending me 8 swirl flap blanking caps. (had 4 from the 320D that I didn't use so I'm getting 6 x 22mm and 2 x 32mm, don't have a clue what size caps I need)

Also getting the vortex breather filter and taking out the loo roll.

Also, having had a chat with Frank Wise, he has a cast iron manifold from an E39 530D which he says he sells continously for the E60's without a problem.

Also have the 2 thermostats

Also have a new starter to fit

Fecking broke I am but she'll be ripped assunder at the weekend and singing thereafter !!!
And I've sent back my tuning box from the 320D for updating to suit the E60 530D so that should make it lighter on juice even more ...

I love them BMWs ...

 

i just took out my manifold today. it was completly split where the 3 bolts go into the turbo. got it welded there and going to put it back in tomorrow