E53 Diesel Exhaust Leak

[Skier1]

Hi ,Has anybody had any issues with exhaust leaks around the exhaust manifold-turbo area on a E53 diesel .Mine has a relatively small exhaust gas leak but I am wanting to repair it before it gets worse ,today I removed as many covers as possible,air filter etc but still cannot locate the leak due to the amount of covers etc that cant be removed without dismantling the engine.Not sure if this may be a common issue or not as when I was looking to purchase this X5 almost all the others had a diesel soot mark around the A/C hose area that runs near the turbo.Also does the oil separator and EGR valve require replacement/cleaning on a regular basis ?

[bigwave2255]

ive seen discussions on the UK site where people have had cracked exhaust manifolds, it seems they are pressed metal (Tin) and NOT cast iron as in the good old days, they tried repairing it by welding but it warped slightly and wouldn't seal to the head.

they ended up putting a replacement on. might be worth looking at, apparently if you can get in there you can see the black stain from the exhaust gasses.

[huntertec]

Hi Skier, your in Newcastle to, thats three of us so far. Regarding the EGR valve I cleaned mine a number of times but ended up replacing it which has reduced the exhaust soot dramatically, I have a supplier in UK cheap if needed, also one of the critical components is the crankcase oil breather if you have'nt already replaced it, you may have seen my post on the AUS forum. With the exhaust, I have a great mech in town who has done my cars for over 20 yrs, very cluey on X5s. You can send me a PM if you want happy to help where I can. Cheers.

[Oz Sport]

Hey Hunter, who is your egr supplier if you dont mind me asking ?

[huntertec]

Hi OZ, BMW Car Parts,Spares,Accessories,Motormec,UK is the supplier I have been using, good people the deal with, they usually deliver to my door in 7 days. I paid $264AUD for the EGR valve which was less than half price from buying it here. ( no surprise )

[rb0135]

Hi Guys,

A Diesel driver from southern suburbs of Sydney.

I just wanted to drop in an say that the best parts place is right here in Australia, usually overnight delivery and OEM parts about 1/2 to 2/3rds cheaper than BMW. Talk to Cliff at Parts Agent Australia (PM me for phone number/email).

With respect to your manifold question, the exhaust manifold can get cracks (easily).. I cant find it now, but there is a good writeup of what the manifold looks when it is cracked and how to inspect.. Do a Google search and you will find it.

When I inspected mine, I used a mirror that I could just fit down around the turbo and view.. Lucky, I didnt have that issue (yet).

You cant repair the manifold as it has been mentioned, it will warp and wont fit properly.

Keep us posted.

Regards,
Rob

[DanX5d]

I have had this exhaust leak noise only when the engine was cold and could be heard when having to accelerate into traffic. I went and investigated this on the weekend.

Yes a cracked manifold in two places either side of the turbo inlet. You need a mirror and a good torch to see it. The manifold is not cast iron rather it looks like S/Steel to me. The tell tale is exhaust soot on the waste gate can/diaphragm and also on the inner mud guard or strut tower on my car.

I am speaking with Cliff at partsagent.com.au about this part now.

I also have an oil leak dripping from under the compressor housing which I need to get tot the bottom of. PCV valve was changed 15K ago so I am hoping it isn’t the turbo seals, rather it is oil vapour getting past the PCV valve and leaking from the hoses externally on it way to the turbo inlet.

Starting to question why came back to BMWs after so many years or reliability with Subaru and Mazda.

Cheers, Dan.

[deepblonde]

Dan, did you ever get your exhaust manifold repaired or replaced? Did you consider a cast iron replacement instead of the original stainless steel which is prone to cracks?

[DanX5d]

G'day Deep Blonde?

Yes I had the manifold replaced by Autologic in Bentleigh. I look into the cast iron version when I found out that the manifold looks like 2 layers of pressed tin but the versions around at the time suited the earlier model engine. I could not find anyone in Oz who has either got one to inspect or has had it fitted so that I could do some comparisons. The OEM unit is typical BMW design over durability, much like the stupid design of the door handles that fail!

From what I now know, they crack due to high EGTs. The most common reasons are -
Towing 1t or more (the previous owner of my car towed a 2t powered trailer.. Discovered that after the purchase!)
Rechipped/Reflashed or fuel delivery upped to increase power without attending to the increased exhaust gas flow, and subsequent EGT increase.


BTW, love the Lemans blue.
Cheers, Dan.

[powers1]

Originally Posted by DanX5d

G'day Deep Blonde?

Yes I had the manifold replaced by Autologic in Bentleigh. I look into the cast iron version when I found out that the manifold looks like 2 layers of pressed tin but the versions around at the time suited the earlier model engine. I could not find anyone in Oz who has either got one to inspect or has had it fitted so that I could do some comparisons. The OEM unit is typical BMW design over durability, much like the stupid design of the door handles that fail!

From what I now know, they crack due to high EGTs. The most common reasons are -
Towing 1t or more (the previous owner of my car towed a 2t powered tralier.. Discovered that after the purchase!)
Rechipped/Reflashed or fuel delivery upped to increase power without attending to the increeased exhaust gas flow, and subsequent EGT increase.

BTW, love the Lemans blue.
Cheers, Dan.

Yep,you are right,bad manifold design and material and should have been made of more durable cast iron.
High EGTs makes them crack even quicker,however ,we get this problem on all 3.0D engines even stock!
Here is an example of where it usually cracks