Exhaust blowing
 

Hi guys, when I bought my X 2 years ago, shortly after exhaust manifold split. I had this replaced by my local Indy for another genuine one and everything was well (except my bank balance!). Yesterday I noticed on startup a little smell of fumes and in opening the window can hear the ticking noise of an exhaust leak! How prone are these manifolds to splitting again? Or is it likely to be leaking elsewhere? TIA


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You don't say but I'm guessing this is on a 3.0d right? Seems it's rather a common issue but mostly in the U.K for some odd reason - never heard of one happening down under. :dunno:

The OEM part is stainless, brittle and apparently prone to cracking. The aftermarket cast part is better, lasts longer and ridiculously cheap...

For BMW Cast Iron Exhaust Manifold E46 E39 E60 E61 E38 E65 E83 E53 3 5 7 X3 X5 | eBay

The labour to fit it, not so much. :(

Yea it is a 3.0d! Also high mileage, 180-000. It’s the only thing I didn’t know to check when buying one! When the Indy took the old one off it was pretty much destroyed, but he advised to fitting the OE part again over the cast version as the fitting can be poor apparently? The say the OE is brittle is an understatement, it’s barely heavier than a tin of beans! Anyway, I’m wondering if anything else may have failed other than this as it seems too early to have problems with this? Must have only done 20k since it’s fitting? Thanks for the reply!


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Can't really say if something else has failed but I guess it's possible - only an inspection will reveal the source of the leak. I guess you are hoping it's a failed gasket or something cheap, although the labour could be a killer either way.

Looking at the manifold on eBay that I linked too, the finish looks pretty good. I can't vouch for the fit but at 60 quid, how could it be worse then the brittle OEM manifold, in terms of value for money? Many threads indicate a good fit with these and also indicate fit issues with welded repairs on the OEM units (they warp when welded).

I have no personal experience with the manifold failure but I see a LOT of thread traffic about it - and like I said, mostly in the U.K. It seems to affect most BMW I6 diesels (well, the M57 family anyway...), in cars like the X5 3.0d, the 530d etc. I wonder if the diesel fuel over there is contributing to this? :dunno:

I’ll be honest I am hoping for a cheap repair rather than the shy of £1000 bill last time! Although the cast replacement will bring this cost down loads! Maybe the fuel here is contributing? Like a higher octane? Once I pop it in the garage I should know more but think I will buy the cast one as the stainless tin will have to come off anyway to inspect so if it is damaged I have a replacement to hand!


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Update: at the end of a 15min commute I listened for the ticking noise to see if it had got worse...and it had gone? Suggesting something may be a little loose and when expanding when hot stopping the leak?


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Might need to get a small telescopic mirror and check for soot around the manifold... and have a closer listen when it's cold.

https://images-na.ssl-images-amazon....cL._SX355_.jpg

Interestingly the M57D3002 in my 2009 X3 has a cast iron manifold.

Yeah, methinks BMW (or Magna Steyr) finally figured it out! :D