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F10 520d Exhaust fumes in cabin

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Have exactly the same problem and the fumes come from the same place as the arrow shows on the OP.  Had it diagnosed and they confirmed what I expected.  

 

The bypass pipe on the rear of the EGR cooler has sprung a leak on the corrugated part of the pipe at the back of the cooler.  Unfortunately BMW are the only ones that make this part and they only sell it as a unit complete with a new EGR valve and other bits.  It's about £500+ retail but you can usually get about a 15% discount bringing it down to about £440.  BMW quote 1.5 hrs about to replace.  You'll also need 3L of coolant, 2x pipe unions, a metal gasket and just to be safe, the two hex bolts that secure it on to the exhaust side.

 

Mine's booked in on Saturday to get done!

Edited by Frobius

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Car back today. Totally cured and back to normal. There’s quite a bit of soot build up around the acoustic covers and the throttle, but that’s a problem for future Frobius.

 

I forgot to take pics, but I asked to see the old EGR cooler and where the crack was. As they said, on the bypass pipe on the rear, there are two corrugated sections. Both sections had 1mm x 10mm splits in them. It was no wonder I was getting fumes in the cabin! 

 

I might change the cabin filters just for good measure now, although I believe they’re only for particulates and so shouldn’t have trapped anything from the exhaust, save for a couple of particles of soot that made it that far.

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On 16/12/2017 at 5:48 PM, Frobius said:

Car back today. Totally cured and back to normal. There’s quite a bit of soot build up around the acoustic covers and the throttle, but that’s a problem for future Frobius.

 

I forgot to take pics, but I asked to see the old EGR cooler and where the crack was. As they said, on the bypass pipe on the rear, there are two corrugated sections. Both sections had 1mm x 10mm splits in them. It was no wonder I was getting fumes in the cabin! 

 

I might change the cabin filters just for good measure now, although I believe they’re only for particulates and so shouldn’t have trapped anything from the exhaust, save for a couple of particles of soot that made it that far.

 

Thanks for the update! I am still waiting for the weather to improve to do mine. It obviously seems to be a common problem, the service guy said there had been 128 egr coolers ordered throughout BMW dealership. They won’t admit it will they! More dosh for them! 

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Thing is its a massive safety issue given the fact that failure results in cabin air contamination - must be worth asking relevant authorities, I'd like my warranty excess back at any rate... 

 

+1 for changing cabin filter afterwards 

Edited by SuperDave

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My EGR cooler was replaced under a 'quality enhancement' fix during a service this time last year (car was still under warranty). 

It seems that it was not a safety recall otherwise you could still get it done for free outside of warranty.

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