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Flap jacks it

I have a 2003/53 BMW530d SE E60 auto that has 101k on the clock and full service history (BMW up to 60k then synthetic oil every 10k after that.). The engine has just been written off because an intake manifold swirl flap (there are 6) disintegrated and was ingested into the No 6 cylinder. On examination of the manifold, one of the other 5 flaps was about to go the same way and a third one was stuck in the closed position. The swirl flap failure has therefore destroyed the inlet manifold, head and block. Incidentally, I only run this car on V-Power diesel and I do about 20k miles pa. The car is out of warranty. Rybrook BMW Shrewsbury (helpful and competent) has submitted a claim for goodwill and BMW has authorised a 50% contribution towards parts. This will leave me with a bill for £6,600 including VAT. I contacted BMW customer services myself by phone and they will not increase their offer, giving the mileage as the reason. My question is, do you think this is a reasonable final offer? Is BMW effectively saying that if you run one of its 3.0 litre diesels beyond 100k you risk the engine and a bill of £6,600? I do not expect to run the car for nothing, but I wouldn't have expected an E60 engine to self-destruct at 100k, either. Am I fortunate to be offered anything, or will BMW pay out more if pressed? The dealer told me he sees about 3 of these a year and BMW sometimes authorises 90% or 100%, but won't in my case because it doesn’t have a full BMW service history.

Asked on 7 February 2009 by

Answered by Honest John
It's known on 3 and 5 Series diesels. You'll see it in BMW forums. But it is comparatively rare. It also happens to Alfa 1.9 diesel engines in Alfas, FIATs, SAABs and Vauxhalls. And to Honda 2.2iCDTIs and Mondeo III 2.0 litre engines, petrol and diesel. FIAT has now adopted a new type of fully motorised swirl actuator for its latest 1.6 ECO diesel engines. Remember, for your £6,600 you are getting a new engine that would normally be £12k +. Not much consolation, but some.
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