02 2.5 525d engine failure - swirl flaps - boygould
I own a late 2002 BMW 525d SE auto. Recently the car started running very poorly. I took the car into the local BMW specialist (not dealer) who diagnosed low compression!!
On stripdown it transpired that two of the swirl flaps had failed & parts had passed into the cylinders causing damage to one pistion & several valves. The repair is going to cost £2k & the mechanic said I was lucky!!
Swirl flaps are small butterfly valves located in the plastic inlet manifold of the engine.

Discussing the problem with the mechanic & searches on the internet have shown that this to be a common problem on all 6 cylinder BMW diesel engines upto 3 litres - so a definate design fault. In some cases BMW have paid for replacement engine & repairs - but this appears to be selective.

My car has completed 90k miles with full service history, but not BMW.

My question is this;
Do I have any recourse with BMW - after all this is a known design issue?

I appreciate that warranty claims have long gone but surely BMW have a right to inform owners of such issues (eg replace manifold at xxxxx miles)??

My car will be returned this week. I could not afford to put into a main dealer for investigation & repair. However the work is done to BMW stds & with BMW parts.

Thanks in advance.

Chris.

Edited by Pugugly on 19/01/2009 at 20:04

02 2.5 525d engine failure - swirl flaps - cvosteve
Swirl flap ingestion is a documented problem but it is debatable how frequent an occurence it is. I deflapped my 2001 525d to be on the safe side. Having said this it is scant comfort to someone who has actually suffered the problem.

BMW do not seem to accept that this is an issue and my local dealer only knew of any problem withe the 2 litre 4 cylinder engines. If you had a full BMW dealer service history you might perhaps have shamed them into some sort of contribution but without this unfortunately I fear that your chances will be nil.

On one of the BMW forums someone was trying to launch a campaign to get BMW to accept the problem but I do not know if they had any success. It would be worth searching to see.
02 2.5 525d engine failure - swirl flaps - gordonbennet
Sorry for your problem there Chris on an otherwise excellent car.

The problem is well known but mainly to regular bmwland forum users or indeed victims to whom the knowledge comes a bit late in the day.

From my reading of the forums it seems to be a case of maximum 100K miles and full BMW service history required for goodwill to be triggered so i doubt you'll have any joy.

Is your manifold now deflapped as cvosteve's (above) or has it been renewed as part of the repair?
02 2.5 525d engine failure - swirl flaps - WorkshopTech
as mentioned, this is a well known problem with these cars, seen quite a few myself. I dont think you will have any chance pursuing BMW, car is old now and not got complete BMW service history. Live and learn.
02 2.5 525d engine failure - swirl flaps - injection doc
BMW aint the only ones, Mercs have a thirst for these too! at one time the waiting list for manifolds for Mercs was horrendous.
Mondeo 1.8 petrols also do the same thing!
02 2.5 525d engine failure - swirl flaps - gordonbennet
BMW aint the only ones Mercs have a thirst for these too!


Thats been kept a bit quiet ID, don't suppose you'd care to say which engine's it might be prudent to have checked carefully or can the flaps be easily removed and blanked like the BM's?
02 2.5 525d engine failure - swirl flaps - injection doc
I can't remember all the model ranges effected but same thing applies! plastic rods connecting the flaps under the manifolds, they fall of then the butterflies rattle around on their spindles &wear out & in they go. Manifolds used to ne about £900 a go but understand they are now about £400ish.
It hasn't been kept quiet, its common knowledge but carp all the same!
I think the 320cdi was a classic at consuming them
02 2.5 525d engine failure - swirl flaps - gordonbennet
Thanks ID, noted...hasn't been the same anount of forum coverage that BM's have had, or as is more likely i missed it, much obliged m'lud.
02 2.5 525d engine failure - swirl flaps - DEADBMW525D

Hi, as a new sufferer of a swirl valve flap failure on my BMW 525D, I would like to try and raise its profile even higher and try and warn other users of the predicament they face if they do NOT do something to try and prevent the problem. The longer you keep the car, the greater are your chances that the problem will occur because, as a design fault of this BMW diesel engine, the problem is inherent in the engine itself. Sooner or later it will happen to you. I wasn't aware of this not infrequently occurring problem. My valve failure occured on the motorway - the car started shuddering and stuttering and its speed decreased alarmingly. Fortunately, I was in the inside lane and managed to pull over safely onto the hard shoulder. If it had been on the faster lanes...

BMW report that the engine needs to be replaced at a cost of £7000 + VAT = £10,000.

Since this diagnosis was reported to me by BMW 3 days ago, I have discovered a plethora of information on the internet (this website included), and a swarm of specialist companies dealing with the aftermath of this engine-design failure. As I said a not infrequently occurring problem. Shame BMW didn't advise me of this problem at any of the 18 services I've taken the car to or at any of the MOTs. Wouldn't it have been civic of them if they had advised a replacement of the flaps to blanks say at 60,000 miles as part of that normal service procedure - remember the timing belts of old. Perhap fraught with difficulty for the motor giant. In any case, it would have saved me from having to scrap an otherwise beautiful car - a prized possession. Be warned.

02 2.5 525d engine failure - swirl flaps - Collos25

You seem to be the only 5 series owner who doesn't know about this problem must be the most documented failure in any engine ever, while your at it do a google about "Vanos".

02 2.5 525d engine failure - swirl flaps - skidpan

BMW report that the engine needs to be replaced at a cost of £7000 + VAT = £10,000.

Basic maths lesson. £7000 + VAT = £8400. Where did £10000 come from?

02 2.5 525d engine failure - swirl flaps - focussed

One of the best, if not the best engine remanufacturing company in the UK.

http://www.ivorsearle.co.uk

Used to deal with them-excellent professional company.