[cm335d]

I'm still experiencing a slight diesel smell in the cabin of my 335D. I thought I had resolved it by engaging the charge pipe correctly. Although I think that helped, there's still something stinking it up with exhaust.
I've heard that the EGR cooler can crack and cause this issue. Does anyone have a photo or description of where the crack typically is? Thanks!

[nicklockard]

The underside or backside of the accordion bend segment cracks where it's hard to see it, even with a mirror.

[gaz_ball]

I've got diesel exhaust smell in the cabin. Originally had it after recent dpf delete, egr blank & remap work. The garage said the egr was misaligned after they reinstalled it and the smell disappeared once they had rectified but it's back now. Not sure if it's related to that work or something totally different.

[cm335d]

Thanks for the replies, it is much appreciated! I swear this damn car and the freakin' emmissions B.S. are driving me insane. If it is cracked on the bellows of the EGR cooler and I can't TIG weld it to fix it up, I'm deleting all of this crap, I can't take it anymore....

[kb2755]

Be sure to check the small hose running from the turbo to the pressure sensor. I just had mine blow apart this week, was getting quite a bit of diesel exhaust coming through the vents into the cabin. It was a quick, simple fix for my tech.

[gaz_ball]

Cheers. Haven't really had a chance to have a good look under the bonnet yet but that'll be an easy one to check when I do

[cm335d]

I'll be checking that pipe this weekend. Thanks for the tip!

[cm335d]

Looks like my problem was a cracked EGR cooler. It cracked on the bellows pretty bad. Was gagging me with nasty diesel exhaust in the cabin. All fixed up now. Took 2-1/2 hours total time from the time I stepped into the garage to tools put up and done. Not too bad. Below are a couple pics to show how bad the crack was.

Pic 1: https://photos.app.goo.gl/e4XwdfZiR8vVoh9c6
Pic 2: https://photos.app.goo.gl/nwZT5yBpwd6c9Anu5

Here is what is looks like underhood with a crack. Notice the black soot circled as evidence of a leak. You could also smell it very strongly in that area as well.
Pic: https://photos.app.goo.gl/53TqRUPhiDj96Ccw5

As I'm in California, I just replaced the part.

[rbreding]

Another thing to note for those that still have the egr and are smelling exhaust. When I deleted my egr cooler the two bolts securing the cooler on the hot side werent exactly the tightest. There was also a small amount of soot around the gasket that signified some leakage.

[BB_cuda]

I’ve went back to that flange after cooler deletes d guy did partially lose screws too. Ima bit scared to overcrank after hearing what happened to Taras.

[cm335d]

Originally Posted by BB_cuda

I’ve went back to that flange after cooler deletes d guy did partially lose screws too. Ima bit scared to overcrank after hearing what happened to Taras.

--

How about using some high temp Loctite on those screws, or a lockwasher?

[gaz_ball]

Managed to sort this out today. It was a split in the bellows of the EGR takeoff, just like cm335d above. My EGR valve is mapped out anyway so I just blanked off the outlet in the exhaust manifold. Problem solved. I'll keep an eye out for a second hand EGR cooler assembly in case i need to return to stock at any point.

[S65B40YYC]

I just replaced my thermostat and now have a major exhaust smell in the cabin so I suspect I may have cracked the bellows while handling the EGR cooler. I have a race pipe on hand with blanking plate but was not planning on installing that until the new year whem I can buy a tune. If I blank off the EGR cooler at the manifold and do the paper clip delete, will I be in limp mode if I leave the rest of it plugged in?

[RL18]

Originally Posted by S65B40YYC

I just replaced my thermostat and now have a major exhaust smell in the cabin so I suspect I may have cracked the bellows while handling the EGR cooler. I have a race pipe on hand with blanking plate but was not planning on installing that until the new year whem I can buy a tune. If I blank off the EGR cooler at the manifold and do the paper clip delete, will I be in limp mode if I leave the rest of it plugged in?

You could do it that way. You’ll have an engine light, not limp though. Can you even fit the blank in there with the flange from the egr still there? I’m assuming you’re using the blank from the race pipe kit..

[gaz_ball]

Originally Posted by RL18

You could do it that way. You’ll have an engine light, not limp though. Can you even fit the blank in there with the flange from the egr still there? I’m assuming you’re using the blank from the race pipe kit..

There's a guy in the UK who sells blanks for the exhaust manifold & cooler hoses. These can be fitted whilst leaving the whole EGR assembly fitted as well for stealth purposes (emissions visual checks etc).

He's on Facebook:

https://m.facebook.com/Ciarons-BMW-EGR-Blanks-230762044002706/

[S65B40YYC]

Originally Posted by RL18

You could do it that way. You’ll have an engine light, not limp though. Can you even fit the blank in there with the flange from the egr still there? I’m assuming you’re using the blank from the race pipe kit..

Turned out that the bottom EGR bolt at the exhaust manifold was loose, I must not have cinched it up when reinstalling by mistake. I installed the blanking plate from the race pipe kit and did the paper clip delete and all is good now until I get a tune.

[cm335d]

Originally Posted by S65B40YYC

Turned out that the bottom EGR bolt at the exhaust manifold was loose, I must not have cinched it up when reinstalling by mistake. I installed the blanking plate from the race pipe kit and did the paper clip delete and all is good now until I get a tune.

---
I used some red Loctite on those bolts just to be sure because when I removed the old one, I noticed the bolts were loose and thought I might have forgotten to tighten them when I had previously removed the EGR cooler to replace the thermostat. I don't think that was the case after hearing a few folks have had the same issue.

[bmwdiesel]

so my car some oil residue on that harmonic part on EGR but I dont feel any exhaust smell. could it be still cracked? I have slightly lower charge air or boost as well.

[dave330]

on mine it was coolant leaking from it, i just blanked if off either end a left it in place so it looks stock, now mapped out.

[Bham]

Where the v clamp mounts to the egr valve