Problem with my E39 530d

Hello CTzens!

Unfortunately I have a problem with my BMW E39 530d. I think its not a big thing but I’m going to share my story and maybe someone will be able to give me some hints.

I was driving home a couple of days ago and felt a small explosion under the hood. Stopped to check it out and it was the EGR pipe - the one that comes from exhaust manifold. It blew right in the middle of the wavy pipe.

As soon as I bought the car, I fitted a EGR bypass with the same shape of the real EGR so the vacuum pipe would be right there doing nothing and that exhaust pipe was in place either but it ended right there because the EGR wouldn’t open for dirty air to get in.

As soon as I heard that explosion, the car started to sound like it had a straight pipe. Actually it had because I let the pipe there until I arrived home. So I thought it was because of that open pipe and decided to buy a proper EGR bypass kit, deleting 100% that exit from exhaust manifold and blocking the vacuum pipe.

EGR kit fitted, its time for a test drive!
But the engine still sounds like straight piped, black smoke goes out from the muffler and lack of power…

Oh and one more thing:
When the EGR pipe blew out, it melted a small area of intake manifold but I checked myself and I “think” it doesn’t have any cracks or holes.

The following steps I intend to do are:

• Plug the computer and look for fault codes;
• Remove intake manifold and take it to an expert to check it out;

So, if someone had the same problem or know what to do/where to look, I will be very grateful.

Have a good day!