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Diesel Egr Bypass


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#1 Jamesy Boy ACS3d

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Posted 14 November 2009 - 07:14 PM

Fitted my EGR Bypass & new crank case breather the other day, and took it for a 'test drive' down the M1 today. The improvement is unbelivable! Acceleration is now so much smoother, the turbo seems to pull stronger & generally the car feels like it has more power. I would recommend doing this if you have a derv.

I got the EGR Bypass from eBay, it's the Gen2 version that's black powder coated and has a mounting block for the now disused vacuum pipe. It cost only £45 and is worth every penny! When I removed my EGR valve (done 69k) and couldn't believe the amount of c**p that had built up from the exhaust gas. The turbo now spins better with clean & COLDER air.

I also decided that whilst I had the engine covers off it was as good a time as any to change the crank case breather (the oil air separator). Mine unfortunatley still had the rubbish old 'loo roll' style one fitted which was clogged to hell. This has now been replaced with the 'Vortex' style one which does not get clogged up and apparently works a lot better. Due to the importance of what the crank case breather does I can't believe it's not covered in the Insp 1 or 2!!!! This cost me £26 new from Sytner BMW and I would recommend it to all derv drivers, as it keeps the engine working!!

Fitting both of these is definately DIY and took me about a hour (good Sunday afternoon job), and from what I found it gave the old girl a new set of legs!

Quick DIY guide to replacing the EGR valve with a bypass (please note I have nicked these pics of the internet)

Firstly remove the cabin / pollen filter:
1 - Push and turn the 3 clips holding the cover down
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2 - Remove the cover & filter
3 - Use a Torx screwdriver to remove the 4 screws holding the filter in place
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Next remove engine covers
1 - Remove oil filler cap and put a cloth in to cover the hole to stop bits falling in
2 - Remove all Hex bolts holding the engine covers in place (7 or 8 I think)
3 - No need to remove all of the air intake, just disconnect from the engine cover over the air filter

Engine should now look something like this

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Now you can remove the the EGR valve
1 - Undo the clip securing the rubber hose from the turbo into the EGR valve
2 - Undo the clip securing the Exhaust Gas Recycled metal pipe
3 - Disconnect the vacuum pipe into the side of the EGR valve (this is black with a blue stripe in it)
4 - Use a 10mm (I think) socket to undo the 4 bolts securing the EGR valve to the inlet manifold

You can now remove the EGR valve

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All this black gunk is the rubbish from the recycled exhaust gas and basically clogs up your engine, nice!!!

Now you can fit the EGR Bypass
1 - Fit the 4 securing bolts
2 - Refit the turbo rubber pipe
3 - Refit the EGR pipe onto the EGR bypass (This inlet is now blocked and will not allow any recycled gas into the inlet manifold)
4 - Refit vacuum pipe onto mounting point (if on your EGR bypass or block with a self tapping screw and secure with tape as to not allow it to move around when the car is moving)

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Now finish up
1 - Refit engine covers
2 - Refit cabin / pollen filter
3 - Refit oil filler cap (make sure you remove the rag you used to cover this up during the procedure)
4 - Start car to ensure all works as it should


To replace the Crank Case Breather it is located under the housing highlighted by the yellow circle:
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The housing is held in place by a couple of hex screws. Simply undo these, remove the housing, pull out the Crank Case Breather (it looks like a spongy cylinder), give the housing a wipe down, put the new Vortex style breather in and repalce.

Link to realOEM for Crank Case Breather (Loo roll style) - 1999-2003, M57D30 engine; Part No: 11127793164
http://www.realoem.c...316&hg=11&fg=15

Link to realOEM for Crank Case Breather (Vortex style) - 2003-2005, M57TUD30 engine; Part No: 11127799366
http://www.realoem.c...935&hg=11&fg=15

The replacement of the loo roll style to the Vortex style is straight forward are requires no other parts as it is a direct swap and fits the existing housing.


Hope this helps.

Edited by Jamesy Boy ACS3d, 04 February 2011 - 12:59 PM.

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#2 Rob-

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Posted 14 November 2009 - 08:24 PM

I did the EGR mod a few months back its great. Need to get round to doing the crankcase breather too. Might be a job 4 thursday when the car has got a day off :rolleyes:

Is there anywhere alse i can get the crankcase breather for the m47 engine?

#3 Jamesy Boy ACS3d

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Posted 14 November 2009 - 08:42 PM

Unfortunatly I have only seen the crank case breather for sale from BMW.
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#4 momo

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Posted 14 November 2009 - 08:57 PM

Although I can't do the egr on my M57N - I've done the crankcase breather filter in my car and my brothers M47N 320d engine while we fit the egr bypass to his engine too..

Deffo worth doing!

It's probably easiest to pick up te filter from your local BMW garage but if you can't - BMMiniParts should be able to get it for you!

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#5 Rob-

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Posted 14 November 2009 - 09:05 PM

Cheers

#6 Rob-

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Posted 16 November 2009 - 12:30 AM

One thing i dont understand is why people say you are running a hotter engine with the EGR bypass. Surely blocking hot gasses from entering the engine would cool it down?

#7 Rob-

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Posted 16 November 2009 - 12:26 PM

Just rang up Trenichs BMW specialist about the vortex filter and they say i have to buy the filter housing as well as the the filter on the M47 engine? Can anyone comfirm this?

#8 suhail97

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Posted 16 November 2009 - 01:01 PM

I've got a filter if you want to buy it.

I got it off ebay ages ago to have fitted when the car was serviced but my car has the upgraded filter so didn't need it

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#9 Rob-

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Posted 16 November 2009 - 01:10 PM

I've got a filter if you want to buy it.

I got it off ebay ages ago to have fitted when the car was serviced but my car has the upgraded filter so didn't need it


Will it fit a pre-facelift 320d with the older m47 engine? BMW have lead me to believe the older ones have to have the housing aswell.

Cheers

#10 suhail97

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Posted 16 November 2009 - 01:16 PM

As far as I know, its just a replacement item as the indie who was going to change it never mentioned a housing. It comes with some rubber seals too. Leave it with me until tonight, I'll dig it out and get a part number for you cos I'm sure its an original BMW part

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#11 Jamesy Boy ACS3d

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Posted 16 November 2009 - 01:17 PM

These links might be of some help

M47
http://www.realoem.c...o...hg=11&fg=15
Crank Case breather - 'Loo roll' style part no: 11127791552

M47N
http://www.realoem.c...o...hg=11&fg=15
Crank Case breather - Vortex part no: 11127799367

By the looks of it the breather is the same as with the 330d, and uses the same casing for both engines.
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#12 Rob-

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Posted 16 November 2009 - 01:22 PM

Cheers to both :D

#13 s crane

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Posted 16 November 2009 - 02:03 PM

Fitted my EGR Bypass & new crank case breather the other day, and took it for a 'test drive' down the M1 today. The improvement is unbelivable! Acceleration is now so much smoother, the turbo seems to pull stronger & generally the car feels like it has more power. I would recommend doing this if you have a derv.

I got the EGR Bypass from eBay, it's the Gen2 version that's black powder coated and has a mounting block for the now disused vacuum pipe. It cost only £45 and is worth every penny! When I removed my EGR valve (done 69k) and couldn't believe the amount of c**p that had built up from the exhaust gas. The turbo now spins better with clean & COLDER air.

I also decided that whilst I had the engine covers off it was as good a time as any to change the crank case breather (the oil air separator). Mine unfortunatley still had the rubbish old 'loo roll' style one fitted which was clogged to hell. This has now been replaced with the 'Vortex' style one which does not get clogged up and apparently works a lot better. Due to the importance of what the crank case breather does I can't believe it's not covered in the Insp 1 or 2!!!! This cost me £26 new from Sytner BMW and I would recommend it to all derv drivers, as it keeps the engine working!!

Fitting both of these is definately DIY and took me about a hour (good Sunday afternoon job), and from what I found it gave the old girl a new set of legs! :D



I just ordered a gen 2 egr from ebay, how long did it take to be delivered thanks

#14 suhail97

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Posted 17 November 2009 - 10:02 AM

Here's a picture of the filter I have, its the loo roll style one.

The rubber seals have BMW part numbers: 22 7793 166 and 14 7793 165

The filter has BMW part number: 7 789 397 (there are other numbers of: f 01c 340 005 + 39 310 50 912, I think these are Bosch part numbers)

Plus a rubber O ring

I've just done a quick check on realoem and the filter number doesn't work. The box the filter came in has a bwm sticker with part number 11127793164

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#15 momo

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Posted 17 November 2009 - 12:43 PM

Suhail, I'd send that back if you still can mate - no point replacing the filter with another loo roll type one as you still have the problem further down the line where if it breaks it'll destroy the turbo!

E46wirral - Get the vortex one directly from BMW - its the easiest option..

Also, its best to get the housing too as with the vortex type the filter clips into the housing and its just easier to replace the full thing..

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#16 suhail97

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Posted 17 November 2009 - 01:17 PM

this was a spare that I had, my car has the upgraded one on already.

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#17 Rob-

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Posted 17 November 2009 - 10:00 PM

Suhail, I'd send that back if you still can mate - no point replacing the filter with another loo roll type one as you still have the problem further down the line where if it breaks it'll destroy the turbo!

E46wirral - Get the vortex one directly from BMW - its the easiest option..

Also, its best to get the housing too as with the vortex type the filter clips into the housing and its just easier to replace the full thing..


Cant get one unfortunately, they dont make them for the m47 engine, only the bog roll one??

#18 Jamesy Boy ACS3d

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Posted 17 November 2009 - 10:04 PM

I just ordered a gen 2 egr from ebay, how long did it take to be delivered thanks


Took about a week i think.
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#19 Rob-

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Posted 17 November 2009 - 10:11 PM

I just ordered a gen 2 egr from ebay, how long did it take to be delivered thanks


Mine took forever, ended up leaving bad feedback because it took so long.

#20 Jamesy Boy ACS3d

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Posted 17 November 2009 - 10:14 PM

Cant get one unfortunately, they dont make them for the m47 engine, only the bog roll one??



Mine is the M57D30 engine and they only did the 'loo roll' style one for mine. The vortex style one is only 'apparently' for the M57TUD30 (as BMW said when I ordered it), but this does fit the crank case breather casing for both engines as they are the same.

Looking at the M47 and M47N engines it look like it is exactly the same situation, the 'loo roll' and vortex oil separators both fit into the same crank case breather casing. For only £26 it's worth a punt as you can always just return it.

When you are changing over from the 'loo roll' filter to the vortex one there is a boutple things to bear in mind:
1 - The filters look completely different but fit fine.
2 - The loo roll filter has a retaining bracket inside the casing that is not required for the vortex one.
3 - The vortex filter fits in snugly but is not held in place with any clips the shape of the casing holds it in place.
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