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
2 - Remove the cover & filter
3 - Use a Torx screwdriver to remove the 4 screws holding the filter in place
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
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
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)
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:
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
Link to realOEM for Crank Case Breather (Vortex style) - 2003-2005, M57TUD30 engine; Part No: 11127799366
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.