3.5d EGR cooler replacement DIY?

I'm facing a need of replacing the EGR cooler, most likely at own expense; has anyone DIY'd it, or so far everyone was lucky to have it covered under warranty? Any tips/instructions/pics/etc.?

There have been numerous recalls on the e.g.r have you explored that route?

Sent from my MB525 using Bimmer App

I had all recalls done (which kinda adds to the frustration)

There should be a two year warranty on the parts and labor from a BMW shop on that. Have you checked to see if they can do something for you -- that does seem a bit out of line if in fact they actually did replace it.

All diesel recalls were/are for other parts, not the EGR cooler. Although I bet it was leaking for a while and they could spot - literally, with all that black residue - the problem during one of the visits.

Originally Posted by smyles

I'm facing a need of replacing the EGR cooler, most likely at own expense; has anyone DIY'd it, or so far everyone was lucky to have it covered under warranty? Any tips/instructions/pics/etc.?

I note you're in DC. If you live in Maryland (and bought the car in Maryland), you're covered by the California Emissions Warranty, which is 7/70. The EGR cooler may be covered - but you have to go to the dealer or call BMWNA - the number is in the warranty booklet.

I just went through this for my SCR metering valve... what a pain, the local SA's and managers don't have a clue.

Ironically, I bought it in MD and even work in MD, but reside in VA, so the CA thing doesn't apply. Also, MD wasn't included in 2010, not sure if it's retroactive anyway.

What seems to be the issue?

I too need to replace my EGR cooler. It is badly leaking and I have 70k miles. Does anybody know if BMW has a campaign on this component before I purchase a new one? I also plan on doing it myself - has anybody done it themselves? Any help or guidance is most appreciated.

Originally Posted by bmanke

I too need to replace my EGR cooler. It is badly leaking and I have 70k miles. Does anybody know if BMW has a campaign on this component before I purchase a new one? I also plan on doing it myself - has anybody done it themselves? Any help or guidance is most appreciated.

I wrote to customerrelations@bmwusa.com describing the issue. Not hoping for much, but if enough owners complain, may be - maybe! - we'll get at least partial compensation. As for diy, I found very brief instructions here, but waiting for warmer weather to do it.

No response from BMWNA, so filed a safety complaint with US DOT NHTSA. I suggest other diesel owners with a similar problem to do the same.

I took my 35d in for the alternator recall. There was also a campaign on the EGR valve. BMW changed out the EGR valve, EGR cooler, SCR catalyst and mixer under goodwill warranty. The computers also had to be reprogrammed for the new components. Besides running much better, I am getting better mileage and no more diesel smell. Sometimes going to the dealer is worth it!

Originally Posted by smyles

No response from BMWNA, so filed a safety complaint with US DOT NHTSA. I suggest other diesel owners with a similar problem to do the same.

What's the safety issue?

Sent from my MB525 using Bimmer App

Originally Posted by bmanke

I took my 35d in for the alternator recall.

Are you referring to the pulley bolt recall?

Edit: Never mind - realized we are talking about the same thing...

Originally Posted by BMWTurboDzl

What's the safety issue?

eh, exhaust fumes in the cabin? Carbon monoxide poisoning?

Well, gotta give BMW props for stepping up and covering the costs. New shiny cooler installed.

Hope the Europeans appreciate us Americans helping BMW debug what will soon be the rollout of their new clean diesels.

smyles, how many miles after your EGR valve replacement they discovered the EGR cooler leak?
I had similar issue with my X5d. My EGR valve was replaced around 76k, they discovered the exhaust leak at EGR cooler around 79k. I was out of the warranty. I call BMWNA, they told me I was too far off the warranty to help me. I explained to them that I had EGR valve recall done 3k miles prior, this could possible related. BMWNA told me that there was anything they can do for me except if I file the complain, it will get submit to the dealer service manager, and they have the discretion to do something about it. It took my SA few days, but he was able to get the parts replaced under the warranty. I paid the labor and also pay for the cabin filters to be changed. My total bill was around $480.00
just curious, how many others EGR cooler failure soon after the EGR valve replacement.

Originally Posted by KeithS

Hope the Europeans appreciate us Americans helping BMW debug what will soon be the rollout of their new clean diesels.

AFAIK it's part of Euro 4 compliance system and has been around for awhile.

Originally Posted by Plutogogo

smyles, how many miles after your EGR valve replacement they discovered the EGR cooler leak?

I don't think one is related to another. From what I've read on EU forums, failed EGR coolers (and EGR, for that matter) is quite common.

Originally Posted by smyles

AFAIK it's part of Euro 4 compliance system and has been around for awhile.

If you read the diesel workbooks used for mechanic training, it's quite clear that the M57TU2D30 engine controls are the *FIRST* use of them. In particular, the DDE and the "positive control" features of the system on the US M57 were not on any previous engine models, and not in EU. Further, it's clear from reading the overseas forums that similar controls were not on the M47 4-cylinder.

Hence our conspiracy theory that the US 335d & X5d are being used for beta testing.

Again, EU diesel models, at least those using M57 engine, have these coolers too.

Originally Posted by smyles

Again, EU diesel models, at least those using M57 engine, have these coolers too.

Not sure if you're responding to me, but I wasn't talking about the EGR coolers; however, I didn't notice the missing "1" - thought you were talking about the new Euro standards that come into effect in 2014 (which is Euro 6, I believe.)

Originally Posted by floydarogers

Not sure if you're responding to me, but I wasn't talking about the EGR coolers; however, I didn't notice the missing "1" - thought you were talking about the new Euro standards that come into effect in 2014 (which is Euro 6, I believe.)

Well then what systems do we test that EU folks don't have?

Originally Posted by smyles

Well then what systems do we test that EU folks don't have?

I'm just going to refer you to the pdfs for "ST810 Advanced Diesel Technology Workbook" and "Introduction to Diesel Technology" that have been posted into this forum.

If you want to call small tweaks to accommodate US diesel fuel and to comply with US emission standards "new control systems" and nominate yourself as a "beta tester" - more /diesel/ power to you.