[ChawenHalo]

Hi peeps.

Just found this video done by JohnDragonMan (could not find him on here) removing and cleaning EGR valve and intake manifold.

To date I had not seen a complete video of this and though it would be useful for many.

That's part 1.

Well done to him for doing this

Part 2

[sirleeofroy]

Legend!

I've been looking for something just like this, thank you!

[Andy198712]

Are those different to the m57 swirl flaps then? Looking at the blanking skits you see on eBay....

Very helpful cheers

[rasa bmw]

never heard of a suckery in thingy ha ha..also it should be one of the first jobs to do(disconnect battery)terminal...first thing i did when i deflapped my e46

[ChawenHalo]

Originally Posted by Andy198712

Are those different to the m57 swirl flaps then? Looking at the blanking skits you see on eBay....

Very helpful cheers

completely different as is the rest of the engine...

[ChawenHalo]

Originally Posted by rasa bmw

never heard of a suckery in thingy ha ha..also it should be one of the first jobs to do(disconnect battery)terminal...first thing i did when i deflapped my e46

Yeah, "burned hand hairs" laught my head off at that

Interesting though that the glowplugs turn on to preheat from the moment you open the door!

[Andy198712]

Originally Posted by ChawenHalo

completely different as is the rest of the engine...

Got it

[Benskett]

I've done this job twice on my N57.

First time was to clean the IM, 2nd time was to clean the IM (again, FML) & fit swirl flap blanks.

I have also fitted an oil catch can now to stop the crud forming.

[Andy198712]

I’m thinking EGR mapped out will be the best way, that soot is the issue, the oil not so much, just my opinion
Both would be best but if I had to choose one....

[rasa bmw]

Originally Posted by ChawenHalo

Yeah, "burned hand hairs" laught my head off at that

Interesting though that the glowplugs turn on to preheat from the moment you open the door!

yeh mine is an e90 pre face lift,,and when i open the door i hear a click..im woncdering if this is the glow plugs starting up,,i did wonder a while back how the glow plugs triggered anyhow,,was waiting for winter temps to see if it was temp based start up of glow plugs,but this may have answered my question..i also thought it may have been to depress the start button without clutch down to trigger glow plugs,but again this is just guessing

[sirleeofroy]

Originally Posted by Benskett

I've done this job twice on my N57.

First time was to clean the IM, 2nd time was to clean the IM (again, FML) & fit swirl flap blanks.

I have also fitted an oil catch can now to stop the crud forming.

You removed the swirl flaps on your N57?

I was under the impression the N57 didn't suffer swirl flap problems like the M57?

[Benskett]

Originally Posted by sirleeofroy

You removed the swirl flaps on your N57?

I was under the impression the N57 didn't suffer swirl flap problems like the M57?

Suffer?
Take the IM off a car with 50k+ miles and look at them. Yes, they won't snap into the bore, but they will be caked in soot and oil & hardly move. The airflow is seriously restricted.

My car makes the boost it was meant to now & holds it until further up the rev range with no impact to low end torque.

The first time I stripped it off there was a coffee mug worth of gunk that I had to chisel off & clean out.



The above alone came off of the flaps, that's excluding the crap in the actual IM.

Be careful just locking the EGR closed via software as it will impact the DPF regens, which will be very costly if the car is not actively regenerating the DPF.
During a regen the EGR will ever only open between 0-40% to ensure the exhaust temps are raised for regeneration.

[Andy198712]

Interesting point there about regens

[rasa bmw]

Originally Posted by sirleeofroy

You removed the swirl flaps on your N57?

I was under the impression the N57 didn't suffer swirl flap problems like the M57?

its not the flap its what holds it on that comes away..little screw on the n57

[sirleeofroy]

Originally Posted by Benskett

Suffer?
Take the IM off a car with 50k+ miles and look at them. Yes, they won't snap into the bore, but they will be caked in soot and oil & hardly move. The airflow is seriously restricted.

My car makes the boost it was meant to now & holds it until further up the rev range with no impact to low end torque.

The first time I stripped it off there was a coffee mug worth of gunk that I had to chisel off & clean out.

<snip>

The above alone came off of the flaps, that's excluding the crap in the actual IM.

Be careful just locking the EGR closed via software as it will impact the DPF regens, which will be very costly if the car is not actively regenerating the DPF.
During a regen the EGR will ever only open between 0-40% to ensure the exhaust temps are raised for regeneration.

Wow, every day is a school day!

Mine is on 111K and runs well, its been well serviced but if that's what they look like after just 50K+ then it looks like I have a day under the bonnet to organise!

[ChawenHalo]

Originally Posted by sirleeofroy

Wow, every day is a school day!

Mine is on 111K and runs well, its been well serviced but if that's what they look like after just 50K+ then it looks like I have a day under the bonnet to organise!

Worth dismantling EGR and manifold for a good clean. It will lower consumption.

[sirleeofroy]

Originally Posted by ChawenHalo

Worth dismantling EGR and manifold for a good clean. It will lower consumption.

Yeah, the EGR was the thing I originally wanted to clean and asked in another thread about the cooler as my previous cars didn't have EGR coolers..

I also need to replace the Glow Plug controller and can do all of this at the same time, just need it to stop raining.....

[Benskett]

Originally Posted by rasa bmw

its not the flap its what holds it on that comes away..little screw on the n57

It's actually a 50cm metal bar that runs the entire length of the manifold which the flaps sit on (imagine a kebab on a spike). That is linked to an actuator that twists the bar & opens / closed the flaps.

They are not so much 'flaps', more spherical pieces with slices in them.

I do motorway 97% of the time with 20+ miles each trip, however if you run Torque (app) and watch the EGR % you will find that if at any point you are coasting / sat at 5-10% throttle the EGR will be at 95% open.
Thus filling the IM with soot...!
Without an oil catch can this will be mixed with oil vapour when you go into boost and clog it all with crap.

Off throttle - soot
On throttle - oil vapour

You cannot win! Best to fit a proper baffled oil catch can to ensure that clean air is returned into the turbo / FMIC / IM.

[Benskett]

Originally Posted by sirleeofroy

Yeah, the EGR was the thing I originally wanted to clean and asked in another thread about the cooler as my previous cars didn't have EGR coolers..

I also need to replace the Glow Plug controller and can do all of this at the same time, just need it to stop raining.....

The controller is under the IM, you might be able to get at with the IM on, but it's going to be a pain in the butt.

Might as well take the IM off, change all the glow plugs (be careful they don't snap!) & the controller.
Whilst you are at that, you might as well delete the flaps.

[Benskett]

N57 swirl flap (you'll have 6x).

... and this is why you take them out, they were clogged solid. 59k miles.

[sirleeofroy]

Originally Posted by Benskett

The controller is under the IM, you might be able to get at with the IM on, but it's going to be a pain in the butt.

Might as well take the IM off, change all the glow plugs (be careful they don't snap!) & the controller.
Whilst you are at that, you might as well delete the flaps.

Yeah I tried to do the controller without removing anything and it is indeed a PITA, I only realised once I'd unbolted the controller that the the replacement I had was for the M57.... doh.

I now have the replacement and figured I'd spend a day pulling the IM off, replacing the controller, cleaning the EGR and now cleaning the IM.

When you say delete the swirl flaps, are there blanking plates to use like the M57 or can you simply remove them and leave as is?

Thanks

[ChawenHalo]

Originally Posted by sirleeofroy

Yeah I tried to do the controller without removing anything and it is indeed a PITA, I only realised once I'd unbolted the controller that the the replacement I had was for the M57.... doh.

I now have the replacement and figured I'd spend a day pulling the IM off, replacing the controller, cleaning the EGR and now cleaning the IM.

When you say delete the swirl flaps, are there blanking plates to use like the M57 or can you simply remove them and leave as is?

Thanks

I don't think you can do it on N57 engines as all the sensors will detect that, issue an engine/ emmisions warning on the dash and eventually make the car go into limp mode. It will alsp stop the car initialosing regens for the DPF.

On the older engine (M54?) EGR was vacum actuated, N57 is electric.