DIY clean EGR and manifold

RED circle's are bolt's that need removing GREEN'S are parts that need to be removed. Undo all the bolt's take off part that are green remove plastic engine covers. The silver cover with the logo also has a click system just pull it off.

RED: this is where the EGR valve is located (I already removed it see pic. below) BLACK: this is the hose coming from the turbo (intercooler) high pressure BLUE: this is the return pipe from the exhaust (where all the black smudgy stuff comes from) GREEN: this is the air intake manifold (also full of smudgy black gooey stuff) PURPLE: this is the MAF sensor LIGHT BLUE: this is the air filter housing (u will need to take it off to replace the breather)

EGR valve full off the nasty black stuff RED: 4 bolts u need to remove to get the EGR out GREEN: 2 hose clamps need undoing BLUE: THIS IS IMPORTANT !!! the little black and blue hose that's connected to the EGR. it controls the EGR valve its a vacuum controlled valve that means if u disconnect the vacuum hose the EGR valve stops working (what I did is diconnect it) this means no dirty stuff will ever go thru my EGR or manifold. The EGR is meant to lower emissions from the exhaust by burning the exhaust gasses again. As im not a real envioronment freak and pay 300 euros in taxes every month(in Holland) I figure they can plant some tree's from the 300 euro, I care more for my car then the little more CO's in the air(bad man I am :) its ur own choice to do this or not!!!

RED: These bolts need to be removed (be careful not to drop them) on the upper row of bolts there are 2 brackets to hold on the engine cover remove them and remember where they go u can see them in the pic. I already took them off I wedged them between the airfilter housing (see pic.) GREEN: Remove + powercord (the plastic cover is held in place with 2 plastic clips on the bottom of the cover) cover it up first thing if ti touches anything it will short curcuit your battery Remove the bracket holding the dipstick (1 bolt again dont drop) Remove an electrical plug on the back of the manifold u can just reach it its held on with the last bolt of the manifold (see next pic.)

CLEANING

The cleaning its self is up to you. I used any degreaser I could get my hands on, really the stronger the better. tips: make sure u wear ur oldest clothes because its a dirty job, really dirty! I think in total I removed about 1 kilo of grit (see pic. above) Some garages have degeasing machines if u can get ur hands on one I advise to use it. Also some old tooth brushes and stuff could be usefull. Make sure u remove the pressure sensor located on the far end of the manifold before cleaning starts!!!! Ow before I forget make sure to cover up the engine intake valves as they are open and free for anything to fall into the cyllinderhead, WARNING!!! if something falls into the engine it will break and it will cost u $$$$$$$$$$$$$ so be careful !!!!! (I used some paper cloth as u can see in the next pic.)

RED: This is the breather I advise u to change it it only costs 35 something euro's at my $tealer make sure u get the new and improved one (see pic. below) BLUE: This is the electrical harnass for the high pressure injectors u need to remove it to get to the breather again WARNING be very careful with it, its held on with 3 torx screws just remove them and slide the harnass out of the way. GREEN: Airfilter THE BREATHER

RED: 4 bolts hold on the breather remove them becareful not to drop them GREEN: Old breather just slide it up just a bit of fiddling to free it

GREEN: Old style breather with an actual fabric filter witch was totally clogged (BMW part nr. 1928403998) RED: New style breather this doesnt have the fabric filter anymore its some kind of vent and duct filter should not get clogged again (BMW part nr. 11127799224)

Reverse steps Reinstall all the parts and enyoy...!!! CONCLUSION My 530d 99' has done 194.000 km now, I love the car I chip-tuned it, so im taking good care of it. Always change the oil every 15.000 km same with the filters. Also always make sure oil is warm before I floor it. I could have never imagined the intake and EGR valve could be this dirty, I say it was well worth the effort, even if its just for peace of mind... Interesting however when I changed my MAF sensor last week the car smoked like wo2 gun ship, while it never did. Thats also one of the reasons for doing this DIY, hoping it would help the smoking. I am pleased to say "IT DID!" wow now the car doesnt even smoke when the engine is cold, also power delivery is very smooth unlike I ever experienced. To back it up sinds I did the MAF and the DIY cleaning job, I clocked the car at 0-60 mph in 6,9 sec. "WOOT" O_o and top of 250 kmh (155 mph) is now within my reach :D So al and al I say keep 2 days free, buy some gloves and go crazy ! Technical difficulty level: 4 (on a 1-10 scale) Costs: about 50 euro in total and 100 euro for the MAF sensor Dirtiness: OFF THE SCALE.....