BMW M57 engine: faults and reliability

• M57D25, 2.5 litres (150-197 hp, 2000-2010 depending on application)

  2000–2010 · 150–197 hp · M57D25, M57D25TU

  With caution

  It shares the swirl flap risk of the rest of the M57 family in its automatic versions; a specialist workshop points to a final 197 hp revision as an exception, but for the earlier versions we have found no clear confirmation of whether or not they have them.^[2]

• M57D30, first-generation 3.0 litres (177-193 hp, 1998-2006 depending on application)

  1998–2006 · 177–193 hp · M57D30

  With caution

  A specialist workshop points out that the versions with an automatic gearbox have the swirl flaps that are prone to breaking, while the E53 X5 3.0d (across its whole production run) and the manual versions of the first 330d and 530d are free of them.^[2]

• M57D30TU, first revision 3.0 litres (201-272 hp, 2001-2006)

  2001–2006 · 201–272 hp · M57D30TU

  With caution

  A BMW specialist workshop places this revision among those that generally have the swirl flaps prone to breaking.^[2]

• M57D30TU2, second revision 3.0 litres, aluminium block (204-286 hp, 2004-2010)

  2004–2010 · 204–286 hp · M57D30TU2

  With caution

  A specialist workshop expressly names the 231 hp E90 330d/330xd and the twin-turbo 335d/535d among the versions with swirl flaps; it points to only a final 197 hp revision of the 325d/525d as an exception.^[2]

Buy: No known serious faults, or they have already been corrected, in this version. With caution: Worth buying if something specific is verified: history, a replaced part or a completed campaign. Avoid: High risk of a serious fault that is hard to check for or prevent.

1. 1Critical severityFrequency: CommonIntakeBroken intake swirl flapsYes: most automatic M57 and M57TU engines (330d, 530d, 535d, 730d, X3 3.0d and so on) have six metal flaps in the intake manifold that can seize, come loose and wreck a cylinder. The E53 X5 3.0d and the manual gearboxes of the first 330d/530d are free of them, according to a specialist workshop.
2. 2High severityFrequency: CommonLubricationCrankcase ventilation (PCV) valve failureThe valve that separates oil from the crankcase gases (PCV) degrades over time, especially after 120,000-150,000 km, and can cause oil consumption, bluish smoke and a rough idle and, if ignored, foul the turbo, the EGR or the particulate filter.Appears at around 120,000 km
3. 3Medium severityFrequency: OccasionalCylinder head and blockCracked exhaust manifoldThe M57 exhaust manifold can crack, causing loss of power, an unstable idle and a smell of exhaust fumes in the cabin; the recommended repair is to replace it with a cast one.
4. 4Medium severityFrequency: OccasionalOtherCrankshaft pulley vibration damper failureThe M57 crankshaft vibration damper (pulley) can fail with use, warning with abnormal noises and knocking at the front of the engine before it breaks completely.

Severity colours: low, medium, high, critical. How we rate them

Manufacturer

BMW

Family

M57

Fuel

Diesel

Displacement

—

Cylinders

6

Fuel system

Turbo

Injection

Common rail

Timing

Chain

Power

150–286 hp

Peak torque

580 Nm

Production

1998–2010

Makes

BMW, Land Rover and Opel

Technical data^[1][4]

1. 1998–2006

   M57D30, first-generation 3.0 litres (177-193 hp, 1998-2006 depending on application)

   First generation of the 3.0-litre M57 (2,926 cc), with a cast-iron block; it replaced the M51 as the main diesel in BMW's upper range. Land Rover adopted the same block for the Range Rover III, in a 177 hp state of tune as the TD6, and kept it until 2006, beyond the point when BMW had already moved to the M57TU in its own models.^[1][6]

2. 2000–2010

   M57D25, 2.5 litres (150-197 hp, 2000-2010 depending on application)

   The M57D25 replaced the M51-engined 525td/tds as BMW's entry-level diesel, with common-rail injection and an aluminium cylinder head on a cast-iron block. Opel also adopted it, in a gentler state of tune (150 hp) for the Omega B 2.5 DTI, compared with the 163 hp with which it started out in the BMW E39 525d.^[1][5][7]

3. 2001–2006

   M57D30TU, first revision 3.0 litres (201-272 hp, 2001-2006)

   Technical revision of the M57D30 (now 2,993 cc) with improvements to the common-rail injection and outputs of 201 to 272 hp depending on application; it debuted in the E83 X3 in 2003 and also reached the E65/E66 730d in 2002.^[1][8][9]

4. 2004–2010

   M57D30TU2, second revision 3.0 litres, aluminium block (204-286 hp, 2004-2010)

   Second revision of the M57D30, with the block and sump now in aluminium to save weight and higher injection pressure; in the twin-turbo 335d and 535d versions it added piezo injectors and reached 286 hp.^[1][4]