Correcting clogged up EGR

[mekondelta]

So we bought a '14 X3 F25 30d last year with 24k miles on it. The car is great artist from a little hiccuping at low speeds on part throttle. I guess it could be to do with the low miles and probably short runs fine by the previous owner. My question is, now that we have it we're doing a little town driving but regular 100mile motorway trips every couple of weeks will the situation get better with the EGR valve or just stay bad? Current mpg is 31 with all these long journeys and was expecting better. I don't need better but others seem to achieve good mpg and I'm crossing at 70 with eco on and cruise control. We've got the car going in for a check next month for the recall and hopefully under AUC we might be able to get the valve and cooler replaced but I guess they'll do the minimum. What's my best option?

[Slippydiff]

My concern wouldn’t be with the EGR, more the DPF and the inlet ports/inlet manifold.
My ‘63 F30 330D suffered with bad carbon build up in the inlet ports and intake manifold. It took upwards of 6 hours to walnut shell blast the ports, and they fitted a new intake manifold (along with a temperature sensor) under warranty.

[mekondelta]

Thanks, was that under BMW AUC, did you have to insist or fight to get them to sort it? What do I say to them, just say the car hesitates etc and let them prescribe the fix?

[Slippydiff]

The engine was rattly (my old E90 335D engine was far quieter)
I took the car to Sytner Central in Birmingham on three occasions, the first time they fobbed me off by giving me three or four cans of fuel additive to use in every other tank of Derv. This was allegedly a BMW sanctioned initial “fix”. It made the problem worse...

Two more visits, two more extended road tests with “senior/master technicians” one inconclusive, (the technician had a bad ear infection) seriously !!
The second technician wasn’t particularly interested and immediately said “They all do that” ...

I cut my losses and went to Sytner Oldbury where I have a contact in the workshop. He test drove the car and immediately said the noise wasn’t right or indeed acceptable.

I received a call a couple of days later to say their investigations had revealed the inlet ports were 50% obstructed, and the intake manifold was so coked up the swirl flaps were jammed in one position, and additionally the excess coke had masked the inlet air temp sensor to the point it was giving erroneous readings.

All the work was carried out under the BMW AUC warranty.
When I got the car back it was waaaaay quicker, and the rattling was reduced by 90%. That was at 40k miles IIRC. The car has now done 91k miles and the rattle is as bad as ever (it slowly returned between 40-59k miles).

[mekondelta]

Many thanks !