BMW M57 engine

BMW has always designed reliable, hard-wearing powertrains. One of the best in the line of diesel engines is considered to be the six-cylinder BMW M57, which first appeared on the market in 1998. The power units replaced the outdated M51. During the production period, the motors of the M57 series were repeatedly awarded at prestigious exhibitions and competitions.

M57 engines were based on high-quality and reliable M51 power units, new diesel engines began to be installed on cars in 1998. Structurally, the internal combustion engine had a cast-iron cylinder block, the cylinder diameter increased to 84 mm. The crankshaft also underwent changes in design. The piston stroke increased to 88 mm, and the height to 47 mm. The length of connecting rods reached 135 mm. The manufacturer installed 2.5 and 3 liter engines. Modifications M57D30 and M57D25 were developed almost simultaneously.

For the production of the cylinder head, aluminum alloy was used. The design of the crankshaft included counterweights in the number of 12 pieces. A single-row roller chain drive was used to transmit torque to the camshafts. Gas distribution mechanism was equipped with 24 valves, 4 pieces for each of the 6 cylinders. Inlet and exhaust valves were driven through a lever, the diameter of the leg is equal to 6 mm. The manufacturer used valves similar to those installed on the 4-cylinder engine M47.

To transmit torque to the camshafts, a timing chain is used. The main advantage of the node is considered to be a long service life. Under normal operating conditions, the chain does not need to be replaced during the entire period of use of the engine. Another feature of the engines is the presence of a tapered notch, due to which the mixing of the combustible mixture is faster and more efficient. Crankshaft crankpins are located at an angle of 120 degrees to each other. The engine is designed in such a way that it remains virtually stationary during operation.

The BMW M57 engine lineup utilizes the Common Rail fuel injection system, as well as turbocharging with an intercooler. The powertrain comes with a Garrett GT2556V variable geometry turbine. One or two turbochargers are included with every motor in this series, regardless of modification.

M57 motors received their first update in 2002. The modification with the marking M57TUD30 has a volume of 3 liters. The crankshaft is made with a piston stroke of 90 mm. Developers have installed a new turbine Garret GT2560V and a new control module DDE.

Power units of 2002 were also produced in several modifications. The most powerful motor has a marking M57TUD30 TOR. From the standard version, the engine differs by the presence of two turbochargers with different sizes. BorgWarner modules KR39 and K26 have a boost pressure of 1.85 bar, the compression ratio of the pistons is 16.5 units.

Geometry of the turbocharger impeller is electronically adjustable. The presence of Common Rail fuel injection system with pressure accumulator is also a feature of M57 power units. It was possible to achieve an increase in the volume of air supply due to the work of the intercooler. The level of lubrication in the engine is also controlled by electronics. For accurate fuel supply, the designers have implemented piezo injectors. This approach makes it possible to save on fuel and improve the environmental friendliness of the exhaust.

Developers of the power unit have implemented innovative solutions in order to make the M57 as compliant with environmental standards as possible. The intake manifold is equipped with special swirl flaps. When the engine is running at low speeds, the flaps close 1 intake channel each. As a result, the fuel mixes better and burns completely, with minimal exhaust emissions.

An EGR valve is implemented in the powertrain. Its work has a positive effect on the quality of the exhaust. Part of the exhaust gases is redirected back into the cylinders and additionally burned. Bosch DDE4, DDE6 blocks are used to control the power unit.

In 2005, the M57 engine lineup underwent another update. The modified M57TU2 engine with an aluminum cylinder block received an updated Common Rail system. Also, changes were made to piezo injectors, camshafts, intake valves. The diameter of the latter increased to 27.4 mm. Power units were equipped with a cast iron exhaust manifold, Garrett GT2560V turbocharger, electronic control unit DDE6. At the time of introduction of modifications, the engine was fully compliant with Euro-4 standard.

The most powerful version of the engine after the modification in 2005 received the marking M57TU2D30 TOR. In addition to two BorgWarner KR39 and K26 turbines, the top version of the engine was equipped with an electronic control unit DDE7. The engines of the M57 range were produced until 2012. Then new turbodiesels N57 were put on the assembly line.

Characteristics of the BMW M57D30 engine

The M57D30 series engines are diesel inline 6-cylinder engines produced from 1998 to 2012. They are known for their reliability, high torque and good power figures. These engines were widely used in BMW cars and some Range Rover models.

Typical BMW M57 engine failures and faults

The BMW M57 is a powerful and reliable diesel engine that is known for its durability. However, like any powertrain, it has its typical problems and weak points:

1. High fuel quality requirements: M57 engines are particularly sensitive to diesel fuel quality. The use of low-quality fuel leads to rapid wear of the injectors and pressure regulator. Under normal conditions, the injectors last up to 100,000 km, but with poor fuel quality their service life is significantly reduced.
2. Pump and turbine reliability: The high-pressure fuel pump (HPF) in the M57 engine is more reliable than its predecessors, such as the M51. The turbine also has a high life expectancy and can last 300-400 thousand kilometers if quality oil is used. It is important to change the oil and oil pump cap in time to avoid damage.
3. Engine overheating: One of the serious problems is engine overheating, which can lead to serious damage and costly repairs. The overheating problem is also associated with malfunctioning gas recirculation valve and flow meters, which often fail.
4. Oil Sweating: Oil marks on the turbine to intercooler connections and around the crankcase vent valve are a common problem. This is due to poor crankcase gas cleaning and worn flanges. Replacement of the oil separator and regular cleaning of the cyclone is recommended to solve the problem.
5. Vortex Flap Problems: The vortex flaps on the intake manifold can break and debris can enter the engine, causing serious damage. The optimal solution is to remove the flaps and re-flash the control unit.
6. Crankshaft Damper Wear: Extraneous engine noises are often caused by a worn crankshaft damper. There may also be loss of power and exhaust fumes in the engine compartment due to cracks in the exhaust manifold.
7. Timing chain: The M57 and N57 engines utilize a quality and durable timing chain that rarely fails. Compared to the two-liter versions, the chain in three-liter M57 engines is more reliable.
8. Longevity and durability: the M57 is one of BMW’s most reliable diesel engines. With proper care and quality maintenance, it can last more than 500,000 kilometers. The key to a long service life is the use of recommended oil and quality fuel.

Recommendations for maintenance

In order to maximize the service life of the BMW M57 power unit, it is important to adhere to the following recommendations:

• Use only high quality diesel fuel and the manufacturer’s recommended oil.
• Regularly perform maintenance and replacement of consumables.
• Monitor the condition of the turbine, injectors, exhaust manifold and gas recirculation valve.
• Avoid engine overheating and correct the slightest signs of malfunction in good time.

Following these rules will help you to avoid most problems and enjoy reliable operation of the M57 engine for a long time.

BMW M57D30 engine modifications

1. M57D30O0 (1998 – 2003) – M57D30 base engine with Garrett GT2556V turbocharger. Power is 184 hp at 4000 rpm, torque is 390 Nm at 1750-3200 rpm. The motor was designed for BMW 330d E46 and 530d E39.
   For BMW X5 3.0d E53 and 730d E38 there was a version with an output of 184 hp at 4000 rpm and torque of 410 Nm at 2000-3000 rpm.
2. M57D30O0 (2000 – 2004 vintage) is a slightly more powerful version for the BMW E39 530d. Its output reaches 193 hp at 4000 rpm, torque 410 Nm at 1750-3000 rpm.
   For BMW 730d E38 there was a modification of 193 hp at 4000 rpm, torque of 430 Nm at 2000-3000 rpm.
3. M57D30O1 / M57TU (2003 – 2006) – a replacement for the motor M57D30O0. The main differences of the M57TU series lie in the working volume of 3 liters and in the turbine Garrett GT2260V. Power of this engine is 204 hp at 4000 rpm, torque is 410 Nm at 1500-3250 rpm. It can be found on BMW 330d E46 and X3 E83.
4. M57D30O1 / M57TU (2002 – 2006) is a more powerful version of the above motor. Power is 218 hp at 4000 rpm, torque is 500 Nm at 2200 rpm. It was put on BMW E60 530d, 730d E65, X5 E53 and X3 E83.
5. M57D30T1 / M57TU TOP (2004 – 2007) – the top version of M57TU. The main differences of the motor are two turbines BorgWarner BV39 + K26. As a result, power reached 272 hp at 4400 rpm, and torque of 560 Nm at 2000-2250 rpm.
6. M57D30U2 / M57TU2 (2006 – 2010) – version for BMW 525d E60 and 325d E90, which came out to replace the M57D25. The main difference is in the aluminum cylinder block, modified fuel system and in compliance with Euro-4 standards. The engine has an output of 197 hp at 4000 rpm and torque of 400 Nm at 1300-3250 rpm.
7. M57D30O2 / M57TU2 (2005 – 2008) is a model with 231 hp at 4000 rpm and 500 Nm of torque at 1750-3000 rpm. The motor is found on the E90 330d and E60 530d. For the E65 730d, torque is increased to 520 Nm at 2000-2750 rpm.
8. M57D30O2 / M57TU2 (2007 – 2010) is a variation for the E60 530d at 235 hp at 4,000 rpm and with 500 Nm of torque at 1,750-3,000 rpm. For E71 X6 and E70 X5 models, torque is increased to 520 Nm at 2000-2750 rpm.
9. M57D30T2 / M57TU2 TOP (2006 – 2012) – the most powerful engine of the M57 series. It is distinguished by two BorgWarner KP39 + K26 turbines. Engine power is 286 hp at 4400 rpm, and torque is 580 Nm at 1750-2250 rpm.

BMW M57 engine tuning

Chip tuning

Motors of M57TU2 series are not badly tuned and with usual firmware it is possible to raise power by about 40 hp, and with downpipe it is possible to increase power by 10-20 hp. Power of 335d/535d/635d can be raised to 330-340 hp, and on Stage 2 with downpipe you can get 360 hp.

The older series M57TU gives a similar result: plus 40 hp and another + 10-15 hp with downpipe.
The very first versions of the M57D30 with ECU firmware give about 220 hp.

ENGINE RATING: 5-