Clean diesel is a pain V2.0

[primeral]

Hey folks, I have an '09 35D. From various searches I read everywhere that the DPF delete pipes available in Europe are not compatible with the US models. I come here with some learned facts. Some vendors offer two distinct delete pipes for the E70 diesels; one is specifically for the 235ps 3.0D and another for the 286ps 3.0SD. The outlet ODs of the DPFs differ between the two, being 61mm for the 3.0D and 70mm for the 3.0SD.

The American 35D is measured at 70mm. Having basic fabrication skills and being a hobbyist TIG welder I ordered the 3.0SD DPF delete pipe from France and the results are in the picture. It appears no fabrication or modification to the new downpipe is needed.

Having a closer look at the sensor bungs, they are all in the same general locations and of the same size and thread pitch. Even the underside mounting surface matches with the OEM piece via an extension rod. The only real difference is the lack of an exhaust cooler flange. From some research, some EU countries get an E70 X5 diesel with the exhaust cooler, France does not. I will need to bridge the inlet and outlet coolant lines intended for the exhaust cooler and that is very easy.

What I do want to know is what to do about the cooled exhaust inlet. That mates with the exhaust cooler using a 40mm v-band clamp. Am I to simply block it off? I have not found anyone from the EU formerly equipped with an exhaust cooler to ask for advice.

I have to mention, this job does not qualify as a basic DIY. Access from above is only possible if a jumble of electronics are removed and the exhaust manifold is removed. With all of the auxiliary systems connected to our American X5 diesels, I decided to get it from below like the 335D and 535D guys do. There is barely any room to work with underneath and I had to drop the front subframe an inch to finally extract the DPF. I also had to remove the pliable heat shielding and after removing the passenger side motor mount to gain precious millimeters and I had to jack that side of the engine up. The right axle and its associated bracketry, the subframe itself, and the exhaust tunnel contributed to this job's difficulty.

My original honest intention was to thoroughly clean the DPF matrix inside and reinstall it, but the above mentioned space constraints were such a pain in the ass that I decided to go with the slimmer aftermarket downpipe. I'm not apologetic for deleting the DPF based on this reason alone. I imagine it being close to giving birth to twin babies simultaneously without an epidural.

Any info on bypassing the exhaust cooler would be appreciated.