As I had mentioned earlier the stock OEM HID bulbs seemed to have become dull, and the output was very pedestrian. I had a friend carry down these replacement bulbs from the U.S.
BMW's manual says you cannot replace the HID bulb as they are a "lifetime" bulb, and you should goto the service centre for any issue. However the replacement was quite simple. Turn the wheel fully out, remove the cover held in by two philips head screws, turn the dust cap out, disconnect the connector, turn and carefully remove the bulb, put the plastic fitment in the same angle as the old bulb onto the new one, and do everything in reverse. Ensure your car is locked and that no power is flowing to any bulb.
New bulb on driver's side, old one on passenger's side. Can see the difference in brightness.
Nice OEM colour
Long low beam throw
High beam is good too
I had already done the EGR soft delete, along with my stage 1 remap, however given the issues with the BMW egr cooler, and that some flow of EGR still happens even with the soft delete, I got a 55GBP kit from the U.K to block everything off fully. A full egr + cooler delete will reduces inlet air temperatures, prevent inlet and turbo from clogging up and removes the problematic EGR Cooler. This is a fairly advanced DIY, and I would dissuade most people from doing it. It took me around 8 hours to do the whole job, along with help from my friend Akshay of GT Tunerz DIY garage. I didn't want to do it alone at home, as I am pretty sure I don't have all the weird bits and sockets needed by this German car(all my tools are for Jap cars), plus removing the intake manifold is much easier with two people as it is fairly long.
After removing lot of acoustic packing, airbox, wiring looms and various electrical connectors, one has some access to the egr valve, cooler and pipe.
Engine bay ready to be worked on
Cooled and non-cooled EGR gases flow via this Y-pipe into the manifold
The egr cooler + valve mechanism is attached directly to the rightmost end of the exhaust manifold and we had to block this out as well. While the top bolt was somewhat accessible, the one below was totally out of sight and reach.
I worked on removing the rest of the EGR cooler, thinking that I remove and could rotate the egr cooler+valve a little as there was a flex pipe section. This rotation would give access to the bolt below.
Coolant drained out on removing the cooler from the block. A friend had picked up 3 litres of BMW coolant from a dealer, and he dropped this off just in time. Rs. 950 for 1.5 litres of BMW coolant concentrate.
One the egr cooler+valve was moved a little, I could remove the bolt. Pic with the whole mechanism out. Arrow points to the exhaust manifold. Port numbered 1 and Port numbered 2 are the 2 coolant ports which need to be plugged.
I then put the blanking plate + gasket and closed the exhaust manifold.
Next I put in the coolant plugs into the block and head and via the blanking plates and gaskets screwed everything shut. The arrow points to the plate which covers the port in the head which transports the cooled egr toward the intake manifold. I'm guessing the ECU carefully controls when and how much of the exhaust is to be released, how much to be cooled, how much not to be cooled etc.
I've read a lot about how BMW intake manifolds get clogged up with this EGR gunk. I did not initially plan on removing my manifold, as I knew it would take a lot of time, but one pipe carrying the cooled egr gases from the head into the intake manifold, needed the manifold to be removed. The arrow points to the part which is tucked in between the intake manifold and head.
I frankly expected more gunk, compared to the stuff I'd seen online, but was quite happy that my intake manifold was fairly clean. It still took 4 cans of brake cleaner and half a litre of diesel to get it almost fully clean. The dirty manifold.
With a rag soaked in brake cleaner, I tried and cleaned as much of the intake ports as I could. The round port below intake port no.4, is from where the cooled egr gases come and via a metal pipe go back into the intake. Dirty manifold shown below.
Putting everything back was much easier as with the EGR cooler, valve, pipes and hoses out, there was much more space. I wrapped the now open connectors with self-fusing silicone tape. A vacuum hose into the egr valve was fairly knackered and that was fully removed and sealed off as well. When my car had gone in for the BMW inspection, BMW said my egr cooler+vacuum hoses need to be replaced and quoted a 1Lakh +figure for the same. I frankly found my egr cooler to be fine on a physical inspection after removing it. I could be wrong but maybe just the rubber hoses needed to be renewed, which is a fairly simple job.
EGR cooler + Valve:
Am glad I got this job done, as the words of that BMW service advisor about my leaky EGR cooler were constantly at the back of my mind, and even though the coolant levels were fine, it still kept nagging me. Also, it now means my cleaned intake manifold will remain clean as no EGR gases flow back into it. On starting up we did not see any codes

, as the quantum stage 1 remap + EGR soft delete would have already disabled the readings from those sensors. Car seems to rev more freely now especially in the 3-5000RPM range and it seems more silent(could be placebo). If BMW offers an intake manifold cleaning service, people who's diesels have done more than 60k+ km should definitely get it done. Huge shout out to Akshay of GT Tunerz for all the help and for getting his hands dirty as well while trying to clean my intake manifold.

Hope this post helps and was useful for those facing similar issues.