en
0

Shopping Cart

closeCart
€0.00

What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them

  • /
  • Blog
  • /
  • What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them
Post Name
25.03.2024

 

Swirl flaps are a BMW system that has been introduced to help burn the fuel mixture in the cylinder better due to the fact that diesel engines do not have throttle valves and it is not possible to adjust the air-fuel ratio. A diesel engine without vortex valves operates between a poor and a rich fuel mixture, because the only way to regulate it is through fuel injection.

Design of the first generation swirl flaps that are made of made of metal.
 


Unfortunately, swirl flaps are responsible for countless damaged engines and costly repairs due to design errors or metal fatigue. Once damaged, the cylinder sucks them in and causes great damage.

This is how damaged valves damage the cylinder.
 


Typical swirl flaps  suction damage.
 


The vortex valves are positioned in the inlet and are controlled by vacuum (DDE 4.0) or electrically (DDE5.0 / DDE6.4) by the engine ECU.

Effects of malfunctioning valves:

  • Swirl valves are  stuck in open position: Deterioration of exhaust gas performance at lower speeds.
  • Swirl valves are stuck in closed position: Approximate power loss of 10% at high engine speeds.

How swirl flaps work:

 

Performance characteristics:

The vortex valves are in the closed position, at low engine speeds and small amounts of fuel injected (controlled by the ECU card).

They open under the following conditions:

  1. coolant temperature <14 ° C OR * fuel quantity> 24 mg OR
    2. engine speed 2250 rpm OR
    3. inlet air temperature <-5 ° C.

BMW and Pierburg have decided to produce diesel engines with metal vortex valves. The speed at which the pistons in the diesel engine operate is at least 60 rpm, so a sucked vortex valve will break and cause a number of damages inside the engine.

In most cases, one or more pistons are severely damaged, as a bonus you get valves, in some cases a head or turbocharger. And this combination with a BMW engine is like a cumulative jackpot  🙂

In 2004, BMW began work on the problem and improved the design, however, a number of owners reported ongoing problems in this area.

The solution to this problem is by removing the vortex valves and plugging, which does not affect the performance of the engine and at the same time, you can safely pass the exhaust test.

Engines:

M47 (136hp VP44 fuel pump) has no valves.

M47N common rail engine (including M47N / M47TU / M47TUD20) (150hp. Face lift model from 2001 -) has valves.

M57 engines (M57D) (525d & 187hp. 330d) cars with manual transmission do not have valves, but those with automatic have.

M57N engines (M57TUD) (525d & 330d 204hp) have vortex valves.

Ruined swirl flapss:

 

The plugs that replace the vortex valves are easy to find on the internet, but you can also find them here on our website.

Typical plugs:

Disassembly of vortex valves:

 

The vortex valves can be safely dismantled and in most cases if they are  removed properly no loss of power is felt.

Final list of models for which vortex valves are installed:

Engine: M47N/M47TU/M47TUD20

Applications:

* 110 kW (148 hp) and 330 N·m (243 lb·ft)

o E46 320d 2001-2005

o E83 X3 2.0d (up to end of 2006)

Engine: M47TU2D20

The engine was updated again in 2004 as the M47TU2D20. Still at 1995 cc, it produced more power across the range.

Applications:

* 120 kW (161 hp) and 340 N·m (251 lb·ft)

E60/E61 520d

E87 120d

E90/E91 320d

E83 X3 2.0d (end of 2006 onwards)

Engine: M57/M57D25

M57D25 was introduced in 2000.

Applications:

* 166 PS (122 kW; 164 hp) at 4000 rpm, 350 N·m (260 lb·ft) at 2000-2500 rpm with a 4750 rpm redline, models:

2000-2003 E39 525d *Vehicles With Automatic Transmission ONLY*

Engine: M57N/M57TU/M57TUD25

M57TUD25 was introduced in 2004.

Applications:

* 177 PS (130 kW; 175 hp) at 4000 rpm, 400 N·m (300 lb·ft) at 2000-2750 rpm models:

E60/E61 525d

Engine: M57/M57D30

M57D30, also called M57D29, was introduced in 1998.

Applications:

* 184 PS (135 kW; 181 hp)@4000, 390 N·m (290 lb·ft)@1750-3200 models:

E39 530d *Vehicles With Automatic Transmission ONLY*

E46 330d/330xd *Vehicles With Automatic Transmission ONLY*

* 184 PS (135 kW; 181 hp)@4000, 410 N·m (300 lb·ft)@2000-3000 models:

E38 730d *Vehicles With Automatic Transmission ONLY*

E53 X5 3.0d

* 193 PS (142 kW; 190 hp)@4000, 410 N·m (300 lb·ft)@1750-3000 models:

E38 730d

E39 530d

Engine: M57N/M57TU/M57TUD30

M57TUD30 was introduced in 2002. It originally produced 160 kW (215 hp) at 4000 rpm and 500 N·m (370 lb·ft) at 2000-2750 rpm, but was tweaked for 150 kW (201 hp) at 4000 rpm and 410 N·m (300 lb·ft) at 1500-3250 rpm for 2003 and again for 200 kW (268 hp) at 4000 rpm and 560 N·m (410 lb·ft) at 2000-2250 rpm in 2004.

Applications:

* 204 PS (150 kW; 201 hp)@4000, 410 N·m (300 lb·ft)@1500-3250 models:

E46 330d/330Cd/330xd

E83 X3 3.0d

* 218 PS (160 kW; 215 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E53 X5 3.0d

E60/E61 530d/530xd

E65 730d

* 272 PS (200 kW; 268 hp)@4000, 560 N·m (410 lb·ft)@2000-2250

E60/E61 535d

* 245 PS (180 kW; 242 hp)@4000, 500 N·m (370 lb·ft)@2000-2250

* 286 PS (210 kW; 282 hp)@4000, 580 N·m (430 lb·ft)@2000-2250

Engine: M57TU2D30

M57TU2D30 was introduced in 2007, making its debut in the facelifted E60 and E61.

* M57TU2D30-UL: 197 PS (145 kW; 194 hp)

* M57TU2D30-OL: 235 PS (173 kW; 232 hp)@4000, 500 N·m (370 lb·ft)@2000-2750

* M57TU2D30-TOP: 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft)

Applications:

* 197 PS (145 kW; 194 hp), 400 N·m (300 lb·ft) models:

E90/E91/E92 325d

E60/E61 525d/525xd

* 231 PS (170 kW; 228 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E65 730d

E90/E91 325d

E90/E91 330d/330xd

* 235 PS (173 kW; 232 hp) models:

E60/E61, BMW E70, BMW E71

* 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft) models:

E60/E61 535d

E70 X5 3.0sd

E71 X6 xDrive35d

E83 X3 3.0sd

E90/E91 335d

The above models are listed for information only if you want to to make sure your engine has valves installed, please contact a competent person.

Please note that the information described above is for informational purposes only and does not claim to be reliable. Mr-key.com is not responsible for any repair work you undertake that is related to the topic described in this article.

Related Posts

Do Car Keys Have GPS? What You Need to Know About Key Tracking
24.04.2025

Do Car Keys Have GPS? What You Need to Know About Key Tracking

In an age where smartphones can locate us with pinpoint accuracy and lost luggage can be tracked halfway around the world, it’s easy to assume car keys are just as smart. But for many frustrated drivers, losing a car key feels like sending it into a black hole. The lack of a clear way to find them often leads to stress, wasted time, and sometimes costly replacements. So here’s the big question: Do car keys have GPS, and can they be tracked like other smart devices? This article explains the technology behind key tracking, compares GPS with Bluetooth, and offers practical ways to find lost keys in a connected world. The Truth About GPS in Car Keys While GPS technology has become common in many consumer devices, the vast majority of car keys do not include built-in GPS. Even the most modern remote key fobs, which allow for keyless entry and push-button start, generally lack the components necessary for GPS functionality. These components include a satellite GPS receiver, a data transmission module, and a sustainable power source—none of which are typically found in a key fob. The design of a car key prioritizes compactness, cost-efficiency, and low energy usage. Adding GPS would not only increase manufacturing costs but also introduce battery life challenges. That’s why most manufacturers have opted against including GPS tracking in car keys. GPS requires constant power and data transmission — something a small coin cell battery in a typical key fob can’t support." – Marcus Lee, Automotive Tech Analyst How Can Car Keys Be Tracked? Although your keys may not have GPS, there are other technologies that make it possible to track or locate them when they’re lost. These include Bluetooth trackers, crowdsourced networks, and GPS systems that track the vehicle instead of the key itself. 1. Bluetooth Trackers (Apple AirTag, Tile, Chipolo) These small, attachable gadgets can be added to your keychain and linked to a mobile app. They rely on Bluetooth to provide location data when within a certain range. If your keys are somewhere nearby—like in your home or office—these trackers can play a sound or show you their last known position on a map. The range is generally up to 120 meters (400 feet), and battery life can last up to a year, making them a practical, low-maintenance option for most users. 2. Crowdsourced Networks (Find My, Tile Network) If your Bluetooth tracker is out of range, some brands offer a smart workaround. Apple’s AirTag, for instance, uses the “Find My” network, which consists of millions of iPhones around the world. If someone with an Apple device passes near your lost keys, the location is anonymously and securely sent to your phone. This creates a global, decentralized tracking system that mimics GPS functionality without requiring satellites or cellular connections. 3. Car GPS Systems (Vehicle Only, Not the Key) Some high-end cars offer integrated GPS systems, but these track the vehicle, not the keys. Brands like Tesla, BMW, and Mercedes-Benz allow owners to locate their car through mobile apps. If your keys are left inside the car, you may be able to find them by locating the vehicle. However, once the keys are removed, they cannot be tracked unless equipped with a separate Bluetooth tracker. GPS vs Bluetooth: What’s the Difference? To better understand why GPS isn’t commonly included in car keys, it’s useful to compare the two technologies: GPS provides global, real-time tracking with high precision, but it’s power-intensive and costly. Bluetooth, while more limited in range, is ideal for small items and short distances, offering a cost-effective solution for everyday use. Global Perspectives on Key Tracking Around the world, the adoption of key tracking technologies differs based on privacy laws, tech infrastructure, and consumer behavior. In Japan and South Korea, smart home and car integration are advanced, yet GPS-enabled keys are still not the norm. In many parts of Europe, particularly in countries like Germany, Bluetooth solutions are favored due to strict data privacy regulations. In contrast, the U.S. market has embraced personal tracking devices like Apple AirTag and Tile, making them increasingly common accessories. These differences highlight how technology adoption often reflects broader cultural and legal norms, as well as the balance between convenience and privacy. Smart Tips to Keep Track of Your Keys Whether your keys have advanced tech or not, you can take simple steps to avoid losing them. Attaching a Bluetooth tracker is a great first line of defense. Keeping your keys in a consistent, designated place at home reduces the chances of misplacement. Many tracking apps also offer “left behind” alerts, which notify you if you leave your keys behind when moving out of range. It's also smart to keep a spare key somewhere safe and consider going keyless if your next car allows it. Implementing a few of these habits can save you time, frustration, and the cost of replacing a lost key. The Future of Key Tracking While car keys may not have built-in GPS, technology continues to evolve with practical alternatives. Bluetooth trackers, supported by app alerts and community networks, already provide effective ways to find lost keys. As innovation progresses, we can expect even more seamless solutions, such as Ultra Wideband (UWB) technology and Internet of Things (IoT) integrations, to become mainstream. As our tools become smarter, so must the way we use and manage them. With a little foresight and the right accessories, you'll never lose track of your keys again.

Inside a Key Rescue: How to Salvage a Wet or Flooded Car Key
10.07.2025

Inside a Key Rescue: How to Salvage a Wet or Flooded Car Key

Water damage is one of the most common – and most stressful – problems car key owners face. Whether your key fell into a puddle, went through the wash, or was simply caught in a downpour, it can stop working in an instant. But does water exposure always mean you need to buy a new key? Not necessarily. In many cases, a quick and proper response can save your key, restore its function, and spare you an expensive replacement. This guide walks you through how to rescue a wet or flooded car key, what not to do, and how to know when it’s beyond repair. How Car Keys Get Wet Modern car keys, especially keyless remotes and fobs, aren’t designed to be waterproof. Even small amounts of moisture can cause damage if the internal components are exposed. Some of the most common causes of water-damaged keys include: Being left in clothing and run through the washing machine Falling into sinks, toilets, or puddles Exposure to rain, snow, or slush Dropped at the beach or near pools Stored in damp gym bags or jackets Once water enters the key shell, it can corrode the circuit board, damage the battery, or short-circuit the transponder chip. What to Do Immediately After Getting Your Key Wet The first few minutes after exposure are critical. Acting quickly can mean the difference between a working key and a dead one. 1. Remove the Key from the Water Take the key out of the water as quickly as possible. The longer it sits, the more damage can occur inside. 2. Open the Key Shell If your key has a removable shell, gently open it using a small screwdriver or plastic tool. This allows you to access the internal parts and dry them properly. If you’re unsure how to open it, look up a video or guide specific to your car model. 3. Take Out the Battery Immediately remove the battery. A wet battery in contact with electronics can cause short circuits and corrosion. Do not reinstall the same battery later; it may be compromised. 4. Dry the Internal Components Gently pat all visible parts dry with a lint-free cloth. Do not use paper towels, as they can leave behind fibers. Then allow the key to air-dry using one of the following methods: Option A: Use Silica Gel or Desiccant Packs Place the opened key and all components in an airtight container with silica gel packets. Leave it sealed for at least 24 to 48 hours. Option B: Use Uncooked Rice If silica gel isn’t available, uncooked rice can work as an alternative. Place the key in a bowl of rice and cover it completely. Leave it for 2 to 3 days. Do not use a hair dryer, microwave, or place the key near a heater. High heat can warp the plastic shell and damage sensitive electronics. After Drying: Will the Key Work Again? After a full drying period, insert a new battery and test the key. In many cases, it will begin working again — especially if water exposure was brief and the board was not damaged. If the key still doesn’t respond, try the following steps: Inspect the circuit board for corrosion or residue Try replacing the outer shell if buttons feel worn or unresponsive Check if the vehicle recognizes the transponder chip If none of these steps work, the internal chip or electronics may be permanently damaged. When to Replace the Key Sometimes the damage goes beyond what cleaning and drying can fix. You’ll likely need a full replacement if: The key no longer sends a signal The LED light doesn’t flash when pressing buttons There is visible corrosion on the circuit board The transponder chip fails to communicate with the vehicle Buttons are physically damaged or unresponsive The key was underwater for an extended time In these situations, replacing the key is often the most reliable solution. Don’t Wait Until It’s Too Late – Keep a Spare Key If you’ve experienced water damage once, there’s a good chance it could happen again. Keeping a backup key stored in a safe, dry location is one of the best precautions you can take. You can find replacement key shells, blades, batteries, and fully programmed keys for most vehicle brands at mr-key.com . Investing in a spare can save time, money, and stress. Final Tips for Car Key Water Damage Act fast and remove the battery as soon as possible Use silica gel or rice for slow, safe drying Avoid heat, rubbing, or shaking the electronics Replace the shell if it’s worn, cracked, or damaged If in doubt, test with a new battery before replacing the entire key Need Replacement Parts? Whether you need a new shell, battery, or a complete key, visit mr-key.com to find compatible parts for a wide range of vehicles. Our selection includes: Key shells for all major brands CR2032 batteries Key blades and electronics Fully assembled remote keys with chip and programming options If your key has been exposed to water, don’t panic. With the right steps, many keys can be rescued — and if not, we’re here to help you find the right replacement.

How to Properly Maintain Your Car Keys and Lubricate Locks: A Complete Guide
24.01.2025

How to Properly Maintain Your Car Keys and Lubricate Locks: A Complete Guide

Car keys and locks are everyday essentials that we often take for granted—until they malfunction. From ensuring the longevity of your car keys to properly lubricating locks for smooth operation, maintenance plays a vital role in avoiding inconvenience and costly repairs. In this guide, we explore how to care for your car keys and master the art of lock lubrication. Common Issues with Car Keys and How to Prevent Them Car keys are more than just tools; they’re lifelines to your vehicle. Whether you have a traditional metal key or an advanced smart key, these essential devices are prone to wear and tear. Understanding common problems and their solutions can save you time and stress. 1. Worn-Out Key Blades Over time, the metal blades of traditional car keys can become worn, making it difficult to start your car. This is especially common in keys used frequently or roughly. To prevent this, avoid using your car key for tasks like opening packages or prying objects. 2. Weak Key Fob Batteries For those with remote or smart keys, a weak battery is a common issue. A fading signal or difficulty locking/unlocking your car remotely are signs it’s time for a battery replacement. Replacing the battery every 1-2 years can help maintain consistent performance. 3. Scratched or Damaged Smart Keys Smart keys have sensitive electronics that can be damaged by rough handling or exposure to extreme temperatures. Always store your key in a protective case and keep it away from direct sunlight or freezing conditions. Pro Tip: Always have a spare key on hand. This not only saves time during emergencies but also reduces the wear on your primary key. Why Locks Need Regular Lubrication Locks are intricate mechanisms designed to provide security. However, dirt, grime, and regular use can cause them to stick or malfunction. Lubrication ensures smooth operation and prevents long-term damage. How Locks Deteriorate Locks endure constant exposure to the elements, which makes them vulnerable to dirt, dust, and moisture. Over time, these factors can lead to stiffness, making it difficult to turn the key. If left unchecked, the lock may become entirely unusable, requiring costly replacement. Choosing the Right Lock Lubricant Not all lubricants are created equal, and choosing the right one is crucial for maintaining your locks. Here are the best options: Graphite Powder This dry lubricant is a top choice for locks. It doesn’t attract dust and provides smooth operation without residue build-up. Silicone Spray Silicone-based sprays offer moisture resistance and work well for both interior and exterior locks. Avoid over-applying, as excess lubricant can attract grime. Avoid Oil-Based Lubricants Products like WD-40 may seem convenient but are not ideal for locks. They can attract dirt and worsen the problem over time. Step-by-Step Guide to Lubricating a Lock Follow these steps to keep your locks functioning flawlessly: Clean the Lock Begin by removing visible dirt and debris using a soft brush or compressed air. This ensures the lubricant can reach internal components effectively. Apply Lubricant Insert the nozzle of your lubricant into the keyhole and spray or apply a small amount. If using graphite powder, gently squeeze the bottle to distribute the powder evenly. Insert and Turn the Key Insert your key and turn it several times to distribute the lubricant throughout the lock mechanism. Test the Lock Check the lock’s operation by locking and unlocking it multiple times. If it still feels stiff, reapply a small amount of lubricant. Pro Tip: Lubricate locks every 6-12 months, or more frequently if they’re exposed to harsh weather conditions. Maintenance Tips for Long-Term Performance 1. Protect Outdoor Locks For locks exposed to the elements, such as gates or sheds, consider using a lock cover to shield them from rain and snow. Regularly inspect and lubricate these locks to prevent rust and corrosion. 2. Store Spare Keys Properly Spare keys should be kept in a safe, dry place. Avoid leaving them in areas with high humidity, as moisture can lead to rust on metal keys. 3. Address Issues Early If you notice stiffness or difficulty turning a key, address the issue immediately. Ignoring minor problems can lead to complete lock failure. The Global Perspective on Lock and Key Maintenance Different regions face unique challenges when it comes to maintaining locks and keys. In cold climates, freezing temperatures can cause locks to seize, requiring specialized de-icing sprays. In humid or coastal areas, locks are more prone to rust and may need frequent lubrication to combat corrosion. Meanwhile, digital locks are becoming increasingly popular in urban areas worldwide. These systems require their own maintenance, such as software updates and battery replacements, to ensure optimal functionality. A Little Maintenance Goes a Long Way Caring for your car keys and locks is a small investment of time that can save you from major inconveniences. By taking preventative steps like lubricating locks and protecting your keys, you can ensure their longevity and performance. Take a moment today to inspect your keys and locks. Are they in optimal condition? If not, a quick round of maintenance can make all the difference. For more insights on maintaining your everyday essentials, explore our other articles and unlock the secrets to hassle-free living.

Simple and Affordable Solutions for Car Key Replacement and Repairs
03.12.2024

Simple and Affordable Solutions for Car Key Replacement and Repairs

Misplacing or damaging your car keys can be a major inconvenience, but it doesn't have to be a costly ordeal. As a car owner seeking budget-friendly and efficient solutions, understanding your options is crucial. Here's a comprehensive guide to help you navigate the process of replacing your car keys without breaking the bank. Understanding Your Car Key Type Identifying the specific type of car key you have is the first step toward an effective replacement: Traditional Metal Keys : Simple, non-electronic keys that are easy and inexpensive to duplicate. Transponder Keys : Equipped with a chip that communicates with your vehicle's ignition system for added security. Remote Key Fobs : Allow remote locking and unlocking of your vehicle, often integrated with a transponder chip. Smart Keys : Provide keyless entry and start features, utilizing advanced technology for convenience. Cost-Effective Alternatives to Dealership Key Replacement Dealerships are known for charging premium prices for key replacements. Consider these more affordable options: Professional Locksmiths : Specialize in cutting and programming various types of car keys, often at a fraction of dealership costs. Online Key Retailers : Offer replacement keys and fobs that can be purchased and then programmed either by yourself or a professional. Hardware Stores : Some stores can duplicate traditional metal keys on the spot, providing a quick and inexpensive solution. Steps to Take When You've Lost Your Car Key Losing your car key can be stressful, but following these steps can streamline the replacement process: Verify Your Vehicle Identification Number (VIN) : Locate your VIN, typically found on the dashboard or inside the driver's side door, as it is essential for key replacement. Gather Necessary Documentation : Prepare proof of ownership, such as your vehicle registration and personal identification. Contact a Professional : Reach out to a reputable locksmith or key replacement service with your vehicle details to obtain a new key. Removing a Broken Key from the Ignition or Door Lock A broken key can be a frustrating obstacle. Here's how to address it: Use Needle-Nose Pliers : If a portion of the key is protruding, gently extract it using pliers. Apply Lubricant : Spray a graphite-based lubricant into the lock to ease the removal process. Seek Professional Assistance : If the key fragment is lodged deep or these methods fail, contact a locksmith to prevent further damage. Preventative Measures to Avoid Future Key Issues Keep a Spare Key : Having a duplicate stored safely can save time and money in emergencies. Regular Maintenance : Inspect your keys and locks periodically for signs of wear and address issues promptly. Use Key Protectors : Invest in key covers or cases to minimize physical damage.

Logo
More options Accept all Reject all
This website uses cookies

We use cookies to personalise content and ads, to provide social media features and to analyse our traffic. We also share information about your use of our site with our social media, advertising and analytics partners who may combine it with other information that you’ve provided to them or that they’ve collected from your use of their services.

Chat with us