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

How to Choose the Right Car Key Shell for Your Vehicle + Why We Recommend Panasonic CR2032 Batteries
27.05.2025

How to Choose the Right Car Key Shell for Your Vehicle + Why We Recommend Panasonic CR2032 Batteries

Your car key is one of those things you don’t really think about — until it breaks. Whether it’s the worn-out buttons, a cracked shell, or a battery that gives up at the worst possible moment, an aging car key can cause more than just annoyance. But here's the good news: you can restore your key to like-new condition easily, affordably, and from the comfort of your home. In this complete guide, we’ll show you how to choose the right replacement key shell for your car and why the Panasonic CR2032 battery is a trusted choice to keep your key fob performing reliably. Part 1: How to Choose the Right Car Key Shell Think of your key shell as a protective layer. It shields the sensitive electronics inside — the buttons, circuit board, and transponder chip — all of which are essential to operating your vehicle. When the case begins to wear down or fall apart, it’s time to replace it. 1. Know Your Car's Make, Model, and Year Key shells are made to fit specific car models and years. For instance: Flip key shells for Opel are commonly used on models from 2010 to 2024. Audi smart key shells are dependent on the platform code (like A3 8Y or A4 B9). Consult your owner's manual or use a compatibility tool like this one to confirm fitment. 2. Match the Key Blade Blades come in various formats like HU162, VA2, or HU100. Even a slight variation in shape or groove pattern can render the key useless in your ignition or door locks. Carefully compare the blade on your current key to the one listed for any replacement shell. 3. Button Layout and Functionality Make sure the number and positioning of buttons on the replacement shell matches your original. If not, the rubber pads may not line up with the contact points on your key’s circuit board, making the buttons unresponsive. 4. Interior Design and Compatibility The outside might look the same, but inside layouts often differ. Ensure that your circuit board, battery slot, and chip all fit securely inside the new shell. Misalignment can cause rattling, failure to start the car, or buttons that don’t function correctly. 5. Material Quality Avoid very cheap replacements with thin plastic and soft rubber. A good quality shell should be durable, with solid construction and tactile buttons that don't wear out quickly. For example, this Opel flip key shell combines strength with excellent fit. Part 2: Why We Recommend Panasonic CR2032 Batteries When your key fob starts failing — maybe the range drops or it takes multiple presses to unlock — chances are the battery is low. Many car owners replace the shell without considering the battery, only to find the problem persists. Understanding the CR2032 The CR2032 is a 3-volt lithium coin battery, commonly used in remote keys and small electronic devices. It’s compact, stable, and specifically suited for low-power, long-term applications. What Makes Panasonic CR2032 Stand Out? Panasonic’s version of the CR2032 is known for its consistency and reliability. It offers: A stable voltage output, ensuring your key communicates with your car effectively Longer life compared to many generic brands Resistance to leaks, which protects internal circuits from corrosion Choosing a battery from a trusted manufacturer can save you from unexpected failures, especially in colder climates where battery performance matters most. We recommend the Panasonic CR2032 battery for its excellent balance of performance and reliability. Refreshing Your Car Key: A Practical Approach If your car key is showing signs of age, it's usually best to replace both the shell and the battery. The process is simple: Open the old shell carefully, using a flat tool if needed. Remove the circuit board, chip, and battery. Clean the components gently with a dry brush. Place them into the new shell, ensuring alignment. Insert a fresh CR2032 battery. Close and secure the new shell. After completing these steps, your key should be more responsive, look better, and feel sturdier in your hand.

5 Common Car Key Problems and Easy Fixes to Get You Back on the Road
03.07.2024

5 Common Car Key Problems and Easy Fixes to Get You Back on the Road

Losing or encountering issues with your car key can feel like a nightmare, especially when you’re in a hurry. From unresponsive key fobs to stuck keys, these problems are more common than you might think. The good news? Most of these issues have simple, affordable fixes that you can address quickly. This guide will help you identify common car key problems and provide solutions to get you back on track without breaking the bank. 1. Key Won’t Turn in the Ignition Why It Happens: When your car key refuses to turn, it’s often due to a worn-out key, a damaged ignition cylinder, or a locked steering wheel. How to Fix It: Check the Steering Wheel: If the wheel is locked, try gently turning the steering wheel left and right while turning the key in the ignition. Inspect the Key: A bent or worn-out key can cause alignment issues. Try a spare key if you have one. Lubricate the Ignition: Use a small amount of graphite lubricant (avoid oil-based products) to loosen the ignition cylinder. If All Else Fails: Consult a professional to replace the key or ignition lock. Tip: Avoid forcing the key, as this could damage the ignition further. 2. Car Key Fob Isn’t Responding Why It Happens: Modern key fobs are convenient, but they rely on batteries and electronic components that can fail. A dead battery is the most common culprit. How to Fix It: Replace the Battery: Open your key fob (usually with a small screwdriver) and swap out the old battery for a fresh one. Most fobs use coin-shaped batteries like CR2032. Reprogram the Key Fob: If changing the battery doesn’t work, your fob may need reprogramming. Follow your car manual’s instructions or consult a professional locksmith. Check for Damage: Inspect the buttons and internal components for signs of wear or moisture. Tip: Always keep a spare battery on hand to avoid unexpected key fob failures. 3. Key Stuck in the Ignition Why It Happens: This issue often stems from a locked transmission, dirt in the ignition, or a worn-out key that doesn’t align properly. How to Fix It: Ensure the Car Is in Park: For automatic cars, check that the gear shifter is fully in the “Park” position. Clean the Ignition: Use compressed air to remove dirt or debris from the keyhole. Jiggle the Key: Gently wiggle the key while applying light pressure to help free it. Inspect for Damage: If the key is bent, avoid forcing it. A professional can help safely extract it. Tip: If the problem persists, you may need to replace the ignition cylinder or key to prevent further damage. 4. Worn or Damaged Car Key Why It Happens: Over time, constant use can wear down the grooves on your key, making it difficult to start the car or open the doors. How to Fix It: Get a Duplicate Key: If your key is showing wear, have a duplicate made while it still works. Replace the Key: A locksmith can create a new key based on your car’s lock or key code. Upgrade to a Modern Key: If you’re using an older mechanical key, consider upgrading to a transponder key or key fob for added convenience and security. Tip: Don’t wait until your key stops working entirely. Replacing a worn key early can save you time and stress. 5. Key Fob Signal Interference Why It Happens: Sometimes, your car key fob may not respond due to signal interference from nearby electronics or a faulty antenna. How to Fix It: Move Away from Interference: Check for other devices nearby, such as Wi-Fi routers or radios, which may disrupt the signal. Inspect the Fob: Ensure the key fob’s battery is working and the buttons are functional. Reset the Key Fob: Follow your car manual’s instructions to reset or resynchronize the fob. Test the Car’s Receiver: If the problem persists, there may be an issue with your car’s signal receiver. Tip: Parking in a location free from electronic interference can help diagnose if this is the root cause. Preventing Car Key Problems: Simple Tips Taking care of your car key now can save you from bigger headaches later. Here are some quick maintenance tips: Keep Keys Clean: Avoid exposing keys to water, dirt, or chemicals. Store Spare Keys Safely: Always have a backup key in a secure and accessible place. Replace Batteries Regularly: Change key fob batteries annually to prevent unexpected failures. Inspect Your Keys: If you notice wear, cracks, or loose buttons, address the issue early. Why Addressing Car Key Problems Early Saves You Money Ignoring small car key problems can lead to more expensive repairs down the road. For example: A damaged ignition can cost far more to replace than addressing a stuck key early. Reprogramming a lost or broken key fob is more costly than simply replacing a battery. Getting a duplicate key before the original breaks ensures you’re not left stranded. By staying proactive, you can keep your car keys functioning smoothly without spending a fortune.

How to Maintain and Extend the Life of Your Car Keys
10.07.2024

How to Maintain and Extend the Life of Your Car Keys

Your car keys are more than just tools to unlock and start your vehicle—they’re essential components for your car's convenience and security. Taking proper care of them can prevent unexpected failures and ensure they last for years. Here are seven easy and practical tips to help you keep your car keys in the best condition possible. 1. Keep Your Keys Clean and Dry Why It Matters: Moisture and dirt are the biggest enemies of car keys, particularly electronic fobs. Exposure to these elements can cause internal corrosion and failure. How to Do It: Avoid Moisture: Keep your keys away from water, rain, and high humidity. If they accidentally get wet, dry them immediately with a soft, absorbent cloth. Regular Cleaning: Gently wipe your keys with a clean cloth to remove dirt and dust. For crevices around buttons, use a cotton swab to clean hard-to-reach areas. 2. Handle Your Keys with Care Why It Matters: Dropping, tossing, or mishandling your keys can cause physical damage or misalign internal components, rendering them unusable. How to Do It: Avoid Drops: Be mindful when handling your keys. Attach them to a lanyard or key holder for better grip and to reduce accidental drops. Use a Protective Key Cover: A well-fitted key cover adds an extra layer of protection against scratches, drops, and general wear and tear. Plus, they’re available in various styles to match your preferences. 3. Replace Key Fob Batteries on Time Why It Matters: A weak battery can lead to your car key fob failing to work when you need it most, leaving you stranded or locked out. How to Do It: Watch for Warning Signs: If your key fob’s range decreases or requires multiple presses to function, the battery is likely weak and needs replacement. Replace Properly: Follow your car’s manual for step-by-step instructions on changing the battery. Using the correct battery type ensures reliable performance. 4. Protect Your Keys from Extreme Temperatures Why It Matters: Excessive heat or cold can harm the electronic components inside your key fob or damage the metal of traditional keys. How to Do It: Avoid Direct Sunlight and Heat: Don’t leave your keys exposed to the sun on your dashboard or near heaters. Extreme heat can warp materials and damage internal circuits. Keep Away from Freezing Temperatures: In colder months, avoid leaving your keys in your car or outside for prolonged periods, as freezing conditions can impact their functionality. 5. Rotate and Use Spare Keys Why It Matters: Spare keys can deteriorate if left unused for long periods. Regularly using them ensures they remain functional and ready in emergencies. How to Do It: Alternate Keys: Use your spare key occasionally to keep it in good working condition. This prevents any surprises when you actually need it. Safe Storage: Store spare keys in a dry, cool place, away from moisture, heat, or any magnetic devices that could interfere with their programming. 6. Avoid Overloading Your Keychain Why It Matters: A heavy keychain might seem harmless, but the extra weight can wear down your car’s ignition switch or damage your key over time. How to Do It: Limit What You Carry: Stick to the essentials—remove unnecessary keys, charms, or heavy accessories. Use Lightweight Keychains: Choose minimalistic and lightweight keychains to prevent undue stress on the ignition and the key itself. 7. Regularly Inspect for Wear and Tear Why It Matters: Keys, especially those with buttons or electronic components, can show signs of wear over time. Early detection helps avoid complete failure. How to Do It: Look for Physical Damage: Check for cracks, faded buttons, or scratches that might affect functionality. Seek Professional Help: If you notice significant wear or damage, consult a professional locksmith or dealership for repairs or replacement. Ignoring issues could lead to bigger, costlier problems down the line. Why Car Key Maintenance is Worth Your Effort Properly maintaining your car keys ensures they stay reliable, functional, and secure for years to come. Whether it’s a traditional key or a modern electronic fob, these small actions can save you from costly replacements or inconvenient malfunctions. Taking care of your keys isn’t just about preventing problems—it’s also about convenience, peace of mind, and getting the most out of your vehicle’s features. By following these simple tips, you’ll keep your car keys in top shape and avoid the stress of unexpected failures.

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