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 Program a Car Key: A Step-by-Step Guide
19.06.2024

How to Program a Car Key: A Step-by-Step Guide

Lost Your Car Key Programming? Here's What to Do Have you ever lost your car keys or found yourself with a spare key that doesn’t start your vehicle? While the process of programming a car key might seem intimidating, it’s often simpler than you’d expect. In many cases, car owners can program keys themselves without needing a visit to a dealership. This guide walks you through the essentials of car key programming, helping you save time, effort, and potentially a significant amount of money. Understanding Car Key Programming: The Basics Car key programming is the process of syncing a key with a car's internal computer so it can communicate securely. Modern vehicles use transponder keys or smart keys equipped with chips that emit a unique signal. Without proper programming, these keys won’t function, even if they fit perfectly into the ignition. While older mechanical keys didn’t require programming, today’s advanced systems add a layer of security, reducing the risk of car theft. However, this added sophistication means that replacing or reprogramming a key is no longer as simple as cutting a piece of metal. Quick Tip: Check your vehicle’s owner manual to see if programming your car key is a DIY-friendly process, as some models allow self-programming, while others require professional tools. Step-by-Step Guide to Programming a Car Key Before starting, ensure you have all necessary tools and information: The vehicle’s owner manual. All keys that need programming, including the functional ones. Step 1: Access Programming Mode Start by sitting in the driver’s seat with all the doors closed. Insert the already functional key into the ignition and turn it to the “on” position (do not start the engine). Some vehicles require you to cycle the key between “on” and “off” positions a specific number of times to enter programming mode. Step 2: Add the New Key Once in programming mode, remove the functional key and quickly insert the new key into the ignition. Turn it to the “on” position. The vehicle’s security light may flash to indicate the key has been successfully programmed. Step 3: Test the Key After programming, remove the new key and test it to ensure it can start the car and unlock the doors. Note: Each car manufacturer has unique programming steps. Be sure to consult your owner’s manual or the manufacturer’s website for specific instructions. When Professional Help Is Needed While many vehicles allow for DIY key programming, others require specialized equipment or software that only dealerships or locksmiths can access. This is particularly true for luxury or high-end cars with advanced encryption and security features. If your DIY efforts fail, it’s best to seek help from a certified professional. Visiting a dealership is a reliable, albeit more expensive, option. Alternatively, professional locksmiths often provide programming services at a lower cost, making them a practical choice for many drivers. Costs and Considerations The cost of programming a car key varies significantly based on the vehicle’s make and model. For basic models, self-programming might cost nothing if you already have a functional key. However, professional programming can range from $50 to $300 or more, especially for smart keys or proximity fobs. To minimize costs: Have a spare key : Always keep a functional spare to simplify programming if a replacement is needed. Research costs : Call local locksmiths or dealerships to compare pricing. Empower Yourself with Knowledge Programming a car key doesn’t have to be a daunting task. With the right tools and information, many car owners can handle the process themselves, saving time and money. However, it’s essential to recognize when professional assistance is necessary, particularly for complex key systems. By understanding the basics of car key programming and following a step-by-step approach, you can ensure your vehicle remains secure and functional. So, whether it’s a spare key or a replacement, you now have the confidence to tackle the task or know where to turn for help.

How to Choose the Correct Key for Your Westfalia Towbar
27.08.2024

How to Choose the Correct Key for Your Westfalia Towbar

Westfalia towbars are a common choice for many car owners due to their reliability and ease of use. However, because you may use your Westfalia towbar key sporadically throughout the year, it’s not uncommon to misplace it, often at the most inconvenient times—like when you're about to go on vacation. If you've lost your key , you might not know the number of the key you need to order a replacement. Fortunately, there is a way to determine this, depending on whether your towbar lock has a 3-digit or a 5-digit number. Step 1: Check the Number on Your Towbar Lock The first step is to inspect your towbar lock to see if it has a 3-digit or 5-digit number. Here’s what to do next: Sample picture of how 5-digits lock number looks like. If you have a 3-digit number: Unfortunately, the key code remains unknown based on this number alone. We can only manufacture a new key if you have at least one original key and can provide us with the W** or 2W** code from it. If you have a 5-digit number: You're in luck! You can easily determine the correct key code. The key code is based on the last two digits of the 5-digit lock number, prefixed with "2W". Step 2: Calculate Your Key Code If your towbar lock has a 5-digit number, simply ignore the first three digits and use the last two digits. Prepend "2W" to these digits to form the key code. For example, if the code on your lock is 33322 , then your key code is 2W22 . This code will be the number you provide when ordering a replacement key. Even if your 5-digit lock code starts with a different set of three digits, the method remains the same—ignore the first three and focus on the last two digits. For your convenience, we include our key code generator below. What to Do If You’ve Lost All Your Keys If you have lost all your keys and only have the 5-digit number on the lock, you can still determine the correct key using the method described above. Unfortunately, if your lock only has a 3-digit number, the specific key code cannot be determined based on the number alone. Remember, the key code is crucial for obtaining a replacement key. If the towbar was manufactured after 2008, the 5-digit code on the lock cylinder will allow you to identify the correct key. Simply use the last two digits and prefix them with "2W" to get the key code. If you're ever unsure, it's always a good idea to reach out to the manufacturer or a professional who can assist in identifying the correct key. Conclusion Choosing the correct key for your Westfalia towbar is straightforward if you know what to look for. By following these steps, you can quickly determine the correct key code and ensure you're never stuck without access to your towbar when you need it most. Be sure to keep your key code information safe, and consider having a spare key made to avoid future issues. Click Here To Order Your Westfalia Towbar Key >>

Here’s 1 Crazy Mistake 40% of Car Owners Make
13.09.2024

Here’s 1 Crazy Mistake 40% of Car Owners Make

When it comes to car ownership, most of us are pretty diligent. We make sure our insurance is up to date, change the oil like clockwork, and even rotate our tires to avoid any wear and tear. But there’s one crucial aspect that many car owners overlook: having a spare key . It seems like a small detail, right? Yet, nearly 40% of car owners don’t have a backup key for their vehicle. And that’s a huge risk. Why? Because losing your only car key can cause a headache you’re not prepared for—and it’s a lot more common than you might think. The Hidden Dangers of Only Having One Car Key It’s easy to get comfortable with just one key. After all, it’s always in your pocket, bag, or hanging on your keychain. But life happens. Keys get lost, misplaced, or even stolen, and when that happens, you’re looking at a nightmare scenario. Here’s why: Costly Lockouts : Lose your key, and you’re locked out of your car, stranded until you can get help. Calling a tow truck or emergency locksmith is not only frustrating but can cost you hundreds of dollars. Inconvenient Delays : Have an important meeting? Picking the kids up from school? With only one key, losing it means your entire day—or week—grinds to a halt. Damaged Key, No Backup : Keys wear down over time, and if you only have one, a damaged key could lead to ignition problems. Suddenly, your car won’t start, and now you’re stuck paying for both a repair and a replacement. Security Risk : Lost keys are more than just a hassle—they’re a potential security threat. If your key falls into the wrong hands, your vehicle becomes vulnerable. The Pricey Locksmith Option Once you’re locked out or your key is lost, your options become limited—and expensive. Going to a local locksmith is one route, but here’s what you’re facing: High Prices : Traditional locksmiths can charge anywhere from €150 to €400 just to cut and program a new car key. Depending on your car model, it could be even more. Inconvenient : Many locksmiths don’t work around your schedule, and waiting for them to arrive or driving to their location takes time you don’t have. The Smart, Affordable Solution: Mr-Key.com Fortunately, there’s an easier and much more affordable option— Mr-Key.com . Instead of paying top dollar and wasting time, here’s how you can get a spare key in just a few simple steps: Take a Picture : Simply snap a photo of your existing key. Send It to Us : Upload the picture to Mr-Key.com using our secure service. Get Your Key Delivered : We’ll cut a perfect match and deliver it right to your door at a fraction of the cost of a traditional locksmith. Don’t Wait for a Crisis—Get Your Spare Key Now! Why risk being locked out or paying hundreds when you can have peace of mind for less? Visit Mr-Key.com today and get a spare car key cut from just a picture. It’s quick, it’s easy, and it’s affordable. Don’t be part of the 40% that gambles with just one key—protect your car and your schedule with Mr-Key.com!

Key Lock Standards for Ultimate Vehicle Security
03.12.2024

Key Lock Standards for Ultimate Vehicle Security

In today’s world, where vehicle security is more important than ever, understanding the various key lock standards is crucial for protecting your car against theft. Whether you own a luxury vehicle, a family car, or a fleet of commercial vehicles, knowing how different key locking systems work and what standards are in place can ensure that your vehicle remains secure. In this article, we’ll explore the key lock standards that every car owner should know, what makes a secure system, and how they help protect your car from potential threats. Understanding Key Lock Standards Key lock systems play an essential role in vehicle security. Modern car locks are not just about preventing unauthorized entry but also about preventing the car from being started or stolen. A well-designed key lock system integrates advanced technologies that enhance the protection of your vehicle. There are several key lock standards in the automotive industry, each with its specific focus on improving security and minimizing risks. These standards include traditional mechanical key locks, transponder keys, keyless entry systems, and smart keys. Mechanical Key Locks: The Traditional Standard Mechanical key locks are the most basic and traditional form of car locking systems. For many years, these locks were the standard, and they are still widely used today, particularly in older vehicles. A mechanical key lock involves a physical key that is inserted into the door or ignition switch to gain access to the car or start the engine. While simple, mechanical locks are not as secure as newer systems. Over time, thieves have developed methods to bypass or pick mechanical locks, making them less effective for modern vehicle security. However, many vehicles still rely on these locks, and they remain a crucial part of the overall security system. Transponder Keys: A Step Up in Security In response to the vulnerabilities of mechanical key locks, the automotive industry introduced transponder keys in the 1990s. A transponder key is equipped with a microchip embedded inside the key fob. When the key is inserted into the ignition, the microchip sends a signal to the vehicle's engine control unit (ECU), verifying that the key is legitimate and authorized to start the car. Transponder keys significantly enhance vehicle security by making it much more difficult for thieves to clone the key. Without the proper code, the car won’t start, even if the thief has an exact replica of the physical key. This added layer of security has made transponder keys the industry standard in many vehicles. Keyless Entry Systems: Convenience Meets Security Keyless entry systems, also known as remote entry systems, are now common in modern vehicles. These systems allow you to unlock or lock your car without inserting a key. Instead, the car communicates wirelessly with a key fob, sending a unique signal that grants access. The key fob typically includes buttons to lock or unlock the doors and sometimes to start the engine remotely. The convenience of keyless entry is undeniable, but it also introduces certain vulnerabilities. Keyless entry systems rely on wireless signals, which can sometimes be intercepted or duplicated by thieves using sophisticated equipment. To counteract these risks, manufacturers have developed enhanced encryption protocols and rolling codes that change each time the system is used, making it more challenging to hack into the system. Smart Keys: The Next Level of Vehicle Security Smart keys represent the latest evolution in vehicle security. These keys go beyond the capabilities of traditional key fobs and keyless entry systems by offering features like proximity sensing and push-to-start functionality. Smart keys allow you to unlock and start your vehicle without physically touching the key fob. The system detects when the key fob is near the car and grants access automatically. Smart keys are highly secure, as they use advanced encryption methods and rolling codes to protect the vehicle from unauthorized access. In addition, the vehicle can be programmed to disable the engine if an unauthorized key is detected, providing an additional layer of security. International Security Standards for Vehicle Locks To ensure the security of vehicles globally, several international standards have been developed to guide manufacturers in creating secure key lock systems. Some of the most important standards include: ISO 9001 : This standard focuses on the quality management of products, including vehicle locking systems. It ensures that manufacturers meet specific quality control guidelines, which helps ensure the reliability and security of key lock systems. ISO 14298 : This is a more specific standard related to secure key management for vehicles, focusing on preventing unauthorized duplication and tampering with vehicle keys. EC Regulation 1303/2014 : This European regulation outlines the technical specifications for car security systems, including locking systems. It provides a framework to protect vehicles against unauthorized access, theft, and other security risks. Adhering to these standards ensures that vehicle manufacturers meet global security requirements and offer their customers reliable and effective security systems. Why Secure Key Locks Are Essential for Vehicle Protection With increasing car theft rates and sophisticated methods used by criminals, investing in a secure key lock system is no longer optional—it’s essential. A secure key lock system prevents unauthorized access to the vehicle and ensures that only legitimate owners or authorized individuals can use the vehicle. Each level of security, from mechanical locks to smart keys, offers a different degree of protection, and modern vehicles often incorporate multiple systems to strengthen security. The combination of these advanced technologies, alongside international security standards, provides vehicle owners with peace of mind knowing their vehicle is well-protected. Key lock standards have come a long way from the traditional mechanical locks of the past. Today’s vehicles rely on advanced technologies like transponder keys, keyless entry systems, and smart keys to provide higher levels of security. These systems are designed to make it as difficult as possible for thieves to bypass them, giving car owners confidence that their vehicles are protected. By understanding the different key lock standards and their capabilities, you can make informed decisions about your vehicle’s security and take steps to ensure that your car remains safe from theft. Whether you’re driving a new model or an older vehicle, upgrading or maintaining your key lock system can help safeguard your investment and provide peace of mind on the road.

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