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

The Ultimate Guide to Opel, Peugeot, and Citroën Car Keys: Battery Replacement, Flip Key Issues, and Shell Compatibility
12.06.2025

The Ultimate Guide to Opel, Peugeot, and Citroën Car Keys: Battery Replacement, Flip Key Issues, and Shell Compatibility

Car keys have come a long way from simple metal tools to advanced electronic devices. While they offer convenience and security, they're also prone to wear and tear over time. If you own an Opel, Peugeot, or Citroën, you've likely encountered a dead battery, faulty buttons, or a cracked key shell. These issues, though frustrating, are easy to fix with the right approach. This guide explores everything you need to know to maintain or restore your car key's functionality—without unnecessary expense. From understanding how these keys work, to step-by-step maintenance practices, we'll walk you through all the essentials to keep your keys working like new. How Car Keys Work Today Modern car keys are more than just tools to unlock and start your vehicle. They are miniaturized computers embedded with microchips, transponders, and signal systems that communicate with your car's onboard electronics. Most Opel, Peugeot, and Citroën models feature flip keys with integrated remote buttons, and inside each key fob lies a delicate configuration of electronics that perform critical functions like remote unlocking and engine ignition authorization. These keys depend heavily on power from a small coin-cell battery, usually the CR2032. While small and seemingly insignificant, the battery is the heart of your key fob. When it begins to fail, even slightly, the symptoms can range from reduced signal range to complete unresponsiveness. That’s why it’s crucial to replace it in time. Replacing the Battery in Opel Car Keys Your Opel car key is essential to your daily routine. Over time, the lithium CR2032 battery inside may weaken, resulting in slower response or reduced range. The good news is that replacing it is straightforward and requires only a few tools. Once you identify your key type—typically a flip key with two or three buttons—you can open the casing using a small screwdriver or plastic tool. Inside, you'll find a battery nestled within the key's internal framework. Carefully remove the old battery and insert a new CR2032, ideally a reliable model like the Panasonic CR2032 . Proper alignment is crucial; the wrong orientation can prevent the key from functioning entirely. Align the shell halves carefully and press them back together until they click into place. If your key shell is also showing signs of damage or wear, consider replacing it with this Opel 3-button key housing . Replacing the battery is a quick job, but it makes a world of difference in reliability and peace of mind. Plus, it spares you the inconvenience of getting stranded or needing dealer intervention. Common Peugeot Flip Key Issues and How to Fix Them Peugeot flip keys are compact and stylish, but frequent use can expose a few recurring problems. The flip mechanism may lose tension, buttons may stop responding, or the outer shell may crack. In many cases, the spring inside wears down, and the plastic buttons may degrade over time. Exposure to moisture, dirt, or accidental drops can also damage the key fob. These symptoms can often be resolved by replacing both the battery and the key shell. Thankfully, most replacement shells come with a new flip mechanism already installed, making the process quick and cost-effective. If you're dealing with a damaged shell or non-functional buttons, a compatible Peugeot key shell can restore both the look and performance of your key. To repair your key, begin by opening the shell using a thin screwdriver. Remove the internal circuit board and transponder chip carefully. Transfer them into the new shell, ensuring everything fits snugly. Insert a fresh CR2032 battery before closing the key shell, then test all functions. Unlike dealer replacements, this DIY approach is affordable and efficient, putting the control in your hands. Understanding Citroën Key Shell Compatibility Citroën keys often resemble Peugeot models but feature subtle design differences that can impact shell compatibility. Before purchasing a replacement shell, it's important to examine a few key details. First, confirm that the button layout matches exactly—some models include a trunk release, while others do not. Next, check the blade type, usually HU83 or VA2, and make sure your new shell supports that configuration. You’ll also need to ensure there’s a space for the transponder chip, as without it, your car won’t start. Lastly, confirm that your circuit board (PCB) fits securely in the new housing. If you're unsure, compare your key with this Citroën 3-button shell for reference. A mismatched shell can result in poor fitment, misaligned buttons, or failure to lock and unlock your car. That’s why it's important to compare your current key closely to any replacement product. Shell replacements are not one-size-fits-all—small deviations in size or design can render them useless. Going Beyond: Caring for Your Car Key Long-Term Maintaining your car key goes beyond occasional repairs. Think of it as part of your overall vehicle care routine. Keep your key clean by regularly wiping it down with a soft cloth. Avoid exposing it to moisture or extreme temperatures, which can damage the battery and internal electronics. If your key starts to feel loose or if the blade no longer flips smoothly, it's a sign that maintenance is due. Another often-overlooked aspect is the condition of your key ring. Overloaded or heavy keychains can put unnecessary strain on the ignition switch and the key’s blade over time. Keeping your key light and secure can prolong both the key and the ignition system’s lifespan. If you find yourself frequently pressing buttons or experiencing lag in signal response, don't ignore it. These early symptoms are usually signs that a new battery is needed, or the shell's contacts are worn. Addressing small problems before they escalate can save you from full key failure. Car Key Maintenance Caring for your car key doesn’t have to be a daunting task. Whether you drive an Opel, a Peugeot, or a Citroën, regular maintenance and minor DIY repairs can significantly extend the life of your key. Replacing a worn battery and upgrading a broken shell not only restores functionality but also revives the overall appearance of your key. Use quality components, take your time during repairs, and always test your key before final assembly. By taking these small steps, you can avoid costly replacements and enjoy reliable key performance for years to come. Explore trusted replacement parts and accessories online at mr-key.com to keep your car keys in top condition year-round.

Removing Keys from Locks: A Comprehensive Guide
26.08.2024

Removing Keys from Locks: A Comprehensive Guide

Removing a key from a lock may seem simple, but it can become tricky when dealing with stuck or broken keys. Whether you're dealing with a standard lock, padlock, or vehicle ignition, understanding the correct techniques can save you from damage and frustration. This guide will walk you through the essential steps for removing keys from various types of locks, offering practical advice and tips to ensure a smooth process. Common Scenarios and Challenges Keys can become stuck or difficult to remove for several reasons, including misalignment, wear and tear, or damage to the key or lock. Additionally, environmental factors like temperature changes can cause metals to expand or contract, making key removal more challenging. Recognizing the cause of the issue is the first step in effectively addressing it. Basic Techniques for Key Removal Gentle Wiggle and Pull: The first technique to try is a gentle wiggle and pull. Hold the key firmly and move it slightly up and down or side to side while pulling gently. This method works well if the key is simply stuck due to misalignment. Lubrication: If the key is difficult to remove, applying a small amount of graphite powder or a silicone-based lubricant into the keyhole can help. Avoid using oil-based lubricants, as they can attract dirt and grime, potentially worsening the problem. Tapping the Lock: For stubborn cases, lightly tapping the lock with a hammer while gently pulling the key can help dislodge it. This method is effective when the key is stuck due to debris or minor misalignments within the lock. Advanced Techniques for Stuck Keys Using a Key Extractor: If the key is broken off inside the lock, a key extractor tool can be very effective. Insert the tool into the keyhole, hook the broken key piece, and pull it out carefully. This method requires patience and a steady hand. Pliers and Tweezers: If part of the key is still protruding, you can use needle-nose pliers or tweezers to grip and pull the key out. Be careful not to apply too much force, as this can push the key further into the lock or damage the lock mechanism. Heat Application: In cold weather, metal contracts, which can cause the key to get stuck. Gently heating the key with a hairdryer or warm cloth can expand the metal slightly, making it easier to remove. However, avoid using an open flame, as it can damage the lock or key. Preventing Key Stuck Issues Prevention is always better than cure. Here are some tips to prevent keys from getting stuck in the future: Regular Maintenance: Keep your locks and keys clean and well-lubricated with appropriate materials. Regularly inspect for wear and tear, and replace any damaged keys or locks. Use Duplicate Keys: If you notice a key becoming difficult to use, have a duplicate made before it breaks or becomes stuck. This will save you the hassle of dealing with a stuck key. Avoid Excessive Force: Never force a key into a lock. If it doesn’t turn easily, stop and inspect both the key and the lock for damage or obstruction. When to Call a Professional While many stuck key issues can be resolved with the techniques mentioned above, there are times when professional assistance is necessary. If you’ve tried all the methods and the key remains stuck, or if you’re dealing with a high-security lock, it’s best to contact a professional locksmith. They have the tools and expertise to safely remove the key without damaging the lock or key further. Dealing with a stuck key can be frustrating, but understanding the proper techniques can save you time and prevent damage. From basic wiggling and lubrication to more advanced methods like using a key extractor, there are various approaches depending on the severity of the situation. Regular maintenance and careful handling can help prevent these issues from occurring in the first place. When in doubt, don’t hesitate to seek professional help to ensure your lock and key remain in good working condition.

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.

Top 5 Interesting Facts About Audi: The Legacy Behind the Four Rings
13.10.2024

Top 5 Interesting Facts About Audi: The Legacy Behind the Four Rings

When you think of Audi , luxury, innovation, and performance probably come to mind. But behind the sleek design and advanced technology, Audi’s story is filled with fascinating history and achievements. Whether you’re a long-time fan or new to the brand, there’s a lot to discover. In this article, we’ll uncover five of the most interesting facts about Audi that every car enthusiast should know. 1. The Meaning Behind Audi’s Four Rings At first glance, Audi’s logo—four interlocking rings—seems like a simple yet stylish design. However, these rings have deep significance. Each ring represents one of the four founding companies that came together in 1932 to form Auto Union: Audi, DKW, Horch, and Wanderer. A Rich History : This merger marked the beginning of what would eventually evolve into Audi, and the four rings symbolize the unity of these brands. It’s more than just a logo; it’s a reminder of Audi’s prestigious heritage and long-standing dedication to automotive innovation. Survival Through the Ages : Despite wars, economic downturns, and changes in the automotive landscape, the legacy of these four companies continues to live on in Audi’s cutting-edge vehicles. 2. Audi Was the First to Introduce Quattro All-Wheel Drive In 1980, Audi made waves in the automotive world by introducing the Quattro all-wheel-drive system. Originally developed for rally racing, the Quattro system was revolutionary, giving drivers improved traction, handling, and stability in all types of weather conditions. A Game-Changer for Drivers : This innovative system quickly became a staple for Audi vehicles, giving them superior control and stability. Today, the Quattro system is still a key feature, especially in models designed for performance and sport. Setting the Standard : Audi’s Quattro system not only changed the way we think about driving in tough conditions but also set the benchmark for all-wheel-drive technology, making it one of the most trusted names in the industry. 3. The Name "Audi" Has Latin Origins Did you know that the name "Audi" has an interesting linguistic history? The name comes from the Latin translation of the German word “Horch,” which means “listen.” August Horch, the founder of Audi, had to change the name of his company due to legal reasons after he left the Horch company. Rather than giving up his name completely, he chose to translate it into Latin, giving birth to the name “Audi.” An International Touch : This name change added an international flair to the brand and has since become synonymous with high performance and luxury. A Tribute to the Founder : Audi’s name serves as a lasting tribute to August Horch’s vision and his pioneering spirit in the world of automobiles. 4. Audi’s Revolutionary Win at Le Mans In 2006, Audi made history by becoming the first car manufacturer to win the prestigious 24 Hours of Le Mans race using a diesel engine. Audi’s R10 TDI was not only fast but also fuel-efficient, demonstrating the potential of diesel technology in endurance racing. Fuel Efficiency Meets Performance : The victory wasn’t just about speed; it was about showcasing how efficiency and performance could work hand in hand. This win cemented Audi’s reputation for innovation and opened the door for more advanced technologies in racing. Multiple Wins : Audi’s dominance at Le Mans didn’t stop there. Over the years, the brand has secured numerous wins at the event, further proving that Audi’s commitment to excellence extends to the world of motorsports. 5. Audi’s Focus on Lightweight Design: The Audi A8 Audi has always been at the forefront of automotive design, and the Audi A8 is a testament to that. Introduced in the 1990s, the A8 was one of the first vehicles to feature an all-aluminum body, significantly reducing its weight while enhancing performance and fuel efficiency. Aluminum Innovation : By using lightweight aluminum in place of traditional steel, Audi was able to create a vehicle that not only performed better but was also more fuel-efficient and environmentally friendly. An Industry Leader : This innovative approach to vehicle design has influenced the automotive industry as a whole, and the Audi A8 remains a leader in the luxury sedan market. Audi’s Legacy of Innovation Audi is more than just a luxury car brand—it’s a company that consistently pushes the boundaries of what’s possible in automotive technology. From pioneering all-wheel-drive systems to revolutionizing motorsports, Audi has proven time and time again that it’s a brand dedicated to innovation, performance, and quality. As a car owner, whether you’re drawn to Audi for its history or its cutting-edge technology, it’s important to ensure you have reliable and convenient solutions for every aspect of car ownership, including your car keys. Audi’s legacy of innovation can serve as a reminder that planning ahead—whether in technology or practical matters like having a spare key—can save you from unexpected hassles down 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