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

Comprehensive Guide: Common Car Key Problems and How to Solve Them
30.06.2025

Comprehensive Guide: Common Car Key Problems and How to Solve Them

Your car key is a small but essential part of your daily life. When it stops working properly—whether due to a dead battery, water exposure, signal interference, or ignition issues—it can quickly disrupt your plans. Fortunately, many common car key problems can be identified early and resolved effectively with the right approach. In this comprehensive guide, we explore four of the most frequent car key issues and provide detailed solutions to help you stay on the road with confidence. Recognizing a Failing Car Key Battery The battery inside your car key fob is designed to last, but not indefinitely. On average, a CR2032 battery will power a key fob effectively for one to three years, depending on usage patterns and environmental conditions. A weakening battery usually does not fail suddenly; it provides warning signs that many drivers overlook. One of the earliest indications is a noticeable decrease in the remote’s operating range. You may find yourself needing to stand closer to the vehicle for the key fob to work. As the battery continues to lose power, the fob may start working inconsistently, responding only after multiple button presses or with a delay. Some vehicles will display a low battery warning on the dashboard, providing a clear signal that replacement is necessary. Allowing the battery to fully deplete can leave you unable to unlock or start your car at a critical moment. By promptly replacing the battery with a reliable product, such as the Panasonic CR2032, you can restore full functionality and prevent future inconvenience. Addressing Water Damage in Car Keys Water damage is a common cause of key fob failure. Whether it’s from rain exposure, dropping the key in water, or accidental washing, moisture can cause both immediate and long-term damage to the key's internal components. When water enters the fob, it can short-circuit the delicate electronics, rendering the key inoperative. In other cases, corrosion may develop slowly, causing the key to malfunction days or weeks after the exposure. If your car key gets wet, the first step is to remove the battery immediately to minimize damage. Dry the key as thoroughly as possible using a soft cloth and allow it to air dry in a warm, ventilated space for at least 24 hours. It is crucial to avoid using heat sources like hair dryers, which can damage sensitive components. After drying, install a fresh battery and test the key. If the key still does not function, the internal circuits may have been irreparably damaged, and a professional evaluation or shell replacement may be necessary. Understanding Weak Signal Issues in Car Keys A weak key fob signal can lead to frustration and can often be mistakenly attributed to a battery issue alone. While a low battery is a common cause, signal strength can also be affected by other factors. Physical impacts, such as dropping the key, can disrupt the internal connections or damage the antenna, reducing the fob's ability to communicate effectively with the car. Environmental factors can also interfere with the signal. Parking near large metal structures, power lines, or areas with strong electronic interference can block or weaken the signal temporarily. Additionally, worn buttons that no longer make proper contact with the internal circuit board can result in poor signal transmission, even if the battery is new. When experiencing signal issues, it is important to inspect the key carefully. Replacing the battery, ensuring all components are securely seated, and considering the replacement of worn key shells can often restore proper function. Persistent problems, however, may require professional assessment to ensure the key and vehicle are correctly paired. Dealing with Ignition Problems When the Car Key Won’t Turn One of the most alarming car key issues is inserting the key into the ignition only to find it won’t turn. This problem can stem from several sources, and identifying the correct cause is essential for a safe and effective fix. A worn key blade is a common culprit, especially in vehicles with many years of use. Over time, the precision cuts on the key blade can wear down, making it difficult for the key to properly engage the pins within the ignition cylinder. Another frequent cause is the steering wheel lock mechanism. If the steering wheel locks in place, it can prevent the key from turning until the wheel is gently moved to relieve the pressure. In some cases, the ignition cylinder itself may become dirty, misaligned, or mechanically worn. If you have a spare key, testing it can help determine whether the issue lies with the key or the ignition. Cleaning the ignition slot with compressed air can sometimes resolve minor blockages. If the problem persists, professional servicing of the ignition system may be necessary to avoid more serious mechanical failures. Car Key Maintenance and Problem Solving Car key problems are a common inconvenience that most drivers will face at some point. However, understanding the signs and causes of these issues can empower you to act quickly and avoid more significant disruptions. Whether dealing with a failing battery, water exposure, weak signal, or ignition lockout, timely intervention and proper maintenance can prevent escalation. Regularly checking your key's condition, replacing batteries with trusted products, and ensuring your key shell remains intact are simple yet effective practices that can extend the life of your car key. By addressing small issues early, you can maintain reliable access to your vehicle and reduce the risk of unexpected problems. For high-quality replacement shells, batteries, and accessories, visit mr-key.com and explore solutions designed to keep your car key functioning like new.

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.

KEY COVERS: WHAT DO YOU NEED TO KNOW?
05.02.2025

KEY COVERS: WHAT DO YOU NEED TO KNOW?

What is a Key Cover? A key cover , often referred to as a key shell or key case, is the outer part of your key. It houses the electronic board, chip, and battery but excludes the internal electronics themselves. If your key casing is damaged, there’s no need to replace the entire key – just changing the key cover can restore its durability and usability while saving you money. When Do You Need a New Key Cover? You might need a key cover replacement when: The buttons on your key become worn out or stop responding. The outer case cracks, exposing the internal electronics. The key mechanism no longer functions smoothly. You want to refresh the appearance of your key with a new, sturdy shell. Instead of struggling with a faulty key, simply replace the cover and extend the lifespan of your original key! How to Choose the Right Key Cover? When selecting a replacement key cover, consider the following factors: Button Layout: Ensure that the number of buttons and their symbols match your existing key. Blade Shape: If your key includes an integrated blade, make sure the new shell accommodates it correctly. Quality: A good-quality key cover ensures a snug fit, smooth functionality, and long-lasting durability. At MR-KEY , we offer a variety of key covers designed to match your specific car model perfectly, providing both aesthetics and functionality. How to Change Your Key Cover? Replacing your key cover is simple and doesn’t require professional assistance. Here’s how: Purchase a compatible key cover from our website. Open your old key case carefully. Transfer the electronic board and chip from your original key to the new key cover . Reassemble the key, ensuring all components fit securely. Test the buttons and functions to confirm everything is working properly. For step-by-step guidance, we provide video tutorials on our website, showing you exactly how to change your key shell and even replace the battery if needed. What Else Can You Change When Replacing the Key Cover? While changing your key cover, it's the perfect time to: Replace non-functional click buttons on your key’s electronic board. Change the battery since you're already disassembling the key, ensuring it lasts longer. At MR-KEY , we strive to make key replacements easy, affordable, and accessible to everyone. Explore our website to find the perfect key cover, key cutting services, and useful video guides to help you maintain your car key like a pro!

The Essential Car Parts Guide: Understanding Your Vehicle's Core Components
21.06.2024

The Essential Car Parts Guide: Understanding Your Vehicle's Core Components

Unveiling the Anatomy of Your Car Your car is more than just a mode of transportation—it's a complex machine composed of various parts working in harmony to ensure smooth and safe driving. Understanding these essential car parts not only helps you appreciate your vehicle better but also empowers you to identify issues, perform basic maintenance, and communicate effectively with mechanics. In this guide, we’ll explore the key components that keep your car running and why they’re vital for optimal performance. 1. Engine: The Heart of Your Vehicle The engine is the powerhouse of your car, converting fuel into energy to propel the vehicle forward. There are various types of engines, including: Internal Combustion Engines (ICE): Common in most vehicles, using gasoline or diesel. Hybrid Engines: Combining a traditional engine with an electric motor for better efficiency. Electric Motors: Found in EVs, powered by rechargeable batteries. Key components within the engine include pistons, the crankshaft, and the timing belt. Regular maintenance like oil changes and timely inspections are crucial for keeping the engine in good condition. 2. Transmission: Changing Gears Made Easy The transmission system ensures that power from the engine is transferred to the wheels at the correct speed and torque. There are two main types of transmissions: Manual Transmission: Requires the driver to shift gears manually. Automatic Transmission: Shifts gears automatically, providing greater convenience. Proper transmission fluid levels are essential for smooth gear transitions and the longevity of the system. 3. Battery: Your Vehicle's Power Source The car battery supplies the electrical power needed to start the engine and operate various electrical systems, such as lights, wipers, and infotainment. Modern vehicles may also include auxiliary batteries for additional power needs. Maintenance Tip: Regularly check battery terminals for corrosion and ensure proper voltage levels, especially in extreme weather conditions. 4. Braking System: Your Lifeline on the Road The braking system ensures the vehicle slows down or stops when needed, making it a critical safety component. Key parts include: Brake Pads and Rotors: Convert kinetic energy into heat, slowing the car down. Brake Fluid: Transfers force from the brake pedal to the braking mechanism. Regular inspection of the braking system can prevent wear and ensure reliability. 5. Tires and Wheels: Where the Rubber Meets the Road Tires and wheels are vital for traction, handling, and overall vehicle stability. There are various types of tires designed for specific conditions, such as all-season, winter, and performance tires. Maintenance Tip: Regularly check tire pressure, alignment, and tread depth to ensure safe driving and optimal fuel efficiency. 6. Suspension System: Smoothing Out the Ride The suspension system absorbs shocks from uneven road surfaces, ensuring a smooth and stable ride. Key components include: Shock Absorbers: Reduce impact from road irregularities. Struts and Springs: Provide structural support and maintain balance. A well-maintained suspension system enhances comfort and handling. 7. Exhaust System: Keeping Emissions in Check The exhaust system directs harmful gases away from the engine and reduces emissions. Key components include the muffler, catalytic converter, and exhaust pipes. Environmental Note: A faulty exhaust system can increase emissions and negatively impact air quality. Regular checks are essential for compliance with emission standards. 8. Cooling System: Preventing Overheating The cooling system regulates the engine's temperature to prevent overheating. It includes components like the radiator, coolant, and thermostat. Maintenance Tip: Regularly check coolant levels and inspect hoses for leaks to ensure efficient cooling. 9. Fuel System: Delivering Energy to the Engine The fuel system stores and supplies fuel to the engine for combustion. Key parts include the fuel pump, injectors, and fuel tank. Efficiency Tip: Clean fuel injectors and replace the fuel filter as needed to maintain optimal fuel efficiency. 10. Electrical System: Powering Your Vehicle's Features From the headlights to the infotainment system, the electrical system powers numerous features in your car. It includes wiring, alternators, and fuses. Maintenance Tip: Inspect fuses and ensure the alternator is functioning properly to avoid electrical issues. Empowering Yourself Through Knowledge Understanding the essential parts of your car equips you with the knowledge to maintain your vehicle effectively and address issues proactively. By staying informed, you can extend the life of your car, save on repair costs, and ensure a safer driving experience. Whether you’re a car enthusiast or a regular driver, knowing your vehicle’s anatomy is the first step toward smarter car ownership.

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