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

What Makes EV Key Fobs Different from Traditional Car Keys?
03.07.2025

What Makes EV Key Fobs Different from Traditional Car Keys?

When you think about car keys, you probably picture the classic remote fob—the one you click to lock or unlock your car from a short distance. For years, this type of key was the standard. But with the rise of electric vehicles (EVs), key fobs have changed more than you might think. They’ve become smarter, more secure, and packed with new technology that sets them apart from their traditional counterparts. So, what exactly makes an EV key fob different? Let’s dive into the world of modern keys and discover why electric vehicle fobs aren’t just an accessory—they’re a key part of the driving experience. Smarter Connections One of the most noticeable differences between EV key fobs and traditional ones is how much they actually “talk” to your car. Old-school fobs were pretty simple. They sent a basic signal to lock or unlock your doors and maybe popped the trunk if you were lucky. But EV key fobs are much more connected. Many of them communicate with the car’s internal system in real-time. When you press a button on an EV fob, you’re not just opening doors—you might be starting the climate control, checking the battery level, or even setting your seat to your personal position. Some fobs go a step further, automatically unlocking the car as you walk up or adjusting settings based on which key is nearby. It’s no longer just a key—it’s part of your driving profile. Software That Evolves Here’s something traditional key fobs can’t do: get smarter over time. EV key fobs often receive something called Over-The-Air (OTA) updates . Just like your phone or your laptop, your key fob’s software can be updated remotely. This can improve its performance, fix bugs, and even add new features. That means your EV key fob is no longer a “set it and forget it” device. It evolves with your car. Updates can make your key safer, faster, and more reliable without you ever stepping foot in a dealership. For some EV owners, their key fob today might already be more advanced than when they first got it. Stronger Security Security has always been important, but for modern EV key fobs, it’s taken to a whole new level. Traditional key fobs use basic encryption, which—unfortunately—has become easier for tech-savvy thieves to bypass. EV key fobs, on the other hand, often use advanced encrypted signals that change every time you use them. Some are even equipped with Ultra-Wideband (UWB) technology, which makes it nearly impossible for criminals to hack or clone the key’s signal. In a world where keyless car theft is becoming more common, these newer security features offer real peace of mind. Your key fob isn’t just a remote—it’s a digital handshake between you and your car that’s designed to keep you protected. A Little More Power-Hungry All these advanced features, constant communication, and longer-range signals come with a small trade-off: EV key fobs tend to use more battery power than traditional ones. You might notice that you need to replace the battery a bit more often, especially if your fob is always syncing with the car or receiving regular updates. The good news? Most EV key fobs still use common, affordable batteries like the CR2032, and replacements are quick and simple. It’s just something to be aware of if you’re used to your old key fob battery lasting for years without a second thought. The Future in Your Pocket EV key fobs are no longer just about opening doors—they’re smart devices that bring you closer to your car’s full potential. They offer more convenience, better security, and the ability to grow and improve over time. As the automotive world moves toward electric, key fobs are evolving right along with it. Whether you drive an EV today or plan to in the future, your key is becoming just as high-tech as the vehicle it unlocks. At Mr. Key , we’re here to help you keep your key fob in top condition—whether you need a battery, a new key shell, or expert advice on key maintenance. Explore our range of products and keep your smart key working like new. Visit us at mr-key.com for all your car key needs.

How Hot Weather Can Damage Your Car Key Fob – And What You Can Do About It
19.06.2025

How Hot Weather Can Damage Your Car Key Fob – And What You Can Do About It

When you think about how hot weather affects your vehicle, your first thoughts might go to the engine, the tires, or maybe even the air conditioning. But there’s one small, essential part of your daily driving routine that’s often overlooked — your car key fob. It might seem like a tough little device, but the truth is, it’s far more sensitive than it looks. If you’ve ever left your key fob on the dashboard, in a hot glove box, or even inside your pocket during a heatwave, you may have already caused damage without realizing it. Car key fobs are built with delicate electronics, plastic shells, and lithium coin batteries — all of which are vulnerable to extreme temperatures. In this article, you’ll learn how hot weather affects each part of your key fob, how to spot the early signs of damage, and most importantly, what you can do to protect it. Taking just a few simple steps can save you from the cost and inconvenience of a non-functioning remote, especially when you least expect it. The Plastic Shell: First to Feel the Heat One of the first things to suffer from heat exposure is the plastic casing that protects your key fob. While it’s designed to withstand everyday use — being dropped, tossed in a bag, or handled frequently — it’s not built to survive hours in a baking-hot car. The interior temperature of a parked vehicle can soar past 60 or even 70 degrees Celsius on a sunny day, especially if the key is sitting directly in sunlight. Over time, this level of heat can soften the plastic, causing it to warp, bend, or even split at the seams. You may start to notice that your key doesn’t close as tightly as it used to, or the buttons may feel soft and spongy instead of firm. Cracks might appear along the sides, or parts of the shell may become discolored. While this might seem like a cosmetic issue at first, it has serious implications — a compromised shell allows moisture, dust, and debris to enter the fob, putting the internal electronics at risk. If your key fob’s shell is already showing signs of wear, especially after a hot summer, it’s time to consider replacing the casing before the damage gets worse. Battery Breakdown: How Heat Drains Power Inside your key fob, there’s usually a small lithium battery — typically a CR2032 coin cell. These batteries are reliable under normal conditions, but they don’t respond well to high temperatures. In fact, exposure to extreme heat can accelerate chemical breakdown inside the battery, leading to faster discharge and a shorter overall lifespan. What’s worse, in severe cases, the battery can swell or leak, which can damage the internal components of your fob permanently. If you’ve ever noticed your key fob suddenly stops working or becomes unreliable during the summer, there’s a good chance the battery is struggling under heat stress. The signal may become weaker, you might have to press buttons multiple times, or the remote might stop responding altogether. Replacing the battery is a quick and inexpensive fix, but it’s important to recognize that battery issues are often just the first symptom of deeper heat-related problems. Internal Electronics: Silent Victims of the Heat While the shell and battery are easier to see and replace, the most serious damage often happens silently — deep inside the electronic circuit board. This board, often referred to as the platine, is responsible for all communication between your key and your vehicle. It’s a compact, delicate system of soldered connections and microchips, and unfortunately, it’s not designed to cope with repeated thermal stress. When your key fob is exposed to fluctuating high temperatures, the constant expansion and contraction of materials can loosen solder joints or weaken connections. Moisture that gets trapped inside the shell during humid summer months can accelerate corrosion, especially if the casing is already cracked or loose. The damage might not be immediate, but over time you may find that your key fob becomes unpredictable — sometimes it works, other times it doesn’t, and eventually, it might stop working completely. What You Can Do to Prevent Heat Damage The good news is that most heat-related damage to key fobs is preventable with just a little care and awareness. First, never leave your key fob inside a parked car for extended periods, especially not in direct sunlight. It’s easy to toss your keys into the cup holder or leave them on the dashboard while you run errands, but those few minutes can expose them to dangerous levels of heat. Instead, keep your keys on you or store them in a shaded, temperature-controlled area. If you’re regularly in hot environments — such as driving in warm climates or working outdoors — consider investing in a protective silicone or leather cover. These not only shield the shell from heat exposure but also provide added protection against drops and dirt. You should also make it a habit to replace your battery once a year, even if it seems to be working fine. Batteries weakened by heat can fail suddenly, and a fresh cell ensures your key fob keeps working when you need it most. Finally, if your key fob’s shell is visibly worn or loose, replace it immediately. Many online stores, including Mr Key, offer affordable replacement shells that are easy to install and give your remote a like-new feel. Don’t wait for the damage to reach the internal electronics — by then, repair options are limited and usually more expensive. Protect Your Key, Protect Your Drive Your car key fob might be small, but it plays a huge role in your daily routine. From unlocking doors to starting your engine, it’s a modern convenience we all depend on — until it stops working. And while many drivers are careful with their car’s mechanical systems, few think twice about leaving their key fob in the heat. Now that you know how much damage summer temperatures can cause, you can take the steps needed to protect your key before it’s too late. If you’re looking for high-quality key shell replacements, batteries like the CR2032, or even complete key fobs compatible with your vehicle, Mr Key has you covered. Our online shop offers trusted parts for Peugeot, Citroën, Nissan, Suzuki, Fiat, and more — all designed to help you repair and maintain your car keys quickly and affordably.

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 Know If Your Car Key Has a Hidden Transponder Chip
29.04.2025

How to Know If Your Car Key Has a Hidden Transponder Chip

Modern car keys are more than just simple tools to unlock doors—they're powerful components of your vehicle’s security system. Hidden inside many keys is a small yet crucial piece of technology known as a transponder chip . But how can you tell if your car key has one? Whether you’ve lost your key, are looking to replace it, or simply want to understand your vehicle better, knowing if your key contains a transponder chip is essential. This guide will explain what a transponder is, why it matters, and how you can easily check if your key is equipped with one. What Is a Transponder Chip? A transponder chip, short for "transmitter + responder," is a small electronic microchip embedded inside the plastic head of the car key or within a smart key fob. When you insert the key into the ignition—or have it nearby in a push-button start system—the chip emits a unique signal. The vehicle’s onboard computer must recognize this signal before it will allow the engine to start. Without the correct signal, even if the key physically fits into the ignition, the car won’t move. Transponders have been a game-changer in reducing car theft, and today, nearly all vehicles produced after the late 1990s are equipped with them. Learn more about how modern keys work and find replacement options in our car keys collection. Why It’s Critical to Know If Your Key Has a Chip If your key has a hidden transponder chip, replacing it is more complicated than simply cutting a new metal key. You will need a key that not only matches the cut but also includes the correct programming to communicate with your car’s immobilizer system. Failing to recognize this can lead to frustration, extra dealership fees, or even being stranded. Moreover, understanding your key's technology helps you make smarter choices when buying a spare, upgrading your security setup, or troubleshooting ignition issues. How to Check If Your Car Key Has a Transponder Chip Fortunately, you don’t need expensive equipment to find out. Start by considering the age of your vehicle: if your car was manufactured after 1995 (in Europe) or 1998 (in the USA), chances are very high it uses a transponder system. Next, examine the physical key. Keys with large, bulky plastic heads usually house a chip inside. In contrast, purely metallic keys without plastic parts tend to belong to older, non-transponder vehicles. You can also perform a simple foil test. Wrap the head of your key in aluminum foil and try to start the car. Since foil blocks radio frequencies, if the car refuses to start, it’s likely that a transponder chip is present. If you want absolute certainty, consult your vehicle’s manual or speak with a professional locksmith. Many locksmiths use specialized tools to detect whether a chip exists. For additional technical explanation, you can refer to this guide on how immobilizer systems work. What Happens If the Transponder Signal Is Missing? If you try to start your car without the proper transponder signal, the immobilizer system kicks in. Most vehicles will either not crank at all or crank without allowing the engine to fire. Some models will display a warning light on the dashboard, often shaped like a padlock or a car with a key icon. Without a valid transponder signal, you won't be going anywhere—no matter how new or well-cut the key is. Can You Program a Transponder Key Yourself? Depending on the make and model of your car, some basic keys can be programmed at home—especially if you already have one working key available. However, many newer vehicles require professional diagnostic tools connected directly to the car’s computer to program keys securely. Attempting DIY programming on these systems without the right knowledge can lock your car’s immobilizer and lead to expensive repairs. Always consult your car’s manual or seek professional help before attempting any programming yourself. Knowledge = Protection Understanding whether your car key contains a hidden transponder chip isn’t just a fun fact—it's essential for protecting your vehicle and saving yourself time, money, and hassle. Whether you're planning to replace a worn-out key, add a backup, or upgrade your security, knowing what’s inside your key helps you make better, safer decisions. If you ever need a spare key, a battery replacement, or advice on key maintenance, you can explore more in our online store at Mr Key . Remember: a smart driver is a secure driver. Stay informed, stay prepared, and you'll always stay one step ahead.

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