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

Can a Locksmith Cut a Key from a Photo or Code?
12.11.2025

Can a Locksmith Cut a Key from a Photo or Code?

Short answer: yes— for many keys, a locksmith can cut accurately from a photo or a code . The details depend on the key type, the quality of the image/data. Key cutting from code vs from photo By code (most precise). A key code (often printed on locks, key tags, or documentation) translates into a series of cut depths called the bitting . On a code machine, a locksmith dials those depths and cuts a new key without the original present . This is the preferred method for many utility keys (e.g., caravan, retro auto, e-bike battery, furniture, mailboxes, ATVs, roof racks, towbars), but also for car keys. By photo (works in many cases). From a clear, square-on image, a trained technician can decode the cut depths and reproduce the bitting. Research has shown keys can be recreated from ordinary or telephoto shots if the profile and scale are known. This is why publishing close-ups of your keys is discouraged. When a photo is “good enough” If you’re ordering car keys cut by photo or utility keys by photo , expect guidelines like: Flat, well-lit, high-resolution image; key blade perfectly side-on. Ruler/coin in frame for scale; entire blade visible, shoulder to tip. For double-sided/laser keys, shots of both sides. Keyway/profile identification (brand/series). Automotive: cutting from photo or code—plus programming Cutting the blade is only step one for modern cars. Since the late 1990s, most vehicles have immobilisers ; the key’s transponder chip must be recognised or the engine won’t start. In practice: Get the correct blank and cut it (photo or code). Program the transponder/remote (OBD or on-board procedures), or pair a proximity fob. Test mechanical operation and ignition start. Main points UK readers should know: Immobiliser/transponder tech became standard in the mid-1990s; without a programmed chip, a correctly cut key usually won’t start the car. A key code specific to your vehicle lets a locksmith/dealer cut precisely without an original; some guides explain where owners can find it. Utility keys we commonly see cut by code If you have the key code , these are routinely cut accurately online: Retro automobile keys (classic patterns; often stamped codes). Caravan & motorhome key s (e.g., ZADI, FAP/FAWO—codes on barrels). E-bike battery keys (e.g., ABUS/AXA series). Furniture, mailboxes keys (office furniture, cam locks). ATV/quad ignition and compartment keys. Roof racks (e.g., Thule N*** series). Towbars (e.g., Westfalia/Brink code series). For these categories, supplying the printed code (from the lock face, key head, manual, or tag) usually yields the fastest, most reliable result compared to photos. Accuracy expectations & limitations What typically works well Flat cylinder keys with standard depth systems (common utility keys). Many car blades (including laser/sidewinder) if the image is clean and scaled. Keys where the lock/brand series is known and the bitting can be derived . What may be restricted or not feasible from a photo Patented/restricted keyways (require authorised proof and controlled blanks). Highly worn, bent, or obscured keys in photos. Complex security keys that need factory or authorised dealer processes. Car keys where programming tokens, PINs, or security codes are required. For security and consumer protection in the UK, look for MLA-approved locksmiths and insist on identity/ownership checks for sensitive work. Real-world risk: why photos can be enough Academic work and well-reported incidents show that key geometry can be decoded from images at surprising distances. Media have covered expensive lock replacements after keys appeared on camera, underlining the practical risk of sharing key images online. Keep your keys out of frame. What an online order typically requires For car keys (photo or code): Vehicle make/model/year, blade type, and VIN if needed for code retrieval. Clear photos (both sides). Programming method: mobile visit, on-site, or mail-in ECU/fob (varies by model). Expect additional steps for remote locking and proximity systems. For utility keys (cut by code): The code from the lock face or original key (e.g., N123 , Z **). Brand or system (Thule, Zadi, Westfalia, etc.). Quantity and turnaround needs (next-day options often available). Speed and success rates By code : fastest and most consistent for; minimal adjustment needed. By photo : slightly more validation and back-and-forth; still accurate when images meet spec. Why choose an online key cutting service like MR-KEY Unlike traditional emergency locksmiths who mainly handle urgent lockouts, MR-KEY specialises in precision key cutting from photos or codes — ideal when you’re not locked out but need an exact replacement or spare . Through our online platform, you can: Order from anywhere in the UK — simply upload a clear photo or enter your key code. Get fast, expert cutting using professional decoding software and calibrated machines. Receive your key by post , ready to use or, for vehicles, to be programmed locally. With MR-KEY, you save the cost and time of a mobile visit while still getting locksmith-level precision. Each key is verified before dispatch to ensure perfect fitting and reliable operation. FAQs Can a locksmith cut a car key from a photo? Often yes, the blade can be cut from a high-quality photo , but modern cars also need transponder/immobiliser programming before the engine will start. Is cutting by code more accurate than using a photo? For most utility keys , yes . A verified key code maps to exact cut depths, making the process highly repeatable and quick. Can someone copy my key from a social media photo? It’s technically possible; public cases and research have shown keys can be decoded from images . Avoid posting close-ups of keys online. What’s the difference between “key cutting,” “key replacement,” and an “emergency locksmith”? Key cutting : the physical milling of a blade (by code/copy/photo). Key replacement : end-to-end service supplying a working key/fob (cutting + programming if needed). Emergency locksmith : rapid response for lockouts or urgent access/security issues. Order your new key today at mr-key.com — fast, accurate, and cut by professionals from your photo or code.

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.

Car Key Replacement: What to Do, How It Works, and When DIY Saves You Money
14.04.2025

Car Key Replacement: What to Do, How It Works, and When DIY Saves You Money

Losing or breaking your car key can feel like a full-blown emergency. Whether your key won’t turn in the ignition, your remote suddenly stops responding, or you’ve misplaced the whole thing entirely, one thing is certain: you need a replacement—and fast. While most people assume that replacing a car key requires a trip to the dealership and a hefty bill, that’s no longer the only option. In fact, depending on your situation and car model, you may be able to handle it yourself with minimal cost and effort. Here’s what you need to know. Why Car Keys Are More Complicated Than You Think Gone are the days when a spare key meant heading to your local hardware store and getting a basic metal key cut in minutes. Today’s car keys are advanced devices that often include transponder chips, remote locking systems, and built-in immobilizers. Some even come as proximity fobs that allow push-button starting without ever taking the key out of your pocket. Because of this, replacing a lost or damaged key isn’t just about cutting a new blade—it often involves electronic programming and matching frequencies to your specific vehicle. Dealer, Locksmith, or DIY? Your Replacement Options When it comes to replacing a car key, you typically have three choices: Dealership : Offers official replacements, but often at the highest cost. Auto Locksmith : Generally more affordable and mobile, but availability varies. DIY : Ideal for shell replacements, battery swaps, and some remote keys—if you already have a functioning spare key or understand your model's programming process. If you’ve damaged your key shell or the battery has died, DIY is a surprisingly good option—especially if you’re comfortable working with small components. The Rise of DIY: Save Time, Learn Something, and Avoid Dealer Fees More and more drivers are discovering how easy it can be to fix their own car keys. Whether it’s replacing a worn key case, changing a battery, or even installing electronics into a new shell, DIY key repair is growing in popularity. To support that trend, we’ve created a full library of free video tutorials showing how to disassemble and reassemble key fobs for dozens of car models—from BMW and Audi to Peugeot, Fiat, and Toyota. These easy-to-follow guides show exactly how to change a key battery, switch a shell, or upgrade to a new case in minutes. 👉 Check out the full tutorial playlist on our YouTube channel: Mr-Key DIY Tutorials Step-by-Step: Replacing a Battery or Shell at Home Let’s say your remote still works but the case is cracked or the buttons are worn down. In that case, replacing just the outer shell is often all you need to do. Here’s a quick look at what that might involve: Carefully open the old key shell using a flat screwdriver. Remove the internal electronics and transponder chip. Insert them into your new replacement shell. Reinstall the battery or replace it with a fresh one (typically a CR2032 or CR1620). Snap everything together and test the key. If you already have a functioning key and just want a backup, some car models even allow you to program a new key yourself. Always check your owner’s manual or look up on-board programming methods by vehicle brand. Choosing the Right Key or Shell Not all replacement keys are created equal. Here’s what to consider: Chip Type : Most modern cars use a transponder chip (like ID46, PCF7946, etc.). Make sure your new key has the correct one. Blade Profile : HU83, VA2, TOY43—these are just a few examples. Match your key blade exactly. Frequency : Remote keys operate on specific frequencies (433MHz and 868MHz are most common in Europe). You can find affordable, compatible replacement shells and key fobs at reputable online stores like mr-key.com . When to Call a Pro There are still some situations where professional help is the smarter option: You’ve lost all copies of your key. Your car requires encrypted key coding with dealer-only tools. Your key has a broken or unresponsive transponder chip. In those cases, a locksmith or dealership may be necessary. Don’t Overpay—Just Be Prepared Car key replacement doesn’t have to be expensive, stressful, or time-consuming. In many cases, you can replace the shell, battery, or even the entire fob yourself—especially with a little guidance. Our Mr-Key YouTube channel is here to walk you through it. Whether you’re fixing a key today or preparing for the future, knowing your options puts you in control. And sometimes, the right tutorial is all it takes to save the day (and a lot of money).

Hydrogel vs Tempered Glass Navigation Protectors Comparison
04.12.2025

Hydrogel vs Tempered Glass Navigation Protectors Comparison

Cars and vehicles nowadays often include large touchscreen navigation systems that are prone to scratches, fingerprints and cracks. These displays are expensive to replace – one owner reported a factory infotainment screen costing over $3,000 to swap out – so protecting them is crucial. That’s where navigation screen protectors come in. The two main options are hydrogel film protectors and tempered glass protectors . Below, we compare hydrogel vs tempered glass for car navigation screens, looking at fit, durability, clarity and more, so you can choose the best protection for your car. Hydrogel vs Tempered Glass: The Essentials Tempered glass protectors A rigid, hard 9H glass shield. Excellent scratch resistance, very clear, and feels like the original screen. Best for completely flat displays. Hydrogel protectors A flexible, self-healing polymer film originally used in aviation and military applications. Ultra-thin, edge-to-edge fit, excellent for curved or uniquely shaped screens. Key difference: Hydrogel bends. Tempered glass doesn’t. Fit & Coverage (Hydrogel Wins) Modern cars often have curved or tapered displays. Tempered glass cannot follow these shapes, leaving exposed edges, air gaps or weak adhesion points. Hydrogel protectors conform perfectly to flat, curved and 3D-shaped screens. They wrap the edges, eliminate halo gaps, and achieve full-surface coverage. If your car’s screen isn’t perfectly flat, hydrogel is the correct choice. Scratch & Impact Protection Tempered glass: Extremely resistant to scratches Can crack on impact, sacrificing itself to protect the screen Once cracked, must be replaced Hydrogel: Softer surface, but self-heals micro-scratches over time Doesn’t shatter; absorbs everyday bumps Ideal for preventing long-term wear and swirl marks Glass is harder; hydrogel stays clearer longer thanks to self-healing. Clarity, Glare & Touch Sensitivity Both types maintain high clarity and touch accuracy, but behave differently in real use: Tempered glass: Ultra-clear Glossy surface shows fingerprints easily Good touch response Hydrogel: Crystal-clear or matte anti-glare options Reduces reflections in sunlight — very useful in cars Zero touch interference due to ultra-thin structure Minor micro-bubbles self-resolve within hours If you drive in bright sun or hate fingerprint shine, hydrogel’s matte option is a major advantage. Installation & Removal Tempered glass: Simple dry install One-shot alignment Rigid, so easy to place but unforgiving if misaligned Hydrogel: Dry or wet install Allows micro-adjustments Easy bubble removal No cracking during installation Removal is simple for both, though hydrogel is safer (no glass shards, no risk of breakage during removal). If you want to learn more about how to install your hydrogel navigation screen protector visit our guide. Which Should You Choose? For general car owners with modern infotainment systems, the winner is clear: ✔ Hydrogel protectors are better for most car navigation screens. Why: Perfect fit on curved screens Self-healing surface Anti-glare options Full edge-to-edge coverage Zero loss in touch sensitivity Tempered glass is fine for older or perfectly flat screens — but today’s automotive displays benefit more from hydrogel technology. FAQ Does a navigation screen really need protection? Yes. Screens scratch easily, attract fingerprints, and are expensive to replace. A protector preserves clarity and resale value. Is hydrogel or tempered glass better overall? Hydrogel — unless your screen is perfectly flat. It fits better, reduces glare, and self-heals surface scratches. Will a protector affect touch response? No. Both types maintain excellent touch accuracy. Hydrogel is especially responsive due to its thin, adaptive structure. How do I protect my screen from fingerprints and glare? Use a matte hydrogel film. For more techniques, see our guide on [ How to Protect Your Car’s Navigation Screen from Scratches, Glare & Fingerprints ] . Which cars benefit most from hydrogel protection? Any model with curved, large, glossy or high-resolution displays. See our model list: [ Which Cars Benefit Most From Hydrogel Navigation Protection? ] . For custom-cut hydrogel protectors for your exact car model, visit mr-key.com . Related Guides How to Protect Your Car’s Navigation Screen from Scratches, Glare & Fingerprints How to Install a Hydrogel Navigation Screen Protector Which Cars Benefit Most From Hydrogel Navigation Protection?

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