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What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them

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  • What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them
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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.

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Brink / Thule – Thule’s towing division (now Brink) uses ACS keys for many of its detachable hitches. If you have a Thule or Brink detachable towbar, check for an ACS code on the lock. (Brink/Thule locks with codes like 1D## or 2D## are a different series – but ACS## codes are common on earlier Thule/Brink models.) Witter – A very popular towbar brand, Witter uses the ACS system on their detachable swan-neck towbars. A Witter detachable with an ACS key will have “ACS” on the key or lock face. Witter towbar key replacements are readily available by code. GDW – This European towbar manufacturer also uses ACS-series keys for many detachables. If you need a GDW towbar replacement key, the process is the same: find the ACS## code and order a matching key. Tow-Trust – TowTrust (Tow-Trust) towbars, often sold in the UK and EU, utilize ACS keys as well. Tow-Trust detachable models with ACS locks will have codes ACS01–ACS10 on the keys. Other brands like PCT Automotive or Towsure have also been known to use ACS locks in some of their detachable towbar systems. The key point is that multiple brands share this ACS key design. So whether your hitch is labeled Witter, Thule, Brink, GDW, or TowTrust, if the key code starts with ACS, you can get the correct replacement towbar key by that code. This compatibility makes it easier to find spares, since one good supplier can cover many brands under the ACS series. Quick Reference: ACS Key Codes and Brands For easy identification, here’s a summary of which detachable towbars use the ACS01–ACS10 key range: Towbar Brand Detachable Key Code Series Example Key Code ACS (A50-X system) ACS01 – ACS10 ACS07 (on key/lock) Brink (Thule Towbars) ACS01 – ACS10 ACS05 Witter ACS01 – ACS10 ACS03 GDW ACS01 – ACS10 ACS09 Tow-Trust ACS01 – ACS10 ACS02 If your towbar brand is listed above and you see an “ACS*” code on the lock, you can order a new key by that code. 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Select your key code – On the product page, choose your exact code (say, ACS04 or ACS09) from the dropdown or list. 4. Place your order – Add the replacement key to your cart and check out. These keys are very affordable (usually only a few dollars or euros each), and you can often choose expedited shipping if you’re in a hurry. 5. Receive and test the key – Shipping is typically quick (a few days within Europe). Once it arrives, test the replacement towbar key in your detachable towbar’s lock. It should turn smoothly and unlock the mechanism just like the original. Problem solved. Product Link: https://mr-key.com/product/spare-key-for-acs-a50-x-brink-thule-towbar-codes-acs01-acs10 You can order the correct replacement key here: Spare Key for ACS A50-X / Brink / Thule Towbar – Codes ACS01–ACS10. Simply select your code from ACS01 up to ACS10 and choose the key with the matching number. The new key will be cut to that code and sent to you ready to use. 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Having multiple keys means you’re highly unlikely to ever be locked out of your own towbar again. Losing your towbar key can be a frustrating experience, especially when it happens right before you need to use it. But if your detachable towbar uses the ACS lock system (codes ACS01–ACS10), solving the problem is straightforward. With a visible ACS key code and a reliable online key-cutting service, you can quickly get a new replacement towbar key cut to code and delivered. There’s no need for costly new locks or last-minute cancellations of your towing plans. Don’t let a lost towbar key ruin your trip. Take a moment to check your towbar for an ACS code. If it’s there, you can have a new key on the way in no time. And even if your current key is in hand, think ahead – get a spare made now to save yourself stress later. With fast online ordering and prices that won’t break the bank, getting an ACS towbar key replacement is the easiest way to ensure you’re never stuck without the key to your adventures. Safe towing.

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