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

How to Identify the Right Replacement Key Shell for Your Car
25.03.2025

How to Identify the Right Replacement Key Shell for Your Car

If your car key shell is cracked, worn, or the buttons no longer press properly, replacing it with a new shell is often the most affordable and effective solution. But one major challenge stands in the way: figuring out exactly which replacement shell you need. With so many variations in blade types, button layouts, and internal compatibility, it’s easy to buy the wrong part—and waste both time and money. This guide breaks down how to identify the correct key shell for your car, so you can upgrade or replace your damaged remote housing without confusion. Step 1: Identify Your Key Blade Type One of the most important features is the key blade. Even within the same car brand, different models and years may use different blade types. Two of the most common are: HU83 blade – Used by many Peugeot and Citroën models. It has a curved groove on both sides. VA2 blade – Similar in appearance but has a flat groove instead of a curve. Other types include TOY43, TOY47, and SIP22, often used in Toyota, Fiat, and other manufacturers. If you're unsure, comparing your blade side-by-side with online reference images helps avoid errors. Tip: Never rely only on the number of buttons—focus on the blade profile first. Step 2: Count and Match the Button Layout Next, verify how many buttons your original key has, and in what layout. Common options include: 2 buttons: Lock / Unlock 3 buttons: Lock / Unlock / Trunk Smart keys: May have a more complex layout or hidden emergency blade Even a small difference in layout can prevent the rubber buttons from pressing the internal switches correctly. Also check whether the button pad is integrated into the case or if it’s a separate piece. That may affect your fit. Step 3: Check the Internal Electronics Placement When swapping a shell, you’ll be transferring the circuit board and (in most cases) a transponder chip. The replacement case must have: The same mounting points and slots Space for the battery (check if yours is CR1620, CR2032, etc.) A similar design to support the flip mechanism, if your original key has one If the internal layout doesn’t match, your circuit board may not sit securely—or your buttons may not work. Bonus tip: Open your old key carefully and take photos of the internal structure before ordering a shell. Step 4: Consider the Key Type – Flip or Fixed There are two main styles: Flip keys: Blade folds into the case and pops out with a button press Fixed blade keys: Blade is static and exposed You must match your replacement with the original style, unless you're intentionally upgrading. Flip key conversions are popular, but they require extra parts and a bit more installation effort. Step 5: Check the Model Compatibility List Many key shells are marketed as being compatible with a range of car models. Look for a list that includes: Your vehicle’s make and model The production years (e.g., “Peugeot 207 2010–2014”) Even then, cross-reference with your physical key—models change subtly across production years. Step 6: Know What You're Not Getting A replacement key shell typically does not include: The circuit board (you must transfer it from your old key) The transponder chip A pre-cut blade (unless stated) You’ll likely need to cut the new blade or reuse the old one if it's detachable. Choosing the right replacement key shell doesn't have to be trial and error. By focusing on blade type, button layout, and internal structure, you can confidently find a case that fits your needs—and your key electronics. It’s a simple fix that extends the life of your existing key without the cost of a full replacement. Just take your time, check the details, and match your original key carefully. A few minutes of inspection now can save hours of hassle later.

Exploring the Future of Car Key Technology: What’s Next?
02.08.2024

Exploring the Future of Car Key Technology: What’s Next?

In the rapidly evolving world of automotive technology, car keys have transformed from simple metal tools into sophisticated electronic devices. As vehicles become smarter, so do their keys. From keyless entry to biometric authentication, car key technology continues to push boundaries. Let’s explore the next frontier of car key innovations and how they’ll impact convenience, security, and vehicle ownership. 1. Digital Keys: Unlocking with Your Smartphone One of the most exciting advancements is the rise of digital keys. These allow you to unlock and start your car using just your smartphone. How It Works: Digital keys rely on Bluetooth or NFC (Near Field Communication) technology to securely transmit signals between your phone and the car. Convenience: No more fumbling for keys. Your phone acts as your all-in-one device. Security Features: Many digital key apps offer encrypted access and the ability to revoke permissions instantly if your phone is lost or stolen. This innovation is gaining traction among automakers and is expected to become standard in the near future. 2. Biometric Authentication: Keys That Recognize You Biometric car keys are already starting to appear in premium vehicles. These keys use your unique physical features to grant access. Fingerprint Recognition: Similar to unlocking your phone, some car keys now scan your fingerprint to unlock the car. Facial Recognition: Cameras built into the vehicle can identify you and automatically unlock the doors. Why It Matters: Biometrics provide an additional layer of security, making it nearly impossible for thieves to gain unauthorized access. This cutting-edge technology ensures that only you—and those you authorize—can start your vehicle. 3. Smart Key Customization: Personalization at Its Best The future of car keys isn’t just about unlocking cars; it’s about creating personalized driving experiences. Pre-Set Preferences: Smart keys can remember your seat position, climate control settings, and even your preferred music playlist. User Profiles: In households with multiple drivers, smart keys can switch profiles based on who’s using the car. Why It’s Useful: This feature saves time and enhances comfort, making every drive tailored to your needs. As vehicles become more personalized, smart keys will play a vital role in delivering these conveniences. 4. Ultra-Secure Encryption: Fighting Key Hacking As technology advances, so do the tactics of cybercriminals. To combat this, car key technology is embracing stronger encryption. Rolling Codes: Modern key fobs use rolling codes that change with every use, making it harder for hackers to intercept signals. Blockchain Technology: Some experts predict that blockchain could be integrated into car key systems for unbreakable security. Impact on Security: These measures aim to eliminate vulnerabilities, ensuring that only the rightful owner can access the vehicle. Advanced encryption is a critical step in securing the future of car ownership. 5. Integration with Smart Homes: A Connected Lifestyle Imagine your car keys working seamlessly with your smart home devices. This future is closer than you think. Examples: Unlock your car and have your home’s lights turn on simultaneously. Use voice commands to lock your car doors through your home assistant. Convenience Factor: This integration enhances the interconnectedness of your daily routines, saving you time and effort. As smart ecosystems grow, car keys will become a pivotal part of a connected lifestyle. 6. Eco-Friendly Innovations: Sustainable Car Keys Sustainability is a growing concern in all industries, including automotive technology. Car keys are no exception. Recyclable Materials: Future car keys could be made from eco-friendly or recycled materials. Energy-Efficient Batteries: Expect longer-lasting, rechargeable batteries that reduce waste. Why It Matters: These changes not only benefit the environment but also align with the broader push toward sustainable vehicle manufacturing. As the industry shifts toward greener practices, even car keys are becoming part of the solution. A New Era of Car Keys Car key technology is on the cusp of incredible transformations, combining convenience, security, and sustainability. Whether through digital keys, biometrics, or smart home integration, the future holds endless possibilities for making your driving experience safer and more seamless. For car owners, these innovations mean less hassle, greater control, and enhanced peace of mind. As car key technology evolves, so does the way we interact with our vehicles—ushering in a new era of smarter and more secure mobility.

How to Properly Maintain Your Car Keys and Lubricate Locks: A Complete Guide
24.01.2025

How to Properly Maintain Your Car Keys and Lubricate Locks: A Complete Guide

Car keys and locks are everyday essentials that we often take for granted—until they malfunction. From ensuring the longevity of your car keys to properly lubricating locks for smooth operation, maintenance plays a vital role in avoiding inconvenience and costly repairs. In this guide, we explore how to care for your car keys and master the art of lock lubrication. Common Issues with Car Keys and How to Prevent Them Car keys are more than just tools; they’re lifelines to your vehicle. Whether you have a traditional metal key or an advanced smart key, these essential devices are prone to wear and tear. Understanding common problems and their solutions can save you time and stress. 1. Worn-Out Key Blades Over time, the metal blades of traditional car keys can become worn, making it difficult to start your car. This is especially common in keys used frequently or roughly. To prevent this, avoid using your car key for tasks like opening packages or prying objects. 2. Weak Key Fob Batteries For those with remote or smart keys, a weak battery is a common issue. A fading signal or difficulty locking/unlocking your car remotely are signs it’s time for a battery replacement. Replacing the battery every 1-2 years can help maintain consistent performance. 3. Scratched or Damaged Smart Keys Smart keys have sensitive electronics that can be damaged by rough handling or exposure to extreme temperatures. Always store your key in a protective case and keep it away from direct sunlight or freezing conditions. Pro Tip: Always have a spare key on hand. This not only saves time during emergencies but also reduces the wear on your primary key. Why Locks Need Regular Lubrication Locks are intricate mechanisms designed to provide security. However, dirt, grime, and regular use can cause them to stick or malfunction. Lubrication ensures smooth operation and prevents long-term damage. How Locks Deteriorate Locks endure constant exposure to the elements, which makes them vulnerable to dirt, dust, and moisture. Over time, these factors can lead to stiffness, making it difficult to turn the key. If left unchecked, the lock may become entirely unusable, requiring costly replacement. Choosing the Right Lock Lubricant Not all lubricants are created equal, and choosing the right one is crucial for maintaining your locks. Here are the best options: Graphite Powder This dry lubricant is a top choice for locks. It doesn’t attract dust and provides smooth operation without residue build-up. Silicone Spray Silicone-based sprays offer moisture resistance and work well for both interior and exterior locks. Avoid over-applying, as excess lubricant can attract grime. Avoid Oil-Based Lubricants Products like WD-40 may seem convenient but are not ideal for locks. They can attract dirt and worsen the problem over time. Step-by-Step Guide to Lubricating a Lock Follow these steps to keep your locks functioning flawlessly: Clean the Lock Begin by removing visible dirt and debris using a soft brush or compressed air. This ensures the lubricant can reach internal components effectively. Apply Lubricant Insert the nozzle of your lubricant into the keyhole and spray or apply a small amount. If using graphite powder, gently squeeze the bottle to distribute the powder evenly. Insert and Turn the Key Insert your key and turn it several times to distribute the lubricant throughout the lock mechanism. Test the Lock Check the lock’s operation by locking and unlocking it multiple times. If it still feels stiff, reapply a small amount of lubricant. Pro Tip: Lubricate locks every 6-12 months, or more frequently if they’re exposed to harsh weather conditions. Maintenance Tips for Long-Term Performance 1. Protect Outdoor Locks For locks exposed to the elements, such as gates or sheds, consider using a lock cover to shield them from rain and snow. Regularly inspect and lubricate these locks to prevent rust and corrosion. 2. Store Spare Keys Properly Spare keys should be kept in a safe, dry place. Avoid leaving them in areas with high humidity, as moisture can lead to rust on metal keys. 3. Address Issues Early If you notice stiffness or difficulty turning a key, address the issue immediately. Ignoring minor problems can lead to complete lock failure. The Global Perspective on Lock and Key Maintenance Different regions face unique challenges when it comes to maintaining locks and keys. In cold climates, freezing temperatures can cause locks to seize, requiring specialized de-icing sprays. In humid or coastal areas, locks are more prone to rust and may need frequent lubrication to combat corrosion. Meanwhile, digital locks are becoming increasingly popular in urban areas worldwide. These systems require their own maintenance, such as software updates and battery replacements, to ensure optimal functionality. A Little Maintenance Goes a Long Way Caring for your car keys and locks is a small investment of time that can save you from major inconveniences. By taking preventative steps like lubricating locks and protecting your keys, you can ensure their longevity and performance. Take a moment today to inspect your keys and locks. Are they in optimal condition? If not, a quick round of maintenance can make all the difference. For more insights on maintaining your everyday essentials, explore our other articles and unlock the secrets to hassle-free living.

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!

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