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

The Secret to Smooth Locks: How (and Why) to Lubricate Your Locks Like a Pro
29.01.2025

The Secret to Smooth Locks: How (and Why) to Lubricate Your Locks Like a Pro

Regular lock maintenance is essential to prevent key jamming or lock failure. Proper lubrication reduces wear and tear, ensures smooth operation, and extends the lifespan of your locks. A well-lubricated lock decreases the risk of your key getting stuck or breaking inside the lock—an inconvenient and costly problem. At MR-KEY , we understand the importance of well-maintained locks and want to help you keep yours in top condition. How Often Should You Lubricate Your Locks? For most locks, lubricating them every three to six months is sufficient. However, locks exposed to extreme weather conditions—such as those on towbars, roof racks, or outdoor gates—require more frequent maintenance. Rain, dust, and freezing temperatures can cause internal components to stick, making it difficult to insert or turn the key. If you notice resistance when using a lock, it’s time for lubrication. What Lubricant Should You Use for Locks? Choosing the right lubricant is crucial for long-term lock performance. Here are the best options: • Teflon-based (PTFE) spray – Forms a protective film inside the lock, reducing friction and repelling dust buildup. • Dry silicone spray – Excellent for outdoor locks as it resists moisture without attracting dirt. • WD-40 Specialist Dry PTFE or White Lithium Grease – Unlike regular WD-40, these provide long-lasting lubrication and protection against corrosion. • Graphite powder – A great choice for older locks but should not be used if there’s oil residue inside the lock. While WD-40 Multi-Use is a quick fix for stuck locks, it is primarily a cleaner rather than a long-term lubricant. If used, follow up with a dry lubricant to prevent dirt accumulation inside the lock. How to Lubricate a Lock If your lock is functioning properly but feels slightly stiff, follow these steps: 1. Clean the Lock – Insert and remove the key a few times to dislodge debris, wiping it clean each time. 2. Apply the Lubricant – Insert the spray straw into the keyhole and apply two short bursts of lubricant. 3. Work the Lock – Insert and turn the key multiple times to distribute the lubricant inside. 4. Wipe Excess Lubricant – Remove any residue from the key and lock exterior to prevent dirt buildup. For graphite powder , follow the manufacturer’s specific instructions, as overapplication can lead to clumping inside the lock. Special Care for Towbar and Roof Rack Locks Locks on towbars and roof racks are exposed to harsher conditions than typical door locks. To keep them in good shape: • Regularly inspect them for stiffness or corrosion. • Apply dry silicone spray or PTFE lubricant for lasting protection. • If the lock is exposed to frequent moisture, white lithium grease offers superior water resistance. Lock It in: The Key to Long-Lasting Security Regular lock maintenance is a small effort that prevents big problems. By keeping your locks clean and properly lubricated—especially those exposed to the elements—you can avoid costly repairs and ensure they function smoothly for years. For high-quality lock maintenance products, visit MR-KEY and keep your locks in perfect working condition. A little maintenance goes a long way in ensuring security and peace of mind!

How to Locate Your Key Code for a Replacement
20.08.2024

How to Locate Your Key Code for a Replacement

Losing a key can be a hassle, but the process of getting a replacement becomes much easier if you can locate the key code. The key code is a unique combination of letters and numbers that identifies the specific cut and type of your key. This code is essential for accurately replicating a new key, whether it’s for your car, house, or another type of lock. This guide will help you understand where to find your key code and what steps you can take if the code isn’t easily accessible. Why the Key Code is Important The key code is essentially a blueprint for your key. It tells a locksmith or dealer exactly how to cut a new key that will work with your lock. Without this code, creating a replacement key can be a trial-and-error process, which can be time-consuming and costly. Additionally, for certain types of keys, such as those for cars with transponder chips, the key code is necessary for programming the electronic components of the key. Step 1: Inspect Your Key and Lock The first and most straightforward step is to inspect your key and lock for the key code. For many keys, especially older models, the code is engraved or stamped directly onto the key itself. This is common with car keys, where the code may be found on the metal part of the key blade. In some cases, the code might be on the plastic casing of the key, especially if it’s a newer model with electronic components. If the key itself doesn’t have the code, check the lock. The key code is sometimes inscribed on the lock’s cylinder or on a small metal plate attached to the lock. This is more common with padlocks or specialized security locks. If you’re dealing with a door lock, you might need to remove the lock from the door to inspect it closely. Step 2: Review Documentation and Original Packaging If you can’t find the key code on the key or lock, the next step is to review any documentation or packaging that came with the key. For vehicles, the key code is often provided in the owner’s manual or on a key tag that was given to you at the time of purchase. This tag is usually small and easily misplaced, so it’s worth checking any old documentation or vehicle paperwork you might have. For other types of keys, such as those for padlocks, cabinets, or office furniture, the key code might be printed on the original packaging or on warranty cards. These are often overlooked, but they can be invaluable when you need a replacement key. Step 3: Contact the Manufacturer or Dealer If the key code isn’t visible on the key, lock, or documentation, your next step should be to contact the manufacturer or dealer. Most car manufacturers, for example, keep a record of key codes based on the Vehicle Identification Number (VIN). By providing your VIN to a dealership, they can usually retrieve the key code and either cut a new key for you or give you the information needed to get one cut elsewhere. For other types of keys, such as those for cabinets or padlocks, contacting the manufacturer can also be helpful. Provide them with details about the product, such as the model number and any serial numbers, and they may be able to provide the key code or a replacement key directly. Step 4: Professional Locksmith Assistance If you’ve exhausted all other options, a professional locksmith is your best bet. Locksmiths have specialized tools and knowledge that allow them to decode locks or determine the correct key code even when it’s not visible or available through documentation. They can often cut a new key based on the lock itself, bypassing the need for the original key code entirely. Locksmiths are particularly useful if you’re dealing with older locks, unique security systems, or if the key code is no longer accessible through traditional means. They can also help with programming transponder keys for vehicles, ensuring that your new key not only fits the lock but also communicates correctly with your car’s electronic systems. Additional Tips for Key Code Location Record Key Codes: If you find your key code, make sure to record it somewhere safe. This will save you time if you need another replacement in the future. Ask About Spare Keys: If you’re contacting a dealership or manufacturer, ask if they can provide a spare key at the same time, especially if you’re prone to losing keys. Consider a Key Tracking System: For those who frequently lose keys, consider investing in a key tracking system or a digital key organizer where you can store key codes and important information. Locating your key code is a crucial step in the process of replacing a lost or broken key. By carefully inspecting your key and lock, reviewing any relevant documentation, contacting the manufacturer or dealer, or seeking help from a professional locksmith, you can ensure that your replacement key is accurate and functional. Taking these steps not only saves time and money but also provides peace of mind in knowing that you have a reliable solution for key replacement.

Inside a Key Rescue: How to Salvage a Wet or Flooded Car Key
10.07.2025

Inside a Key Rescue: How to Salvage a Wet or Flooded Car Key

Water damage is one of the most common – and most stressful – problems car key owners face. Whether your key fell into a puddle, went through the wash, or was simply caught in a downpour, it can stop working in an instant. But does water exposure always mean you need to buy a new key? Not necessarily. In many cases, a quick and proper response can save your key, restore its function, and spare you an expensive replacement. This guide walks you through how to rescue a wet or flooded car key, what not to do, and how to know when it’s beyond repair. How Car Keys Get Wet Modern car keys, especially keyless remotes and fobs, aren’t designed to be waterproof. Even small amounts of moisture can cause damage if the internal components are exposed. Some of the most common causes of water-damaged keys include: Being left in clothing and run through the washing machine Falling into sinks, toilets, or puddles Exposure to rain, snow, or slush Dropped at the beach or near pools Stored in damp gym bags or jackets Once water enters the key shell, it can corrode the circuit board, damage the battery, or short-circuit the transponder chip. What to Do Immediately After Getting Your Key Wet The first few minutes after exposure are critical. Acting quickly can mean the difference between a working key and a dead one. 1. Remove the Key from the Water Take the key out of the water as quickly as possible. The longer it sits, the more damage can occur inside. 2. Open the Key Shell If your key has a removable shell, gently open it using a small screwdriver or plastic tool. This allows you to access the internal parts and dry them properly. If you’re unsure how to open it, look up a video or guide specific to your car model. 3. Take Out the Battery Immediately remove the battery. A wet battery in contact with electronics can cause short circuits and corrosion. Do not reinstall the same battery later; it may be compromised. 4. Dry the Internal Components Gently pat all visible parts dry with a lint-free cloth. Do not use paper towels, as they can leave behind fibers. Then allow the key to air-dry using one of the following methods: Option A: Use Silica Gel or Desiccant Packs Place the opened key and all components in an airtight container with silica gel packets. Leave it sealed for at least 24 to 48 hours. Option B: Use Uncooked Rice If silica gel isn’t available, uncooked rice can work as an alternative. Place the key in a bowl of rice and cover it completely. Leave it for 2 to 3 days. Do not use a hair dryer, microwave, or place the key near a heater. High heat can warp the plastic shell and damage sensitive electronics. After Drying: Will the Key Work Again? After a full drying period, insert a new battery and test the key. In many cases, it will begin working again — especially if water exposure was brief and the board was not damaged. If the key still doesn’t respond, try the following steps: Inspect the circuit board for corrosion or residue Try replacing the outer shell if buttons feel worn or unresponsive Check if the vehicle recognizes the transponder chip If none of these steps work, the internal chip or electronics may be permanently damaged. When to Replace the Key Sometimes the damage goes beyond what cleaning and drying can fix. You’ll likely need a full replacement if: The key no longer sends a signal The LED light doesn’t flash when pressing buttons There is visible corrosion on the circuit board The transponder chip fails to communicate with the vehicle Buttons are physically damaged or unresponsive The key was underwater for an extended time In these situations, replacing the key is often the most reliable solution. Don’t Wait Until It’s Too Late – Keep a Spare Key If you’ve experienced water damage once, there’s a good chance it could happen again. Keeping a backup key stored in a safe, dry location is one of the best precautions you can take. You can find replacement key shells, blades, batteries, and fully programmed keys for most vehicle brands at mr-key.com . Investing in a spare can save time, money, and stress. Final Tips for Car Key Water Damage Act fast and remove the battery as soon as possible Use silica gel or rice for slow, safe drying Avoid heat, rubbing, or shaking the electronics Replace the shell if it’s worn, cracked, or damaged If in doubt, test with a new battery before replacing the entire key Need Replacement Parts? Whether you need a new shell, battery, or a complete key, visit mr-key.com to find compatible parts for a wide range of vehicles. Our selection includes: Key shells for all major brands CR2032 batteries Key blades and electronics Fully assembled remote keys with chip and programming options If your key has been exposed to water, don’t panic. With the right steps, many keys can be rescued — and if not, we’re here to help you find the right replacement.

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.

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