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

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 Remove or Change a Roof Rack Lock Barrel Easily
15.11.2024

How to Remove or Change a Roof Rack Lock Barrel Easily

Changing or removing the lock barrel on your roof rack may seem like a daunting task, but it’s actually simpler than you might think. Whether you need a replacement due to a lost key, wear and tear, or just want to swap out an old lock for a new one, following the right steps can make the process hassle-free. This guide will walk you through everything you need to know about handling a roof rack lock barrel with ease. Why You Might Need to Change a Roof Rack Lock Barrel ? There are several reasons why you may want to replace or remove your roof rack lock barrel: Lost Key : If you've misplaced the key, replacing the lock barrel is often the most practical solution. Upgrading the Lock : Maybe you want a more secure lock for added peace of mind. Routine Maintenance : Over time, lock barrels can wear down, making it harder to insert or turn the key. Uniformity : If you've recently changed your car key, you may want to match your roof rack lock with it. Knowing why you’re changing the lock barrel will help you determine the steps you need to follow. What You’ll Need Before you start, gather these essential tools and items: Replacement Lock Barrel : Ensure it’s compatible with your roof rack model. Master Key or Removal Key : Often required to remove the old lock barrel. New Key : The key that corresponds to the replacement lock barrel. Flathead Screwdriver : To gently pry and release certain parts if needed. Step-by-Step Guide to Removing a Roof Rack Lock Barrel Removing a lock barrel from your roof rack doesn’t require extensive mechanical skills. Just follow these straightforward steps: 1. Locate the Lock Barrel The lock barrel is usually situated in the center or side of the roof rack. Look for the small lock with the keyhole, as this is where you'll be inserting the master or removal key. 2. Insert the Master Key or Removal Key If you have a master or removal key, insert it into the lock. This is often a universal key provided by the lock manufacturer specifically for removing lock barrels. Once it’s inserted, turn the key slightly to unlock the barrel. Tip: If you don’t have a removal key, contact a professional or see if you can order one specifically for your model. 3. Pull the Lock Barrel Out With the removal key still in place, gently pull the lock barrel out. If it’s resistant, try wiggling it slightly while pulling. Avoid forcing it, as this could damage the lock or roof rack. In some cases, you may need a flathead screwdriver to help pry it out, but be careful not to scratch the surrounding area. 4. Check the Casing After removing the lock barrel, inspect the casing where the barrel was installed. Make sure it’s clean and free of debris. Any dirt or rust could interfere with the new lock barrel, so it’s a good idea to clean this area before proceeding. Installing the New Lock Barrel Once the old barrel is removed, you’re ready to install the new one. Here’s how: 1. Align the New Lock Barrel Take your new lock barrel and align it with the casing where the old one was. Most barrels are designed to fit in only one direction, so make sure you align it properly to avoid jamming. 2. Insert the New Barrel Push the new lock barrel into the casing until it clicks into place. This might require a bit of pressure, but it should fit snugly without needing excessive force. 3. Test the New Key After installing the new lock barrel, insert the new key and turn it to ensure it’s working smoothly. The key should turn easily and lock securely. This step verifies that the new lock is properly aligned and functional. Common Challenges and Solutions While changing a roof rack lock barrel is generally straightforward, you might encounter some challenges. Here’s how to troubleshoot common issues: Stuck Barrel : If the old barrel is stuck, apply a lubricant like WD-40 around the lock to help loosen it. No Removal Key : If you don’t have a master or removal key, consider reaching out to a locksmith or checking if the manufacturer offers a replacement. Barrel Won’t Fit : Ensure you’ve purchased a compatible lock barrel. Even slight differences in design can prevent it from fitting properly. Tips for Maintaining Your Roof Rack Lock To keep your new lock barrel in good condition and prevent the need for frequent replacements, consider these maintenance tips: Regular Cleaning : Dirt and grime can accumulate inside the lock over time, making it harder to operate. Clean the lock regularly to prevent this. Use Lubricant : Apply a small amount of lubricant inside the lock barrel periodically to keep the key turning smoothly. Protect from Rust : If your roof rack is exposed to rain and humidity, use a protective cover or shield to keep moisture out of the lock barrel. Check Key Fit : Avoid using a damaged or bent key, as this can wear out the lock barrel more quickly. When to Seek Professional Help In some cases, removing or replacing a roof rack lock barrel might require assistance from a professional: Lost or Damaged Keys : If both your main key and master key are lost or damaged, a professional can help retrieve or replace the lock barrel. Damaged Lock Mechanism : If the lock itself is damaged or jammed, forcing it can make things worse. A professional locksmith can safely remove and replace it. Replacing or removing a roof rack lock barrel is an affordable and manageable task for most car owners. By following the right steps and keeping up with regular maintenance, you can ensure your roof rack lock stays functional and secure. Whether you’re upgrading for security or replacing a worn-out lock, a new lock barrel can make all the difference in keeping your roof rack safe. Effortless Key Replacement for a Variety of Locks Order 2x Union Keys FT Series, custom-cut to your original key code, for a hassle-free replacement. Compatible with a range of locks, including those from Aston Martin, Jaguar, Land Rover, and more, these keys are perfect for classic cars, caravans, petrol caps, roof racks, and truck canopies. Simply find your lock code (e.g., FT101-FT360) on the lock face and enjoy fast delivery of high-quality spare keys.

The Benefits of Smart Car Keys: A Leap Into the Future of Automotive Convenience
17.06.2024

The Benefits of Smart Car Keys: A Leap Into the Future of Automotive Convenience

Smarter, Simpler, Safer Imagine walking toward your car, and instead of fumbling through your bag or pockets for keys, your vehicle recognizes your presence and unlocks itself. This convenience is not a futuristic concept—it’s the reality of smart car keys, an innovation that has redefined automotive technology. As vehicles become more advanced, smart keys are becoming indispensable for drivers seeking security, convenience, and style. But what exactly makes smart keys so revolutionary? Let’s explore their features and benefits. What Are Smart Car Keys? Smart car keys, also known as proximity keys or keyless entry systems, use advanced technology to simplify the interaction between you and your vehicle. Unlike traditional keys or even remote fobs, smart keys rely on radio frequency identification (RFID) or Bluetooth to communicate with your car. Once within a specific range, the car recognizes the key, unlocking the doors and enabling push-button ignition. These keys offer far more than just access and starting capabilities. They are designed to enhance security and integrate features like personalized settings, making them a step ahead of conventional systems. From luxury sedans to electric vehicles, smart keys are rapidly becoming a standard feature in modern cars. The Key Benefits of Smart Car Keys One of the most noticeable advantages of smart keys is their unmatched convenience. Imagine walking to your car with hands full of groceries or during a rainstorm. With a smart key in your pocket or bag, the car automatically unlocks as you approach, eliminating the need to dig around for your keys. Similarly, starting the engine is as simple as pressing a button, streamlining the driving experience. Smart keys also prioritize security. Unlike traditional keys that can be duplicated, smart keys use encrypted communication to connect with the vehicle. This encryption ensures that unauthorized users cannot access or start the car. Some smart systems even include anti-theft mechanisms that disable the engine if the key is not detected nearby, adding an extra layer of protection. Moreover, many smart keys are equipped with customizable features. Depending on the car, they can store and recall settings such as seat positions, climate control preferences, and mirror adjustments. Some even allow for remote control of the car via a smartphone app, enabling users to lock, unlock, or preheat their vehicle with a simple tap on their phone. Smart Keys Around the World: Trends and Adoption The use of smart keys is growing globally, with different regions adopting the technology at varying rates. In developed markets like North America, Europe, and Japan, smart keys have become standard in mid-range and luxury vehicles. These regions, driven by technological advancements and consumer demand, are setting the pace for smart key adoption. In emerging markets, traditional keys are still more prevalent due to their affordability. However, the demand for smart keys is on the rise, especially among buyers of premium cars. As automotive manufacturers expand their offerings, smart keys are becoming accessible to a broader audience. The future of smart keys is even more exciting. Many automakers are exploring app-based systems and biometric authentication, such as fingerprint or facial recognition. These innovations aim to further integrate vehicles into the digital ecosystems of their owners, offering seamless connectivity and enhanced personalization. Challenges of Using Smart Keys While smart keys bring significant advantages, they are not without their challenges. One of the primary concerns is the cost of replacement. Losing a smart key can be expensive, with replacements often requiring programming by a dealership or specialized locksmith. This cost is significantly higher than that of traditional keys. Another issue is the potential vulnerability to hacking. Relay attacks, where thieves amplify the signal from a smart key to unlock a vehicle, are a known risk. While manufacturers are continually improving encryption methods, owners should take precautions, such as using signal-blocking pouches, to protect their keys. Battery life is another consideration. Smart keys depend on batteries, and if the battery dies unexpectedly, you may find yourself locked out of your car. Most manufacturers include a physical backup key or emergency override options, but staying mindful of your key’s battery status is essential. Why Smart Keys Are the Future Smart keys represent more than just a technological advancement—they symbolize a shift in how we interact with vehicles. Their ability to enhance convenience, security, and personalization makes them a must-have feature for modern drivers. As cars become increasingly integrated with digital ecosystems, smart keys are expected to evolve, incorporating features like biometric security and deeper smartphone integration. For drivers, this evolution means a more intuitive and tailored experience. From automatically adjusting settings based on the detected key to integrating with smart home systems, smart keys are paving the way for a connected and seamless future. Embrace the Smart Key Revolution Smart car keys are more than a luxury; they are becoming an essential tool in modern driving. Their convenience, advanced security, and customizable features make them a game-changer in automotive technology. However, as with any innovation, understanding their potential challenges and how to address them is crucial. Whether you’re unlocking your car as you approach or starting the engine with a simple button press, smart keys represent a leap forward in convenience and functionality. As automotive technology continues to advance, smart keys are leading the charge, offering a glimpse into a future where cars seamlessly adapt to our needs.

The Complete Guide to Car Key Cutting: Everything You Need to Know
19.06.2024

The Complete Guide to Car Key Cutting: Everything You Need to Know

Unlocking the Mysteries of Car Key Cutting Have you ever been in a situation where you needed a spare car key or had to replace a lost one? Car key cutting is an essential process for creating duplicate keys or replacements, but it’s often misunderstood. From traditional keys to modern transponder and smart keys, the art of key cutting has evolved dramatically with advancements in technology. This guide will walk you through the key cutting process, its types, and when professional help is required, helping you navigate the complexities of car key duplication with confidence. What Is Car Key Cutting? Car key cutting is the process of creating a new key that matches the physical shape and specifications of your vehicle’s locks and ignition. This process involves cutting the metal key blade to fit the car’s lock mechanism precisely. For modern cars, this may also include programming the electronic components of the key, such as transponder chips or remote controls. The method used for cutting a car key depends on the type of key and the car model. Traditional keys are simpler to cut, while transponder and smart keys require specialized tools and expertise. Types of Car Keys and Cutting Methods Traditional Keys These are the classic mechanical keys used in older vehicles. Cutting these keys involves duplicating the grooves and ridges of the original key using a key-cutting machine. Transponder Keys Found in most modern cars, transponder keys contain a microchip that communicates with the car’s computer. After cutting the blade, these keys must also be programmed to function. Smart Keys These advanced keys use wireless communication to interact with the car. They don’t require physical cutting but involve programming to sync with the vehicle. Each type of key requires a different approach and level of expertise, making it essential to know what kind of key you have before proceeding with duplication. The Key Cutting Process: Step by Step Identify the Key Type Determine whether you have a traditional, transponder, or smart key. This will dictate the tools and process needed for cutting and programming. Gather Required Information Provide the key cutter with details about your car, such as the make, model, and year. For some keys, a Vehicle Identification Number (VIN) may be required. Cutting the Key Blade For traditional and transponder keys, the blade is cut using a key duplicator or a laser key-cutting machine. Precision is crucial to ensure the key fits perfectly in the lock. Programming (if required) For transponder and smart keys, the key must be programmed to the car’s computer system. This step may require specialized equipment or professional expertise. When to Seek Professional Help While traditional keys can often be duplicated at local hardware stores, transponder and smart keys typically require specialized tools and knowledge. Professional locksmiths and dealerships are equipped to handle these advanced key types, ensuring proper cutting and programming. Reasons to choose a professional: Complexity: Smart and transponder keys require technical expertise. Accuracy: Professionals use precise equipment to ensure the key functions flawlessly. Programming Needs: Only trained specialists can program keys to sync with your vehicle. Cost of Car Key Cutting The cost of cutting a car key varies depending on the type of key and the service provider. Traditional keys are the most affordable, typically costing between $10 and $50. Transponder and smart keys, however, can range from $50 to $300 or more due to the additional programming required. Tips to save money: Have a spare key: This simplifies the duplication process and reduces costs. Compare prices: Contact multiple locksmiths or dealerships to find the best deal. Be Prepared for Every Key Emergency Car key cutting is a vital service for any car owner, whether you’re duplicating a spare key or replacing a lost one. Understanding the process and knowing when to seek professional help can save you time, money, and frustration. By staying informed and proactive, you can ensure that your vehicle remains accessible and secure, no matter what challenges arise.

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