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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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Lost Your Witter, GDW, Thule (Brink) or TowTrust Towbar Key? Here's What to Do.
29.07.2025

Lost Your Witter, GDW, Thule (Brink) or TowTrust Towbar Key? Here's What to Do.

Lost your towbar key right before a holiday or towing trip? You’re not alone. Detachable towbar keys are typically used only occasionally – often just before a caravan holiday or when you need to tow – which means they spend most of the year tucked away. It’s all too easy for that lost towbar key to go missing between uses. The good news is that if your key has an ACS-series code (ACS01–ACS10) engraved on it, you can order a precise replacement online in minutes and avoid throwing a wrench in your travel plans. What are ACS towbar keys? The ACS-series keys are a common type of detachable towbar key numbered ACS01 through ACS10 (for reference: ACS01, ACS02, ACS03, ACS04, ACS05, ACS06, ACS07, ACS08, ACS09, ACS10). These keys fit a specific locking system used by multiple towbar manufacturers. In fact, an ACS towbar key could belong to a detachable hitch from ACS itself or from popular brands like Witter, GDW, Thule (Brink) or TowTrust – all of whom use the same ACS lock design. What matters is the code stamped on your key or lock. If it falls in the ACS01–ACS10 range, that code is all you need to get a new key cut and shipped to you. Check Your Key Code (ACS01–ACS10) Before you panic, inspect your towbar’s lock (or any remaining key) for a small engraved code. Most detachable towbar locks have the key number stamped either on the face of the lock barrel or on the original key itself. For the ACS series, this code will start with “ACS” followed by a two-digit number – for example, ACS04 or ACS09. If you see a code in the format ACS## and especially if it’s between ACS01 and ACS10, you’re in luck. That means your towbar uses the ACS key system, and a towbar key ACS01–ACS10 replacement can be ordered without changing the lock. Why is the key code important? This unique code is what key cutting services use to create an exact match for your lock. No original key is required – the code itself tells the cutter how to shape the new key. As long as the code is clearly visible (and within the supported range), you won’t need to replace the entire towbar lock or mechanism. Just supply the code and a new key can be made to fit perfectly, as if it were the original. Tip: Wipe the lock face clean or use a flashlight if needed – dirt and road grime can obscure the tiny engraving. On some keys the code might be on the plastic head or metal shaft of the key. Look for “ACS” followed by numbers. Compatible Towbar Brands for ACS Keys One big advantage of the ACS lock system is its cross-compatibility. These key codes ACS01–ACS10 aren’t limited to a single towbar brand – they’re used across several major manufacturers of detachable towbars. If you have a detachable towbar from any of the following brands, there’s a good chance it uses an ACS-series key: ACS (A50-X) – ACS is the original supplier of this locking system (often referred to as the A50-X class detachable). Keys for ACS detachable towballs will have codes ACS01–ACS10. 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. 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Ordering online is not only convenient but also ensures you get the precise key you need. These keys are cut by code using professional tools, so you don’t have to worry about tracing an old key or guesswork. As long as the code you provide is correct, the new key will fit perfectly or you can get your money back. Make a Spare Key Now to Avoid Future Stress Once you have your new key in hand (or if you still have your original), it’s time to think ahead. Don’t wait until you’ve lost the only key to take action. Cutting a spare key while you still have a working one is quick and inexpensive, and it can save you a lot of trouble down the road. Here are some benefits of having a spare towbar key: No more last-minute panic: If one key goes missing, you’ll have a backup ready. This means no frantic searches the night before your trip and no postponed travel plans due to a missing key. 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How to Take the Perfect Photo of Your Key for Easy Replacement
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When you need a replacement key , taking a clear, detailed photo of your key can make the process much faster and more accurate. A high-quality image helps key makers understand the exact specifications, cuts, and dimensions of your key, which is especially important if you don’t have a spare. In this guide, we’ll walk you through the best practices for photographing your key so you can get an accurate replacement with ease. Why a Clear Key Photo Matters Photographing a key might sound simple, but it requires a bit of attention to detail. A well-taken photo captures the key’s grooves and unique cuts clearly, helping the key cutter replicate the exact pattern. Saves Time : A high-quality photo reduces the need for multiple attempts to cut a new key . Ensures Accuracy : Clear images help capture specific details, leading to a more precise fit. Convenient Process : With just a smartphone and a few tips, you can photograph your key from home without needing special equipment. 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You may need to tap the screen to bring it into sharp focus. Zoom in Carefully : If you’re using a smartphone, zoom in slightly to capture the details, but avoid over-zooming, which can blur the image. Test Multiple Angles : Sometimes a slight adjustment in angle can capture the cuts more effectively, so take a few shots from slightly different perspectives. 5. Capture Multiple Photos It’s always a good idea to take several photos to ensure you have the best one. Try different angles and lighting adjustments to capture as many details as possible. Close-Up of the Grooves : Take one close-up image focusing on the cuts and grooves of the key. Overall Image : Include one full-length photo that shows the entire key from end to end. Try Different Angles : Slightly tilt the key or move the camera to see which angle best captures the detail of the cuts. 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How to Protect Your Car Key Fob from Relay Attacks
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How to Protect Your Car Key Fob from Relay Attacks

Car theft has entered the digital age — and unfortunately, so have the thieves. As car manufacturers move toward keyless technology, a new type of threat has emerged: the relay attack. Unlike traditional break-ins, this high-tech method allows criminals to steal a vehicle without touching the keys — or even breaking a window. Imagine this: your car is parked safely outside your house. Your key fob is inside, hanging on a hook by the front door. You're fast asleep. But outside, two individuals with small electronic devices are working together. One stands near your front door, scanning for a signal from your key fob. The other waits by your car. Within seconds, your key’s signal is captured, extended, and transmitted to your car. It unlocks, starts, and drives away — and you might not notice until morning. This is not science fiction. It's called a relay attack , and it's one of the fastest-growing vehicle theft methods worldwide. Why Relay Attacks Are So Effective The key to this technique is exploiting the constant communication between your car and its fob. Most keyless entry systems are designed for convenience — you don’t even need to press a button. The car automatically detects the presence of the key fob and unlocks when you approach. This convenience is exactly what makes it vulnerable. Relay devices — which are cheap, portable, and easy to use — can mimic the signal and trick the car into thinking the key is nearby, even when it’s inside your home. Security experts have raised the alarm about this method for years, but many drivers still don’t realize how easily their vehicles can be accessed. In the UK alone, keyless car theft now accounts for more than 90% of vehicle thefts involving high-end models, according to the AA. And with the rise of online tutorials and black-market tools, the problem is growing globally. So, What Can You Do to Stay Safe? Fortunately, protecting your vehicle doesn’t require advanced tech or a huge investment — just awareness and a few smart habits. One of the most effective ways to block relay attacks is also the simplest: store your keys in a signal-blocking container . Often called a Faraday pouch or Faraday box, this lined case prevents radio signals from escaping. When your keys are stored inside, they can’t be scanned or cloned, no matter how close a thief gets to your home. Placement also matters. Many drivers leave their keys near the front door or on an entryway table — spots that are easy to access from outside. Moving your keys to the center of your home, an upper floor, or even a metal box can reduce signal exposure dramatically. Some newer key fobs allow you to manually disable the signal when it’s not in use. This feature is often hidden in the manual and rarely mentioned by dealers. Taking a moment to learn whether your key supports this — and how to activate it — can make a big difference. It’s also worth checking whether your vehicle’s software is up to date. Many automakers periodically release firmware updates that strengthen encryption or reduce signal range. In some cases, updates can even detect and block suspicious unlock attempts. And while it may seem old-fashioned, physical security still works . Devices like steering wheel locks or gear shift immobilisers can be powerful visual deterrents. Even if a thief manages to unlock your vehicle, the sight of a bulky lock inside may be enough to send them looking for an easier target. If you're looking for practical solutions beyond GPS , check out our blog: Do Car Keys Have GPS? What You Need to Know About Key Tracking . In summary, here are a few key takeaways to keep your keys and vehicle safer: Store your fob in a signal-blocking pouch or metal container Keep keys away from entry points like doors or windows Disable keyless signals if your fob supports it Update your car’s firmware regularly Use visible anti-theft devices as a deterrent Looking Ahead: Smarter Cars, Smarter Drivers Relay attacks are part of a larger trend — one where modern technology makes life more convenient, but also creates new risks. Just like we’ve learned to secure our phones and passwords, we now need to think about how we secure our vehicles. As carmakers explore more secure solutions — like Ultra Wideband (UWB) tech and biometric verification — drivers still need to take responsibility for their vehicle’s safety. The tools are already out there, and many of them cost less than a meal out. It’s not just about avoiding theft; it’s about peace of mind. So next time you get home, before tossing your keys on the hallway table, take a second to think: are they really safe there?

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Misplacing or damaging your car keys can be a major inconvenience, but it doesn't have to be a costly ordeal. As a car owner seeking budget-friendly and efficient solutions, understanding your options is crucial. Here's a comprehensive guide to help you navigate the process of replacing your car keys without breaking the bank. Understanding Your Car Key Type Identifying the specific type of car key you have is the first step toward an effective replacement: Traditional Metal Keys : Simple, non-electronic keys that are easy and inexpensive to duplicate. Transponder Keys : Equipped with a chip that communicates with your vehicle's ignition system for added security. Remote Key Fobs : Allow remote locking and unlocking of your vehicle, often integrated with a transponder chip. Smart Keys : Provide keyless entry and start features, utilizing advanced technology for convenience. Cost-Effective Alternatives to Dealership Key Replacement Dealerships are known for charging premium prices for key replacements. Consider these more affordable options: Professional Locksmiths : Specialize in cutting and programming various types of car keys, often at a fraction of dealership costs. Online Key Retailers : Offer replacement keys and fobs that can be purchased and then programmed either by yourself or a professional. Hardware Stores : Some stores can duplicate traditional metal keys on the spot, providing a quick and inexpensive solution. Steps to Take When You've Lost Your Car Key Losing your car key can be stressful, but following these steps can streamline the replacement process: Verify Your Vehicle Identification Number (VIN) : Locate your VIN, typically found on the dashboard or inside the driver's side door, as it is essential for key replacement. Gather Necessary Documentation : Prepare proof of ownership, such as your vehicle registration and personal identification. Contact a Professional : Reach out to a reputable locksmith or key replacement service with your vehicle details to obtain a new key. Removing a Broken Key from the Ignition or Door Lock A broken key can be a frustrating obstacle. Here's how to address it: Use Needle-Nose Pliers : If a portion of the key is protruding, gently extract it using pliers. Apply Lubricant : Spray a graphite-based lubricant into the lock to ease the removal process. Seek Professional Assistance : If the key fragment is lodged deep or these methods fail, contact a locksmith to prevent further damage. Preventative Measures to Avoid Future Key Issues Keep a Spare Key : Having a duplicate stored safely can save time and money in emergencies. Regular Maintenance : Inspect your keys and locks periodically for signs of wear and address issues promptly. Use Key Protectors : Invest in key covers or cases to minimize physical damage.

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