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

Comprehensive Guide: Common Car Key Problems and How to Solve Them
30.06.2025

Comprehensive Guide: Common Car Key Problems and How to Solve Them

Your car key is a small but essential part of your daily life. When it stops working properly—whether due to a dead battery, water exposure, signal interference, or ignition issues—it can quickly disrupt your plans. Fortunately, many common car key problems can be identified early and resolved effectively with the right approach. In this comprehensive guide, we explore four of the most frequent car key issues and provide detailed solutions to help you stay on the road with confidence. Recognizing a Failing Car Key Battery The battery inside your car key fob is designed to last, but not indefinitely. On average, a CR2032 battery will power a key fob effectively for one to three years, depending on usage patterns and environmental conditions. A weakening battery usually does not fail suddenly; it provides warning signs that many drivers overlook. One of the earliest indications is a noticeable decrease in the remote’s operating range. You may find yourself needing to stand closer to the vehicle for the key fob to work. As the battery continues to lose power, the fob may start working inconsistently, responding only after multiple button presses or with a delay. Some vehicles will display a low battery warning on the dashboard, providing a clear signal that replacement is necessary. Allowing the battery to fully deplete can leave you unable to unlock or start your car at a critical moment. By promptly replacing the battery with a reliable product, such as the Panasonic CR2032, you can restore full functionality and prevent future inconvenience. Addressing Water Damage in Car Keys Water damage is a common cause of key fob failure. Whether it’s from rain exposure, dropping the key in water, or accidental washing, moisture can cause both immediate and long-term damage to the key's internal components. When water enters the fob, it can short-circuit the delicate electronics, rendering the key inoperative. In other cases, corrosion may develop slowly, causing the key to malfunction days or weeks after the exposure. If your car key gets wet, the first step is to remove the battery immediately to minimize damage. Dry the key as thoroughly as possible using a soft cloth and allow it to air dry in a warm, ventilated space for at least 24 hours. It is crucial to avoid using heat sources like hair dryers, which can damage sensitive components. After drying, install a fresh battery and test the key. If the key still does not function, the internal circuits may have been irreparably damaged, and a professional evaluation or shell replacement may be necessary. Understanding Weak Signal Issues in Car Keys A weak key fob signal can lead to frustration and can often be mistakenly attributed to a battery issue alone. While a low battery is a common cause, signal strength can also be affected by other factors. Physical impacts, such as dropping the key, can disrupt the internal connections or damage the antenna, reducing the fob's ability to communicate effectively with the car. Environmental factors can also interfere with the signal. Parking near large metal structures, power lines, or areas with strong electronic interference can block or weaken the signal temporarily. Additionally, worn buttons that no longer make proper contact with the internal circuit board can result in poor signal transmission, even if the battery is new. When experiencing signal issues, it is important to inspect the key carefully. Replacing the battery, ensuring all components are securely seated, and considering the replacement of worn key shells can often restore proper function. Persistent problems, however, may require professional assessment to ensure the key and vehicle are correctly paired. Dealing with Ignition Problems When the Car Key Won’t Turn One of the most alarming car key issues is inserting the key into the ignition only to find it won’t turn. This problem can stem from several sources, and identifying the correct cause is essential for a safe and effective fix. A worn key blade is a common culprit, especially in vehicles with many years of use. Over time, the precision cuts on the key blade can wear down, making it difficult for the key to properly engage the pins within the ignition cylinder. Another frequent cause is the steering wheel lock mechanism. If the steering wheel locks in place, it can prevent the key from turning until the wheel is gently moved to relieve the pressure. In some cases, the ignition cylinder itself may become dirty, misaligned, or mechanically worn. If you have a spare key, testing it can help determine whether the issue lies with the key or the ignition. Cleaning the ignition slot with compressed air can sometimes resolve minor blockages. If the problem persists, professional servicing of the ignition system may be necessary to avoid more serious mechanical failures. Car Key Maintenance and Problem Solving Car key problems are a common inconvenience that most drivers will face at some point. However, understanding the signs and causes of these issues can empower you to act quickly and avoid more significant disruptions. Whether dealing with a failing battery, water exposure, weak signal, or ignition lockout, timely intervention and proper maintenance can prevent escalation. Regularly checking your key's condition, replacing batteries with trusted products, and ensuring your key shell remains intact are simple yet effective practices that can extend the life of your car key. By addressing small issues early, you can maintain reliable access to your vehicle and reduce the risk of unexpected problems. For high-quality replacement shells, batteries, and accessories, visit mr-key.com and explore solutions designed to keep your car key functioning like new.

5 Fascinating Facts About Audi That Every Car Enthusiast Should Know
17.09.2024

5 Fascinating Facts About Audi That Every Car Enthusiast Should Know

Audi is a brand that’s deeply ingrained in the world of luxury cars, known for its sleek designs, innovative technology, and unbeatable performance. Whether you're a die-hard car enthusiast or someone who just appreciates good engineering, there's more to Audi than meets the eye. Let's dive into five fascinating facts about Audi that might surprise you and give you an even deeper appreciation for this iconic brand. 1. The Meaning Behind Audi’s Four Rings: More Than Just a Logo When you think of Audi, the first thing that likely comes to mind is its distinctive four-ring logo. But did you know that each of those rings has a special meaning? The rings symbolize the four founding companies of Auto Union: Audi, DKW, Horch, and Wanderer. Back in 1932, these four automakers joined forces to create Auto Union, and each company contributed its own expertise to form what would eventually evolve into Audi. Those four rings serve as a reminder of the brand’s rich history and the combined heritage of those founding companies. So, the next time you see the iconic logo, you'll know there's a story behind it, representing decades of innovation and collaboration. 2. Audi’s Groundbreaking Win at Le Mans: Changing the Game With Diesel Power Audi has a long history of dominating motorsports, but its victory at the 2006 24 Hours of Le Mans was nothing short of revolutionary. Why? Because Audi became the first manufacturer to win the prestigious race with a diesel engine. The Audi R10 TDI wasn’t just fast—it was efficient, too. Diesel engines are known for their fuel efficiency, and Audi capitalized on this advantage, allowing the R10 to spend less time refueling and more time on the track. This win not only cemented Audi's status as a force in motorsport but also challenged the perception that diesel engines were only about fuel economy, not performance. For Audi, this victory was more than just a win; it was a statement about their commitment to innovation and pushing the boundaries of what’s possible in automotive technology. 3. What’s in a Name? The Surprising Latin Origin of ‘Audi’ Here’s a fun fact that even some Audi fans might not know: the name “Audi” has its roots in Latin. The brand’s founder, August Horch, initially used his own surname for his company. However, after a legal dispute forced him to change the name, he decided to get creative. “Horch” means “listen” in German, and August decided to translate this into Latin, which gave him the word “Audi.” The name stuck, and today Audi is synonymous with cutting-edge automotive engineering. It’s a subtle nod to the brand’s history while still looking forward to the future, a balance Audi has always managed to strike perfectly. 4. Audi’s Quattro All-Wheel Drive: Revolutionizing Rally Racing and Beyond When it comes to Audi’s technology, one word stands out: Quattro. Audi revolutionized the automotive world in the 1980s with its Quattro all-wheel-drive system. Originally developed for rally racing, Quattro provided exceptional traction and handling, especially on difficult terrains like gravel and snow. Audi introduced the Quattro system into rally racing, and it wasn’t long before they started winning championship titles. This technology was so successful that it didn’t just stay on the racetrack; it made its way into Audi’s consumer cars, where it continues to be a major selling point. Today, Quattro is still considered one of the best all-wheel-drive systems on the market, offering you a smoother, more controlled ride no matter the road conditions. For those who love the thrill of driving in all conditions, Quattro offers a unique driving experience that’s hard to beat. 5. The Audi A8: A Pioneer in Lightweight Design Audi is known for pushing the envelope when it comes to design, and the Audi A8 is a perfect example of this innovation. Launched in the 1990s, the A8 was one of the first cars to feature an all-aluminum body. Why is that important? An aluminum body is significantly lighter than traditional steel, which not only improves fuel efficiency but also enhances the car’s handling and performance. Aluminum may be lightweight, but it's incredibly strong, offering superior protection without sacrificing speed or agility. By reducing weight and increasing strength, Audi set a new standard for luxury sedans, one that many automakers have since tried to emulate. If you’ve ever had the pleasure of driving an A8, you know exactly what we’re talking about—lightweight design, power, and luxury all rolled into one. Audi’s Legacy of Innovation As you can see, Audi is much more than just a luxury car brand. From its humble beginnings as part of Auto Union to its groundbreaking Quattro technology and diesel-powered victories, Audi has continually set new standards in the automotive world. Whether it’s the iconic four rings that represent decades of collaboration or the cutting-edge engineering that defines every Audi model, this brand continues to inspire and innovate. Next time you see an Audi, you’ll know it’s not just another car—it’s a symbol of innovation, performance, and a commitment to excellence that has stood the test of time. If you’re an Audi owner or simply an admirer of fine automotive craftsmanship, these five fascinating facts give you even more reason to appreciate this iconic brand. So, what’s your favorite Audi innovation? Let us know!

How to Know If Your Car Key Has a Hidden Transponder Chip
29.04.2025

How to Know If Your Car Key Has a Hidden Transponder Chip

Modern car keys are more than just simple tools to unlock doors—they're powerful components of your vehicle’s security system. Hidden inside many keys is a small yet crucial piece of technology known as a transponder chip . But how can you tell if your car key has one? Whether you’ve lost your key, are looking to replace it, or simply want to understand your vehicle better, knowing if your key contains a transponder chip is essential. This guide will explain what a transponder is, why it matters, and how you can easily check if your key is equipped with one. What Is a Transponder Chip? A transponder chip, short for "transmitter + responder," is a small electronic microchip embedded inside the plastic head of the car key or within a smart key fob. When you insert the key into the ignition—or have it nearby in a push-button start system—the chip emits a unique signal. The vehicle’s onboard computer must recognize this signal before it will allow the engine to start. Without the correct signal, even if the key physically fits into the ignition, the car won’t move. Transponders have been a game-changer in reducing car theft, and today, nearly all vehicles produced after the late 1990s are equipped with them. Learn more about how modern keys work and find replacement options in our car keys collection. Why It’s Critical to Know If Your Key Has a Chip If your key has a hidden transponder chip, replacing it is more complicated than simply cutting a new metal key. You will need a key that not only matches the cut but also includes the correct programming to communicate with your car’s immobilizer system. Failing to recognize this can lead to frustration, extra dealership fees, or even being stranded. Moreover, understanding your key's technology helps you make smarter choices when buying a spare, upgrading your security setup, or troubleshooting ignition issues. How to Check If Your Car Key Has a Transponder Chip Fortunately, you don’t need expensive equipment to find out. Start by considering the age of your vehicle: if your car was manufactured after 1995 (in Europe) or 1998 (in the USA), chances are very high it uses a transponder system. Next, examine the physical key. Keys with large, bulky plastic heads usually house a chip inside. In contrast, purely metallic keys without plastic parts tend to belong to older, non-transponder vehicles. You can also perform a simple foil test. Wrap the head of your key in aluminum foil and try to start the car. Since foil blocks radio frequencies, if the car refuses to start, it’s likely that a transponder chip is present. If you want absolute certainty, consult your vehicle’s manual or speak with a professional locksmith. Many locksmiths use specialized tools to detect whether a chip exists. For additional technical explanation, you can refer to this guide on how immobilizer systems work. What Happens If the Transponder Signal Is Missing? If you try to start your car without the proper transponder signal, the immobilizer system kicks in. Most vehicles will either not crank at all or crank without allowing the engine to fire. Some models will display a warning light on the dashboard, often shaped like a padlock or a car with a key icon. Without a valid transponder signal, you won't be going anywhere—no matter how new or well-cut the key is. Can You Program a Transponder Key Yourself? Depending on the make and model of your car, some basic keys can be programmed at home—especially if you already have one working key available. However, many newer vehicles require professional diagnostic tools connected directly to the car’s computer to program keys securely. Attempting DIY programming on these systems without the right knowledge can lock your car’s immobilizer and lead to expensive repairs. Always consult your car’s manual or seek professional help before attempting any programming yourself. Knowledge = Protection Understanding whether your car key contains a hidden transponder chip isn’t just a fun fact—it's essential for protecting your vehicle and saving yourself time, money, and hassle. Whether you're planning to replace a worn-out key, add a backup, or upgrade your security, knowing what’s inside your key helps you make better, safer decisions. If you ever need a spare key, a battery replacement, or advice on key maintenance, you can explore more in our online store at Mr Key . Remember: a smart driver is a secure driver. Stay informed, stay prepared, and you'll always stay one step ahead.

What’s the Difference Between Immobilizer, Transponder Chip, and Key Fob?
02.05.2025

What’s the Difference Between Immobilizer, Transponder Chip, and Key Fob?

In modern vehicles, the once simple car key has evolved into a sophisticated piece of technology. With built-in electronics, anti-theft features, and remote functions, today’s car key is part of a broader ecosystem designed for both convenience and security. Yet with all this advancement comes confusion. Many drivers aren’t sure what terms like immobilizer , transponder chip , and key fob actually mean—or how they relate to one another. This guide breaks down these components in detail, explains how they work together, and clarifies why it matters when you’re replacing, reprogramming, or troubleshooting your car key. What Is an Immobilizer? An immobilizer is an electronic security device installed in most modern cars. Its purpose is to prevent the engine from starting unless the correct key—specifically, the correct coded signal—is detected. When you attempt to start your vehicle, the system searches for a signal from a registered transponder chip. If that signal is missing or incorrect, the immobilizer blocks the ignition system. This means the engine won’t crank or turn over, even if the physical key fits. Immobilizers are embedded in the car’s engine control unit (ECU) and became standard in vehicles after the late 1990s in many countries, in response to rising car theft. They offer a silent, invisible layer of protection against common theft techniques like hotwiring. Without the correct digital authentication, the car simply will not start. What Is a Transponder Chip? The transponder chip is a small electronic microchip located inside the car key or key fob. The word “transponder” is a combination of “transmitter” and “responder.” It is designed to emit a unique code that the car's immobilizer can recognize. When you insert the key into the ignition or bring a key fob close to a push-start system, the chip sends a signal to the car’s ECU. If the code matches the one stored in the car’s database, the immobilizer disables itself and allows the engine to start. Transponder chips are passive. They do not require a battery and are activated by electromagnetic energy from the ignition coil or receiver unit inside the vehicle. Without a functioning or correctly programmed transponder chip, your car will not start—even if the metal key turns in the ignition. What Is a Key Fob? A key fob is the remote control device you carry that allows you to perform functions like locking or unlocking your car, opening the trunk, and activating panic alarms. In modern vehicles, key fobs may also control remote start or proximity-based unlocking features. While key fobs often include a transponder chip inside them, they serve a different function. The key fob operates remote commands via short-range radio signals. The transponder chip, on the other hand, is responsible for enabling or disabling the engine. Smart key fobs, found in many recent vehicles, don’t require insertion into the ignition. Instead, the car detects the fob nearby and permits the engine to start with a button press. If your key fob battery dies, you might still be able to start the car manually if the transponder chip is present and recognized. Most fobs also have a hidden mechanical key inside, which can be used to unlock the door if the electronics fail. How They Work Together Although they are distinct components, the immobilizer, transponder chip, and key fob all work in harmony to secure and operate your vehicle. The immobilizer controls whether the engine is allowed to start. The transponder chip provides the digital identity that must be verified by the immobilizer. The key fob provides wireless control of non-engine functions like locking, unlocking, and trunk access. In most modern cars: You approach the vehicle with the key fob. The fob unlocks the doors. When you start the vehicle, the transponder chip sends a signal to the immobilizer. If the code matches, the engine is authorized to start. If the code doesn’t match, or if the chip is missing or damaged, the engine remains disabled—even if the rest of the key’s functions work perfectly. Why This Knowledge Matters Understanding how your car key works is essential when: Replacing a lost or broken key Buying a spare or duplicate Diagnosing why your car won’t start Choosing between locksmith and dealership services For example, if your key fob unlocks your car but won’t start it, the issue may lie with the transponder chip, not the battery. Conversely, if your fob doesn’t lock or unlock the car remotely, the chip may still be functional, and the issue could simply be a dead battery. Replacing a key without properly programming the transponder chip will result in a non-starting vehicle, even if the key physically fits and the remote works. For reliable replacement keys, fobs, batteries, and accessories, visit our Car Key Collection. Car keys are no longer just mechanical tools. They’re complex, multi-function devices that combine security, convenience, and connectivity. By understanding the role of the immobilizer , transponder chip , and key fob , you’ll not only protect your vehicle better, but also avoid costly mistakes when dealing with repairs or replacements. Whether you’re troubleshooting a non-starting car or simply trying to replace a damaged key, knowing the difference between these three elements gives you the clarity and confidence to take the right action.

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