en
0

Shopping Cart

closeCart
€0.00

What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them

  • /
  • Blog
  • /
  • What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them
Post Name
25.03.2024

 

Swirl flaps are a BMW system that has been introduced to help burn the fuel mixture in the cylinder better due to the fact that diesel engines do not have throttle valves and it is not possible to adjust the air-fuel ratio. A diesel engine without vortex valves operates between a poor and a rich fuel mixture, because the only way to regulate it is through fuel injection.

Design of the first generation swirl flaps that are made of made of metal.
 


Unfortunately, swirl flaps are responsible for countless damaged engines and costly repairs due to design errors or metal fatigue. Once damaged, the cylinder sucks them in and causes great damage.

This is how damaged valves damage the cylinder.
 


Typical swirl flaps  suction damage.
 


The vortex valves are positioned in the inlet and are controlled by vacuum (DDE 4.0) or electrically (DDE5.0 / DDE6.4) by the engine ECU.

Effects of malfunctioning valves:

  • Swirl valves are  stuck in open position: Deterioration of exhaust gas performance at lower speeds.
  • Swirl valves are stuck in closed position: Approximate power loss of 10% at high engine speeds.

How swirl flaps work:

 

Performance characteristics:

The vortex valves are in the closed position, at low engine speeds and small amounts of fuel injected (controlled by the ECU card).

They open under the following conditions:

  1. coolant temperature <14 ° C OR * fuel quantity> 24 mg OR
    2. engine speed 2250 rpm OR
    3. inlet air temperature <-5 ° C.

BMW and Pierburg have decided to produce diesel engines with metal vortex valves. The speed at which the pistons in the diesel engine operate is at least 60 rpm, so a sucked vortex valve will break and cause a number of damages inside the engine.

In most cases, one or more pistons are severely damaged, as a bonus you get valves, in some cases a head or turbocharger. And this combination with a BMW engine is like a cumulative jackpot  🙂

In 2004, BMW began work on the problem and improved the design, however, a number of owners reported ongoing problems in this area.

The solution to this problem is by removing the vortex valves and plugging, which does not affect the performance of the engine and at the same time, you can safely pass the exhaust test.

Engines:

M47 (136hp VP44 fuel pump) has no valves.

M47N common rail engine (including M47N / M47TU / M47TUD20) (150hp. Face lift model from 2001 -) has valves.

M57 engines (M57D) (525d & 187hp. 330d) cars with manual transmission do not have valves, but those with automatic have.

M57N engines (M57TUD) (525d & 330d 204hp) have vortex valves.

Ruined swirl flapss:

 

The plugs that replace the vortex valves are easy to find on the internet, but you can also find them here on our website.

Typical plugs:

Disassembly of vortex valves:

 

The vortex valves can be safely dismantled and in most cases if they are  removed properly no loss of power is felt.

Final list of models for which vortex valves are installed:

Engine: M47N/M47TU/M47TUD20

Applications:

* 110 kW (148 hp) and 330 N·m (243 lb·ft)

o E46 320d 2001-2005

o E83 X3 2.0d (up to end of 2006)

Engine: M47TU2D20

The engine was updated again in 2004 as the M47TU2D20. Still at 1995 cc, it produced more power across the range.

Applications:

* 120 kW (161 hp) and 340 N·m (251 lb·ft)

E60/E61 520d

E87 120d

E90/E91 320d

E83 X3 2.0d (end of 2006 onwards)

Engine: M57/M57D25

M57D25 was introduced in 2000.

Applications:

* 166 PS (122 kW; 164 hp) at 4000 rpm, 350 N·m (260 lb·ft) at 2000-2500 rpm with a 4750 rpm redline, models:

2000-2003 E39 525d *Vehicles With Automatic Transmission ONLY*

Engine: M57N/M57TU/M57TUD25

M57TUD25 was introduced in 2004.

Applications:

* 177 PS (130 kW; 175 hp) at 4000 rpm, 400 N·m (300 lb·ft) at 2000-2750 rpm models:

E60/E61 525d

Engine: M57/M57D30

M57D30, also called M57D29, was introduced in 1998.

Applications:

* 184 PS (135 kW; 181 hp)@4000, 390 N·m (290 lb·ft)@1750-3200 models:

E39 530d *Vehicles With Automatic Transmission ONLY*

E46 330d/330xd *Vehicles With Automatic Transmission ONLY*

* 184 PS (135 kW; 181 hp)@4000, 410 N·m (300 lb·ft)@2000-3000 models:

E38 730d *Vehicles With Automatic Transmission ONLY*

E53 X5 3.0d

* 193 PS (142 kW; 190 hp)@4000, 410 N·m (300 lb·ft)@1750-3000 models:

E38 730d

E39 530d

Engine: M57N/M57TU/M57TUD30

M57TUD30 was introduced in 2002. It originally produced 160 kW (215 hp) at 4000 rpm and 500 N·m (370 lb·ft) at 2000-2750 rpm, but was tweaked for 150 kW (201 hp) at 4000 rpm and 410 N·m (300 lb·ft) at 1500-3250 rpm for 2003 and again for 200 kW (268 hp) at 4000 rpm and 560 N·m (410 lb·ft) at 2000-2250 rpm in 2004.

Applications:

* 204 PS (150 kW; 201 hp)@4000, 410 N·m (300 lb·ft)@1500-3250 models:

E46 330d/330Cd/330xd

E83 X3 3.0d

* 218 PS (160 kW; 215 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E53 X5 3.0d

E60/E61 530d/530xd

E65 730d

* 272 PS (200 kW; 268 hp)@4000, 560 N·m (410 lb·ft)@2000-2250

E60/E61 535d

* 245 PS (180 kW; 242 hp)@4000, 500 N·m (370 lb·ft)@2000-2250

* 286 PS (210 kW; 282 hp)@4000, 580 N·m (430 lb·ft)@2000-2250

Engine: M57TU2D30

M57TU2D30 was introduced in 2007, making its debut in the facelifted E60 and E61.

* M57TU2D30-UL: 197 PS (145 kW; 194 hp)

* M57TU2D30-OL: 235 PS (173 kW; 232 hp)@4000, 500 N·m (370 lb·ft)@2000-2750

* M57TU2D30-TOP: 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft)

Applications:

* 197 PS (145 kW; 194 hp), 400 N·m (300 lb·ft) models:

E90/E91/E92 325d

E60/E61 525d/525xd

* 231 PS (170 kW; 228 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E65 730d

E90/E91 325d

E90/E91 330d/330xd

* 235 PS (173 kW; 232 hp) models:

E60/E61, BMW E70, BMW E71

* 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft) models:

E60/E61 535d

E70 X5 3.0sd

E71 X6 xDrive35d

E83 X3 3.0sd

E90/E91 335d

The above models are listed for information only if you want to to make sure your engine has valves installed, please contact a competent person.

Please note that the information described above is for informational purposes only and does not claim to be reliable. Mr-key.com is not responsible for any repair work you undertake that is related to the topic described in this article.

Related Posts

How to Rescue Your Car Key After It Gets Wet: A Practical Guide
11.02.2025

How to Rescue Your Car Key After It Gets Wet: A Practical Guide

The Modern Dilemma: Wet Car Keys and How to Fix Them Imagine this: you’re caught in an unexpected downpour, and your car key slips from your hand, landing straight into a puddle. Or perhaps you accidentally leave your keys in your pocket while diving into a swimming pool. Whatever the scenario, the moment you realize your car key has been submerged in water can be panic-inducing. With modern car keys embedded with electronic chips and sophisticated technology, exposure to moisture can mean more than just a temporary inconvenience—it could leave you locked out or facing expensive repairs. But before you rush to replace your key, there are several steps you can take to salvage it. Understanding the Risks: What Happens When a Car Key Gets Wet? Car keys today are more than just metal; many include electronic transponders and remote control systems that communicate with the vehicle’s ignition. Water exposure can lead to: Short circuits: Moisture can cause electronic components to malfunction or fail entirely. Corrosion: Over time, water can lead to rust and degradation of internal circuits. Battery failure: Many car keys contain small batteries, and water exposure can lead to leakage or loss of function. While traditional metal keys are less affected by water, smart keys and key fobs are vulnerable. Acting quickly can often save your key from irreparable damage. Immediate Steps to Take When Your Car Key Gets Wet If your car key has been exposed to water, time is of the essence. Here’s what you need to do: Retrieve the key from the water as quickly as possible and wipe off excess moisture using a dry, absorbent cloth or paper towel. Remove the battery if possible since many car key fobs have removable batteries; check your car manual for instructions. If the battery is wet, replace it with a new one rather than attempting to dry and reuse it. Disassemble the key fob if safe to do so, carefully opening the casing to allow internal components to dry. Avoid using force or tools that might damage delicate parts. Use silica gel or rice for drying—place the key fob in a container of silica gel packets (often found in new shoe boxes or electronics packaging) for 24-48 hours; if silica gel is unavailable, uncooked rice can work as an alternative, though it may not be as effective. Avoid using direct heat—do not use hairdryers, microwaves, or ovens to speed up drying, as high temperatures can warp plastic components and damage circuits; instead, allow the key to air dry naturally in a warm, ventilated space. Finally, test the key once you’re confident it is dry by reinserting the battery and testing it on your car; if the key does not work, it may require reprogramming or replacement. When to Seek Professional Help If your key remains unresponsive despite thorough drying, it may have suffered internal damage. In such cases, consider these options: Contact your car manufacturer or dealership—they can provide a replacement key or attempt to reprogram the existing one. Visit a professional locksmith—many automotive locksmiths specialize in repairing and reprogramming electronic keys at a lower cost than dealerships. Check your car insurance policy—some policies cover lost or damaged keys, potentially reducing replacement costs. Global Trends in Key Fob Durability and Waterproofing Car manufacturers are increasingly designing key fobs to withstand water exposure. For example, Tesla’s Model 3 key card eliminates the need for traditional keys by using a waterproof RFID card, Toyota and BMW have introduced water-resistant key fobs, minimizing the risk of damage, and future innovations may include biometric key technology, reducing dependency on physical devices altogether. As technology advances, water-resistant key designs may become the norm, reducing the stress of accidental spills or submersion. Preventative Measures: How to Protect Your Car Key from Water Damage To avoid future incidents, consider these preventative steps: Use a waterproof key case: Available online, these cases provide a protective barrier against water exposure. Designate a dry storage spot: Avoid leaving keys in pockets that may go through the wash or near pools and sinks. Invest in a spare key: Having a backup key can be a lifesaver if your primary key is damaged beyond repair. Check for manufacturer upgrades: Some car brands offer upgraded, water-resistant key fobs for an additional fee. Act Quickly to Save Your Key A wet car key doesn’t necessarily mean it’s the end of the road. By acting swiftly and following proper drying techniques, you may be able to rescue your key without costly replacements. As car technology evolves, so too will key durability, but for now, a little caution and quick thinking can go a long way. If you frequently find yourself around water, taking preventative measures can save time, money, and frustration.

How to Upgrade Your Car Key: A Step-by-Step Guide
26.06.2024

How to Upgrade Your Car Key: A Step-by-Step Guide

Upgrading your car key can significantly improve your vehicle’s security and make your daily routine more convenient. Whether you’re upgrading from a basic key to a remote key or stepping up to a smart key, this guide will take you through the entire process, step by step, ensuring a smooth transition. Understanding Your Key Type Before you start the upgrade process, it’s important to know which type of key you currently have. Here are the most common key types: Traditional Metal Keys : These are basic, mechanical keys, common in older vehicles. They don’t have any electronic components. Transponder Keys : These have an electronic chip inside the key head that communicates with the vehicle’s computer system for added security. Remote Keys : These keys have buttons to lock/unlock the doors remotely and usually have a physical blade as a backup. Understanding your current key type will help guide your decision on the best upgrade path. Choosing the Right Upgrade Once you know what type of key you have, you need to decide what features you want in your upgraded key. Some options to consider are: Remote Locking : Allows you to lock/unlock the doors from a distance. Keyless Entry : Lets you unlock the car without taking the key out of your pocket. Smart Key : Offers advanced functions such as proximity unlocking, push-button start, and remote engine start. Take some time to research the options available for your specific car model. Many car manufacturers offer compatible upgrades for different key types, so it’s important to consult your dealership or a trusted locksmith for recommendations. Gathering What You’ll Need Before starting the upgrade process, make sure you have the following materials: The New Key : This could be a transponder key, remote key, or smart key. Your Original Key : You’ll need this as a reference throughout the process. Key Programming Device : Some keys require a special device to pair the key with your car. Car Manual or Programming Guide : It’s always a good idea to have your car’s manual handy for specific instructions. Having everything ready will make the process much smoother. Step-by-Step Upgrade Process Purchase the New Key Start by purchasing your new key. You can buy it from your car’s dealership, a certified locksmith, or a trusted online retailer. Make sure that the key is compatible with your vehicle’s make and model. Transfer Electronics (if necessary) If your new key is just a shell, you will need to transfer the internal components from your old key. This includes the transponder chip and, if applicable, the key blade. Be careful when transferring the electronics to avoid any damage. Program the Key Programming the new key is crucial for it to work with your vehicle. Here’s a general guide: Insert the original key into the ignition and turn it to the ON position. Quickly remove the original key and insert the new key. Turn the new key to the ON position and wait for the security light to turn off. This might take a few minutes. Test the New Key After programming, it’s important to test the new key to ensure everything works properly. Check the following functions: Locking and unlocking the doors Starting the engine Any additional functions like remote trunk opening or proximity unlocking Troubleshooting Common Issues If your new key isn’t working as expected, don’t worry! Here are some common problems and their solutions: Key Not Recognized : Check if the transponder chip is properly placed in the key. Key Doesn’t Start the Car : Double-check the programming steps to ensure everything was done correctly. Buttons Don’t Work : Verify that the battery in the new key is properly installed and functional. If the problem persists, it’s best to consult a professional locksmith or visit your dealership for further assistance. Upgrading your car key is an excellent way to improve both the security and convenience of your vehicle. By following these steps, you’ll be able to transition smoothly to your new key. If you run into any issues, don’t hesitate to reach out to a professional locksmith who can help you along the way. Enjoy the benefits of your new car key and the added peace of mind that comes with enhanced security.

Top 5 Interesting Facts About Audi: The Legacy Behind the Four Rings
13.10.2024

Top 5 Interesting Facts About Audi: The Legacy Behind the Four Rings

When you think of Audi , luxury, innovation, and performance probably come to mind. But behind the sleek design and advanced technology, Audi’s story is filled with fascinating history and achievements. Whether you’re a long-time fan or new to the brand, there’s a lot to discover. In this article, we’ll uncover five of the most interesting facts about Audi that every car enthusiast should know. 1. The Meaning Behind Audi’s Four Rings At first glance, Audi’s logo—four interlocking rings—seems like a simple yet stylish design. However, these rings have deep significance. Each ring represents one of the four founding companies that came together in 1932 to form Auto Union: Audi , DKW, Horch, and Wanderer. A Rich History : This merger marked the beginning of what would eventually evolve into Audi, and the four rings symbolize the unity of these brands. It’s more than just a logo; it’s a reminder of Audi’s prestigious heritage and long-standing dedication to automotive innovation. Survival Through the Ages : Despite wars, economic downturns, and changes in the automotive landscape, the legacy of these four companies continues to live on in Audi’s cutting-edge vehicles. 2. Audi Was the First to Introduce Quattro All-Wheel Drive In 1980, Audi made waves in the automotive world by introducing the Quattro all-wheel-drive system. Originally developed for rally racing, the Quattro system was revolutionary, giving drivers improved traction, handling, and stability in all types of weather conditions. A Game-Changer for Drivers : This innovative system quickly became a staple for Audi vehicles, giving them superior control and stability. Today, the Quattro system is still a key feature, especially in models designed for performance and sport. Setting the Standard : Audi’s Quattro system not only changed the way we think about driving in tough conditions but also set the benchmark for all-wheel-drive technology, making it one of the most trusted names in the industry. 3. The Name "Audi" Has Latin Origins Did you know that the name "Audi" has an interesting linguistic history? The name comes from the Latin translation of the German word “Horch,” which means “listen.” August Horch, the founder of Audi, had to change the name of his company due to legal reasons after he left the Horch company. Rather than giving up his name completely, he chose to translate it into Latin, giving birth to the name “Audi.” An International Touch : This name change added an international flair to the brand and has since become synonymous with high performance and luxury. A Tribute to the Founder : Audi’s name serves as a lasting tribute to August Horch’s vision and his pioneering spirit in the world of automobiles. 4. Audi’s Revolutionary Win at Le Mans In 2006, Audi made history by becoming the first car manufacturer to win the prestigious 24 Hours of Le Mans race using a diesel engine. Audi’s R10 TDI was not only fast but also fuel-efficient, demonstrating the potential of diesel technology in endurance racing. Fuel Efficiency Meets Performance : The victory wasn’t just about speed; it was about showcasing how efficiency and performance could work hand in hand. This win cemented Audi’s reputation for innovation and opened the door for more advanced technologies in racing. Multiple Wins : Audi’s dominance at Le Mans didn’t stop there. Over the years, the brand has secured numerous wins at the event, further proving that Audi’s commitment to excellence extends to the world of motorsports. 5. Audi’s Focus on Lightweight Design: The Audi A8 Audi has always been at the forefront of automotive design, and the Audi A8 is a testament to that. Introduced in the 1990s, the A8 was one of the first vehicles to feature an all-aluminum body, significantly reducing its weight while enhancing performance and fuel efficiency. Aluminum Innovation : By using lightweight aluminum in place of traditional steel, Audi was able to create a vehicle that not only performed better but was also more fuel-efficient and environmentally friendly. An Industry Leader : This innovative approach to vehicle design has influenced the automotive industry as a whole, and the Audi A8 remains a leader in the luxury sedan market. Audi’s Legacy of Innovation Audi is more than just a luxury car brand—it’s a company that consistently pushes the boundaries of what’s possible in automotive technology. From pioneering all-wheel-drive systems to revolutionizing motorsports, Audi has proven time and time again that it’s a brand dedicated to innovation, performance, and quality. As a car owner, whether you’re drawn to Audi for its history or its cutting-edge technology, it’s important to ensure you have reliable and convenient solutions for every aspect of car ownership, including your car keys. Audi’s legacy of innovation can serve as a reminder that planning ahead—whether in technology or practical matters like having a spare key—can save you from unexpected hassles down the road.

Cold Weather and Your Car Key Fob: What You Need to Know
08.01.2025

Cold Weather and Your Car Key Fob: What You Need to Know

As the temperature drops and winter approaches, it’s not just your car’s engine that needs extra attention. Your car’s key fob is also affected by the cold weather, and it’s important to understand how frigid temperatures can impact its performance. In this article, we’ll explore how cold weather can affect your key fob and what you can do to prevent it from causing you frustration during the colder months. How Cold Weather Affects Your Key Fob Key fobs are small electronic devices designed to make our lives easier. They allow us to lock, unlock, and start our cars without ever having to take the key out of our pocket or bag. However, like any electronic device, key fobs are sensitive to extreme temperatures. When the temperature drops, the battery inside the key fob can be affected. Cold weather causes the battery’s chemical reactions to slow down, which can lead to a reduced charge or even a complete failure to operate. If your key fob suddenly stops working or becomes unresponsive, it's likely due to the cold weather affecting the battery's ability to function properly. In addition to battery performance, the cold can also cause the internal components of the key fob to contract. This may interfere with the fob’s functionality, causing it to not respond when you press the buttons. Furthermore, moisture from snow, rain, or condensation can get into the fob, which can cause short circuits or further damage. Signs Your Key Fob May Be Affected by the Cold If you live in an area where cold temperatures are common, it’s essential to be aware of the signs that your key fob might be struggling with the weather. Here are some indicators that the cold is affecting your key fob: Unresponsive buttons : If you press the buttons on your key fob and nothing happens, it may be due to the battery or the internal components not responding correctly to the cold. Delayed reactions : If you notice a delay in your fob’s response, where the locks or alarm take longer than usual to react, this is another sign of cold-induced malfunction. Reduced range : If your key fob is working, but only from a very short distance, it could be due to the battery’s reduced performance in the cold. If you notice these issues, don’t immediately panic. There are simple fixes and preventative steps you can take to resolve the issue. What You Can Do to Protect Your Key Fob in the Cold Fortunately, there are several things you can do to ensure that your key fob continues to work properly during cold weather. By taking a few precautions, you can protect the battery and internal components of your key fob from extreme temperatures: Keep Your Key Fob Warm One of the easiest ways to prevent cold weather from affecting your key fob is to keep it warm. If you're going outside during cold weather, keep your key fob in your coat pocket or a warm, insulated area. You can even use a small pouch or key fob holder with insulation to protect it from the cold. Replace the Battery Before Winter If your key fob is already showing signs of battery issues, consider replacing the battery before winter hits. Even if it’s not quite dead yet, replacing the battery can help ensure that your key fob works smoothly during colder months. Many key fob batteries are easy to replace and can be done at home with a simple tool. Use a Backup Key If you anticipate being in extremely cold conditions or live in a particularly harsh climate, consider having a backup key. Many cars come with a traditional key hidden inside the key fob, which you can use if the key fob stops working in the cold. Having this backup can save you a lot of hassle if your fob stops working unexpectedly. Avoid Moisture Exposure It’s important to keep your key fob dry, especially in winter, when snow, rain, and condensation can cause moisture to build up inside. If your fob does get wet, dry it thoroughly as soon as possible and avoid leaving it outside in damp conditions. If moisture persists, it may cause the internal components to fail. Test Your Key Fob Regularly To ensure that everything is working properly, make a habit of testing your key fob regularly, especially during the colder months. If you notice any signs of malfunction early, you can address the issue before it gets worse. What to Do If Your Key Fob Stops Working If your key fob stops working despite taking preventative measures, don’t panic. There are a few things you can do: Warm up the Fob : Try warming up the fob by placing it in your pocket for a few minutes or rubbing it in your hands. This can help restore some functionality if the battery has slowed down due to the cold. Replace the Battery : If the fob still isn’t working, it may be time to replace the battery. A new battery can often resolve issues related to cold weather. Contact a Professional : If the fob continues to malfunction after changing the battery, it may be time to take it to a professional locksmith or the dealership to check for internal damage. While it’s easy to overlook the impact that cold weather can have on your car’s key fob, it’s important to understand the effects that extreme temperatures can have on its performance. By taking simple precautions and knowing the signs of potential issues, you can help ensure that your key fob continues to work smoothly throughout the colder months. From keeping it warm to regular maintenance, there are several ways to protect your key fob and avoid the frustration of a malfunction during the winter. So, this season, take a few extra steps to care for your key fob, and you’ll be able to unlock and start your car with ease, no matter how cold it gets outside.

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