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

KEY COVERS: WHAT DO YOU NEED TO KNOW?
05.02.2025

KEY COVERS: WHAT DO YOU NEED TO KNOW?

What is a Key Cover? A key cover , often referred to as a key shell or key case, is the outer part of your key. It houses the electronic board, chip, and battery but excludes the internal electronics themselves. If your key casing is damaged, there’s no need to replace the entire key – just changing the key cover can restore its durability and usability while saving you money. When Do You Need a New Key Cover? You might need a key cover replacement when: The buttons on your key become worn out or stop responding. The outer case cracks, exposing the internal electronics. The key mechanism no longer functions smoothly. You want to refresh the appearance of your key with a new, sturdy shell. Instead of struggling with a faulty key, simply replace the cover and extend the lifespan of your original key! How to Choose the Right Key Cover? When selecting a replacement key cover, consider the following factors: Button Layout: Ensure that the number of buttons and their symbols match your existing key. Blade Shape: If your key includes an integrated blade, make sure the new shell accommodates it correctly. Quality: A good-quality key cover ensures a snug fit, smooth functionality, and long-lasting durability. At MR-KEY , we offer a variety of key covers designed to match your specific car model perfectly, providing both aesthetics and functionality. How to Change Your Key Cover? Replacing your key cover is simple and doesn’t require professional assistance. Here’s how: Purchase a compatible key cover from our website. Open your old key case carefully. Transfer the electronic board and chip from your original key to the new key cover . Reassemble the key, ensuring all components fit securely. Test the buttons and functions to confirm everything is working properly. For step-by-step guidance, we provide video tutorials on our website, showing you exactly how to change your key shell and even replace the battery if needed. What Else Can You Change When Replacing the Key Cover? While changing your key cover, it's the perfect time to: Replace non-functional click buttons on your key’s electronic board. Change the battery since you're already disassembling the key, ensuring it lasts longer. At MR-KEY , we strive to make key replacements easy, affordable, and accessible to everyone. Explore our website to find the perfect key cover, key cutting services, and useful video guides to help you maintain your car key like a pro!

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.

Simple Tips to Free a Stuck Lock: What You Need to Know
29.10.2024

Simple Tips to Free a Stuck Lock: What You Need to Know

Locks are meant to provide security, but when they seize up, they can leave you feeling frustrated and helpless. Dealing with a stuck lock is more common than you might think, and thankfully, there are affordable and effective solutions to get it working smoothly again. Whether it's a car door, trunk, or your home lock, here are some tried-and-true methods to free up a jammed lock. Why Locks Seize Up Understanding the causes behind a stuck lock can help you prevent it from happening in the future. Locks can seize up for various reasons: Dirt and Debris : Over time, dust, grime, or even small particles can accumulate inside the lock mechanism, making it harder for the internal parts to move smoothly. Rust and Corrosion : Exposure to moisture, humidity, or salty air can lead to rust buildup on metal parts within the lock, which can prevent movement. Lack of Lubrication : Locks need to be lubricated occasionally to ensure smooth operation. Without lubrication, friction increases, and the lock may eventually jam. Now, let’s look at some simple steps to tackle a seized lock. Step 1: Use Graphite Powder or Dry Lubricant The first thing to try is applying a lubricant, but be careful about what type you use. Wet or oil-based lubricants can attract dust, which eventually clogs the lock. Graphite Powder : This is one of the best options for freeing up a stuck lock. Sprinkle a small amount of graphite powder into the keyhole, insert the key, and gently move it back and forth. This spreads the graphite, reducing friction and allowing the lock components to move more freely. Dry Lubricants : These are specifically designed for locks and are ideal for situations where you want to avoid residue buildup. Spray a small amount into the lock, then insert the key and gently turn it. Pro Tip : Avoid using regular WD-40 or other oil-based products, as they may lead to a buildup over time, making the problem worse. Step 2: Try the Key with Gentle Force If lubrication alone doesn’t do the trick, the next step is to use a little gentle force with your key. Be cautious here; applying too much force could break the key inside the lock. Insert the Key : Once the lubricant has been applied, insert the key fully into the lock. Wiggle Carefully : Gently wiggle and turn the key without applying too much force. This movement may help distribute the lubricant further and gradually loosen up any stuck components. Caution : If you feel excessive resistance, don’t force the key. Forcing it can cause damage or even snap the key, which would require additional assistance to remove. Step 3: Warm Up the Lock (Especially Useful for Cold Weather) Cold temperatures can cause locks to seize due to ice or metal contraction. If you suspect the cold is the issue, warming up the lock can be effective. Use a Hair Dryer : Direct warm air onto the lock for several minutes to allow the metal to expand and the ice (if any) to melt. Heat the Key : You can also try warming the key slightly with a lighter, but exercise caution and make sure it isn’t too hot before inserting it into the lock. Safety Note : Avoid open flames directly on the lock itself, as this can damage surrounding surfaces or even warp the lock mechanism. Step 4: Use a Vinegar Solution for Corroded Locks If rust is the culprit, vinegar is a great household solution for loosening rust and corrosion in a lock. Apply Vinegar : Put a few drops of vinegar on the key, insert it into the lock, and let it sit for a minute or two. Vinegar can help dissolve light rust, making it easier to turn the key. Follow with Lubricant : After using vinegar, apply a small amount of graphite powder or dry lubricant to ensure the lock remains smooth and functional. Step 5: Work with Compressed Air to Remove Debris If dirt or debris has accumulated inside the lock, compressed air is a quick and efficient way to clear it out. Blow Out Dust : Use a can of compressed air and direct the nozzle into the keyhole. Short bursts of air can blow out dust and small debris that may be obstructing the mechanism. Follow Up : After using compressed air, it’s a good idea to add a dry lubricant to prevent any remaining dust from causing future jams. How to Prevent Lock Seizure in the Future Once you’ve successfully freed a seized lock, it’s helpful to take steps to prevent it from happening again. Here are some preventive tips: Regularly Lubricate : Use a dry lubricant or graphite powder once or twice a year, especially if you live in a humid or dusty area. Keep Locks Clean : Wipe off any visible dirt or dust around the lock mechanism. If the lock is exposed to elements (like outdoor or car locks), covering it can help keep debris and moisture out. Avoid Overusing Keys : If your key shows signs of wear, consider getting a replacement. Worn-out keys can cause more friction inside the lock, leading to jams. When to Seek Professional Help Sometimes, despite your best efforts, a lock just won’t budge. In cases where the lock is significantly damaged, heavily corroded, or if the key breaks inside, it’s best to reach out for professional assistance. A professional has specialized tools and expertise to address these issues without causing further damage. Taking Care of Your Locks A stuck lock can be an inconvenience, but by following these simple steps and using a little patience, you can often resolve the issue without professional help. Keeping locks in good condition with regular care is the key to ensuring they function smoothly for years to come.

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.

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