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

Lost Your Westfalia Towbar Key? Here's What to Do
30.07.2025

Lost Your Westfalia Towbar Key? Here's What to Do

Have you lost your Westfalia towbar key just before a long-planned trip or an important towing job? Don’t worry, you’re not alone. Every year, thousands of drivers face the same issue: the towbar key disappears right when it's needed most. Westfalia detachable towbar keys are usually used only a few times per year – often for summer holidays, camping trips, towing, or moving. Because they are used so rarely, they often get forgotten for months. It's easy to lose track of where they were last placed: in the glove compartment, a drawer in the garage, or a coat pocket? Fortunately, there's a simple solution – without having to replace the entire towbar system. Step 1: Check the Lock Cylinder for a 5-Digit Code Take a close look at the front of your Westfalia towbar lock, around the keyhole. Many models have a 5-digit code engraved directly into the metal. If the code is between 20000 and 50000, it is your personal key code. This code allows professional key services (like MR-KEY) to create a perfectly matched replacement key – without the original. Examples of valid codes: 23456 27891 49821 You can enter this code directly into an online order form. Order a replacement key here: https://mr-key.com/cat/towbars-keys What if You Only See 3 Digits? Sometimes, you might only find a 3-digit number on the lock body (e.g., 104, 287). Unfortunately, these numbers are not valid key codes . They usually refer to batch numbers or internal components. In this case, we recommend: Conducting a thorough search for the original key (glove compartment, toolbox, jacket pockets, etc.) If the key cannot be found, consider replacing the towbar locking mechanism Tip: Make a Spare Key While You Still Can If you still have your original Westfalia towbar key, now is the perfect time to make a copy . Many Westfalia keys show a code like: 2W01 to 2W50 This code is usually engraved on the metal shaft of the key and matches your towbar lock. With this code, we can quickly and affordably produce a precise duplicate. Why make a spare key? Avoid last-minute panic before departure Reduce costs by preventing lock replacement Fast delivery when ordering by code Order here: https://mr-key.com/cat/towbars-keys Fast and Professional Westfalia Key Service At MR-KEY , we specialize in duplicating Westfalia towbar keys by code. Our service is fast, precise, and hassle-free: Simply provide the 5-digit lock code (20000–50000) We cut the key using high-precision machines Every key is checked before shipping In most cases, shipping is completed within 24 hours . Quick Overview Situation Can a New Key Be Made? What to Do 5-digit code on the lock (20000–50000) Yes Order a key by code Only 3-digit number on the lock No Search for the key or replace the lock Original key with "2W" code present Yes Have a spare key made Tips: How to Avoid Losing Your Key in the Future To avoid ending up in this situation again, follow these simple tips: Store your spare key in your vehicle documents folder or glove box Label your keychain with "Towbar" for easy identification Take a photo of your key code and save it on your phone or in the cloud These small steps can save you time, stress, and money. Losing your Westfalia towbar key doesn't have to ruin your travel plans. As long as your lock has a valid 5-digit code between 20000 and 50000 , a replacement key can be made and shipped quickly. And if you still have the original key? Make a copy now – a small investment for long-term peace of mind. Order your Westfalia replacement key now: https://mr-key.com/cat/towbars-keys Safe travels!

What’s the Difference Between a Key Fob, Smart Key, and Proximity Key?
14.07.2025

What’s the Difference Between a Key Fob, Smart Key, and Proximity Key?

Over the past two decades, vehicle security and convenience have evolved dramatically. Traditional metal keys have steadily given way to a range of more advanced systems that offer not only better protection but also more comfort for the everyday driver. Among the most commonly used terms in today’s automotive world are key fob , smart key , and proximity key . While often used interchangeably, these are not identical technologies. Each represents a step forward in how drivers interact with their cars, and understanding the differences between them is essential—especially when replacing, repairing, or purchasing new key components. In this article, we’ll explore each key type in detail, highlight what sets them apart, and offer practical insights to help you identify which type you own—and what that means for functionality, replacement options, and compatibility. Key Fob: The Foundation of Remote Access A key fob , in the modern context, refers to a remote control device that allows users to perform basic functions such as locking or unlocking the car doors. The word "fob" originally described a decorative accessory on a keychain, but it has evolved to refer specifically to these electronic remotes. Most key fobs use radio frequency (RF) signals to communicate with the vehicle. When you press a button on the fob, it sends a coded signal to a receiver inside the car, instructing it to lock, unlock, open the trunk, or activate the panic alarm. Some key fobs also include a physical key blade that can be used manually if the battery is dead or if the remote functionality fails. Key fobs became standard in the early 2000s and are now found in nearly every modern car. They represent the bridge between the traditional mechanical key and more advanced systems. While they don’t offer hands-free operation or engine-starting capabilities by default, they introduced a level of convenience that significantly improved the driving experience at the time of their launch. Smart Key: Hands-Free, High-Tech, Highly Secure The smart key builds on the foundation of the key fob but adds a major element of sophistication: hands-free access and ignition . With a smart key, you no longer need to press buttons to enter or start your vehicle. Instead, the key communicates continuously with the vehicle via low-frequency antennas and encrypted signals . As long as the key is within a certain range—often in your pocket or handbag—the vehicle automatically detects it and allows for keyless entry and push-button start. In many smart key systems, simply touching the door handle unlocks the vehicle. Once inside, starting the car requires nothing more than pressing a button on the dashboard. Some smart keys even store personalized settings, such as seat position or mirror alignment, offering a more tailored driving experience for each registered user. Originally reserved for luxury vehicles, smart keys have become increasingly common across all vehicle classes. Brands like Lexus, Mercedes-Benz, and BMW were early adopters, but today you’ll find smart keys in many Hyundai, Kia, Toyota, Nissan, and Volkswagen models. They offer both convenience and enhanced security thanks to rolling code encryption, which helps prevent signal interception and unauthorized vehicle access. Proximity Key: The Functional Twin of the Smart Key The term proximity key is often used synonymously with smart key, and in many cases, it functions in the same way. A proximity key allows the car to detect when the key is nearby—typically within one to three feet—and respond accordingly. You can unlock the car simply by approaching or touching the handle, and engine start is enabled through a button as long as the key remains inside the cabin. However, while all smart keys are proximity-based, not all proximity systems include the full feature set of a smart key. In some vehicles, the proximity key may lack advanced personalization or remote app integration, but the core functionality— hands-free locking, unlocking, and push-to-start capability —remains intact. The term “proximity key” is more commonly used in owner manuals or by manufacturers in Europe and Asia, while “smart key” has become the marketing standard in North America. Regardless of the terminology, the underlying technology is largely the same, relying on short-range radio waves, signal encryption, and two-way authentication between the key and the car. Breaking Down the Differences To simplify the distinctions between these three key types, it’s helpful to focus on user experience and technical capability. A traditional key fob requires active input—pressing a button to unlock the doors—whereas smart and proximity keys allow for passive, automatic operation. Additionally, the integration of engine start buttons, memory features, and enhanced security protocols tends to be exclusive to smart and proximity systems. Another notable difference lies in design and construction . Key fobs often have visible mechanical blades and rubber buttons, while smart keys are usually more compact, feature fewer or no physical buttons, and hide the emergency key blade inside the unit. Understanding this can help when shopping for replacement shells, batteries, or full units. Identifying Your Key Type Not sure which key your car uses? You’re not alone. Here's how to tell: If you must press a button on your key to unlock the doors and start the engine with a physical ignition slot, you’re likely using a key fob . If your car unlocks automatically when you approach and starts with a dashboard button —without ever removing the key from your pocket—you have a smart key or proximity key . If your car allows for keyless entry but still requires button pressing on the remote , it's most likely a standard key fob with added convenience features. Why Knowing the Difference Matters Understanding what type of key you use is crucial when you’re purchasing replacement components. A smart key cannot be replaced by a basic key fob, as it contains far more complex electronics and vehicle-specific programming. Likewise, replacing a proximity key requires knowing the exact frequency, chip type, and compatibility with your vehicle’s immobilizer system. At mr-key.com , we help car owners find exactly what they need—whether it’s a replacement key shell, a fresh battery, or a full remote unit with electronics and transponder chip included. With detailed listings sorted by make, model, and key type, it’s easy to identify the correct product and avoid costly dealership programming fees. As automotive technology continues to evolve, so does the way we access and operate our vehicles. Whether you're using a classic key fob, a cutting-edge smart key, or a proximity-based system, each offers a different balance of convenience, security, and technical complexity. Recognizing the key you use—and understanding how it works—not only makes you a more informed vehicle owner but also helps you take better care of your key system. When the time comes for a replacement or upgrade, you’ll be prepared to make the right choice quickly and confidently. For high-quality, vehicle-specific replacement parts, visit mr-key.com . From fob covers and CR2032 batteries to complete electronic keys and blades, we’ve got everything you need to keep your key performing like new.

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.

How to Choose the Right Car Key Shell for Your Vehicle + Why We Recommend Panasonic CR2032 Batteries
27.05.2025

How to Choose the Right Car Key Shell for Your Vehicle + Why We Recommend Panasonic CR2032 Batteries

Your car key is one of those things you don’t really think about — until it breaks. Whether it’s the worn-out buttons, a cracked shell, or a battery that gives up at the worst possible moment, an aging car key can cause more than just annoyance. But here's the good news: you can restore your key to like-new condition easily, affordably, and from the comfort of your home. In this complete guide, we’ll show you how to choose the right replacement key shell for your car and why the Panasonic CR2032 battery is a trusted choice to keep your key fob performing reliably. Part 1: How to Choose the Right Car Key Shell Think of your key shell as a protective layer. It shields the sensitive electronics inside — the buttons, circuit board, and transponder chip — all of which are essential to operating your vehicle. When the case begins to wear down or fall apart, it’s time to replace it. 1. Know Your Car's Make, Model, and Year Key shells are made to fit specific car models and years. For instance: Flip key shells for Opel are commonly used on models from 2010 to 2024. Audi smart key shells are dependent on the platform code (like A3 8Y or A4 B9). Consult your owner's manual or use a compatibility tool like this one to confirm fitment. 2. Match the Key Blade Blades come in various formats like HU162, VA2, or HU100. Even a slight variation in shape or groove pattern can render the key useless in your ignition or door locks. Carefully compare the blade on your current key to the one listed for any replacement shell. 3. Button Layout and Functionality Make sure the number and positioning of buttons on the replacement shell matches your original. If not, the rubber pads may not line up with the contact points on your key’s circuit board, making the buttons unresponsive. 4. Interior Design and Compatibility The outside might look the same, but inside layouts often differ. Ensure that your circuit board, battery slot, and chip all fit securely inside the new shell. Misalignment can cause rattling, failure to start the car, or buttons that don’t function correctly. 5. Material Quality Avoid very cheap replacements with thin plastic and soft rubber. A good quality shell should be durable, with solid construction and tactile buttons that don't wear out quickly. For example, this Opel flip key shell combines strength with excellent fit. Part 2: Why We Recommend Panasonic CR2032 Batteries When your key fob starts failing — maybe the range drops or it takes multiple presses to unlock — chances are the battery is low. Many car owners replace the shell without considering the battery, only to find the problem persists. Understanding the CR2032 The CR2032 is a 3-volt lithium coin battery, commonly used in remote keys and small electronic devices. It’s compact, stable, and specifically suited for low-power, long-term applications. What Makes Panasonic CR2032 Stand Out? Panasonic’s version of the CR2032 is known for its consistency and reliability. It offers: A stable voltage output, ensuring your key communicates with your car effectively Longer life compared to many generic brands Resistance to leaks, which protects internal circuits from corrosion Choosing a battery from a trusted manufacturer can save you from unexpected failures, especially in colder climates where battery performance matters most. We recommend the Panasonic CR2032 battery for its excellent balance of performance and reliability. Refreshing Your Car Key: A Practical Approach If your car key is showing signs of age, it's usually best to replace both the shell and the battery. The process is simple: Open the old shell carefully, using a flat tool if needed. Remove the circuit board, chip, and battery. Clean the components gently with a dry brush. Place them into the new shell, ensuring alignment. Insert a fresh CR2032 battery. Close and secure the new shell. After completing these steps, your key should be more responsive, look better, and feel sturdier in your hand.

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