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

The Evolution of BMW: A Journey Through Innovation and Design
13.01.2025

The Evolution of BMW: A Journey Through Innovation and Design

BMW, a name synonymous with luxury, precision, and performance, has a fascinating history marked by relentless innovation. Its journey, from humble beginnings to becoming a global icon of the automotive industry, reflects an enduring commitment to engineering excellence and design evolution. Let’s take a closer look at how BMW’s story has unfolded over the decades, captivating car enthusiasts around the world. The Early Days: Born in Aviation BMW’s story began in the early 20th century, not with cars but with aircraft engines. The company’s roots in aviation are symbolized in its logo, representing a propeller against a blue sky. During World War I, BMW earned recognition for its groundbreaking aircraft engine designs, which were known for their power and reliability. However, with the end of the war came restrictions on aircraft production, prompting BMW to pivot its focus. By the 1920s, BMW shifted gears, literally and figuratively, entering the motorcycle and automotive markets. This transition laid the foundation for the brand’s future. Breaking Into the Automotive World In 1928, BMW launched its first car, the Dixi 3/15, a licensed version of the British Austin 7. Though modest, this compact car symbolized the brand’s entry into the competitive automotive industry. By the 1930s, BMW began developing its own models, showcasing innovation with designs like the 328 Roadster. Known for its sleek aesthetics and impressive performance, the 328 became a motorsport legend, solidifying BMW’s reputation for engineering excellence. Post-War Challenges and Resilience World War II brought both opportunities and challenges for BMW. The company produced military vehicles and engines, which left its facilities heavily damaged by the end of the war. Faced with a ban on manufacturing vehicles, BMW pivoted once again, producing household appliances and bicycles to survive. It wasn’t until the 1950s that BMW returned to car manufacturing, introducing models like the BMW 501. This period was marked by financial struggles, but BMW’s resilience paid off with the release of the Isetta microcar. Affectionately called the “bubble car,” the Isetta was a quirky, affordable solution for post-war consumers, helping the brand regain stability. The 1960s: A New Era of Innovation The 1960s marked a turning point for BMW, as the company introduced the New Class (Neue Klasse) series. These sporty sedans, including the iconic BMW 2002, combined performance with practicality, appealing to a growing market of car enthusiasts. This era also saw the birth of BMW’s reputation for building “ultimate driving machines,” emphasizing driving pleasure as a core philosophy. With its newfound success, BMW expanded globally, entering new markets and establishing a loyal fan base. The New Class not only saved the company from financial troubles but also set the stage for its future success. The Rise of Luxury and Performance By the 1970s and 1980s, BMW had firmly established itself as a luxury brand, offering high-performance vehicles that appealed to both casual drivers and motorsport enthusiasts. The introduction of the BMW 3 Series in 1975 marked the beginning of an enduring legacy. Known for its dynamic handling and elegant design, the 3 Series became a benchmark for compact executive cars. During this time, BMW also made significant strides in motorsport, launching its iconic M division. The BMW M1 supercar and the high-performance M3 further cemented the brand’s position as a leader in both luxury and performance. Embracing Technology and Sustainability The late 20th and early 21st centuries brought rapid technological advancements, and BMW was quick to adapt. The brand embraced cutting-edge features like navigation systems, adaptive cruise control, and hybrid powertrains, blending innovation with sustainability. The introduction of the BMW i Series marked a bold step toward electric mobility. Models like the i3 and i8 showcased the brand’s commitment to reducing emissions while maintaining its signature performance and luxury. A Glimpse Into the Future Today, BMW continues to evolve, pushing the boundaries of automotive technology. From autonomous driving to AI-powered interfaces, the brand is redefining what it means to drive in the 21st century. The development of fully electric models, like the BMW iX , reflects the brand’s vision for a sustainable future. Why BMW’s Evolution Matters Understanding BMW’s journey helps you appreciate the brand’s dedication to innovation and quality. Whether you’re a loyal BMW owner or an aspiring enthusiast, knowing the history of this iconic brand highlights why it remains a top choice for drivers worldwide. Pro Tips for BMW Owners Maintain Regular Service: Keep your BMW in top condition with regular maintenance. Use Genuine Parts: Opt for authentic components to ensure reliability and performance. Stay Informed: Familiarize yourself with your BMW’s features and innovations to maximize its potential. A Legacy of Excellence From crafting propellers to creating luxury vehicles, BMW’s evolution is a testament to its commitment to innovation and performance. The brand’s ability to adapt and excel through challenges has earned it a permanent place in automotive history. As BMW continues to innovate, one thing remains constant: its promise to deliver an unparalleled driving experience.

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.

How Hot Weather Can Damage Your Car Key Fob – And What You Can Do About It
19.06.2025

How Hot Weather Can Damage Your Car Key Fob – And What You Can Do About It

When you think about how hot weather affects your vehicle, your first thoughts might go to the engine, the tires, or maybe even the air conditioning. But there’s one small, essential part of your daily driving routine that’s often overlooked — your car key fob. It might seem like a tough little device, but the truth is, it’s far more sensitive than it looks. If you’ve ever left your key fob on the dashboard, in a hot glove box, or even inside your pocket during a heatwave, you may have already caused damage without realizing it. Car key fobs are built with delicate electronics, plastic shells, and lithium coin batteries — all of which are vulnerable to extreme temperatures. In this article, you’ll learn how hot weather affects each part of your key fob, how to spot the early signs of damage, and most importantly, what you can do to protect it. Taking just a few simple steps can save you from the cost and inconvenience of a non-functioning remote, especially when you least expect it. The Plastic Shell: First to Feel the Heat One of the first things to suffer from heat exposure is the plastic casing that protects your key fob. While it’s designed to withstand everyday use — being dropped, tossed in a bag, or handled frequently — it’s not built to survive hours in a baking-hot car. The interior temperature of a parked vehicle can soar past 60 or even 70 degrees Celsius on a sunny day, especially if the key is sitting directly in sunlight. Over time, this level of heat can soften the plastic, causing it to warp, bend, or even split at the seams. You may start to notice that your key doesn’t close as tightly as it used to, or the buttons may feel soft and spongy instead of firm. Cracks might appear along the sides, or parts of the shell may become discolored. While this might seem like a cosmetic issue at first, it has serious implications — a compromised shell allows moisture, dust, and debris to enter the fob, putting the internal electronics at risk. If your key fob’s shell is already showing signs of wear, especially after a hot summer, it’s time to consider replacing the casing before the damage gets worse. Battery Breakdown: How Heat Drains Power Inside your key fob, there’s usually a small lithium battery — typically a CR2032 coin cell. These batteries are reliable under normal conditions, but they don’t respond well to high temperatures. In fact, exposure to extreme heat can accelerate chemical breakdown inside the battery, leading to faster discharge and a shorter overall lifespan. What’s worse, in severe cases, the battery can swell or leak, which can damage the internal components of your fob permanently. If you’ve ever noticed your key fob suddenly stops working or becomes unreliable during the summer, there’s a good chance the battery is struggling under heat stress. The signal may become weaker, you might have to press buttons multiple times, or the remote might stop responding altogether. Replacing the battery is a quick and inexpensive fix, but it’s important to recognize that battery issues are often just the first symptom of deeper heat-related problems. Internal Electronics: Silent Victims of the Heat While the shell and battery are easier to see and replace, the most serious damage often happens silently — deep inside the electronic circuit board. This board, often referred to as the platine, is responsible for all communication between your key and your vehicle. It’s a compact, delicate system of soldered connections and microchips, and unfortunately, it’s not designed to cope with repeated thermal stress. When your key fob is exposed to fluctuating high temperatures, the constant expansion and contraction of materials can loosen solder joints or weaken connections. Moisture that gets trapped inside the shell during humid summer months can accelerate corrosion, especially if the casing is already cracked or loose. The damage might not be immediate, but over time you may find that your key fob becomes unpredictable — sometimes it works, other times it doesn’t, and eventually, it might stop working completely. What You Can Do to Prevent Heat Damage The good news is that most heat-related damage to key fobs is preventable with just a little care and awareness. First, never leave your key fob inside a parked car for extended periods, especially not in direct sunlight. It’s easy to toss your keys into the cup holder or leave them on the dashboard while you run errands, but those few minutes can expose them to dangerous levels of heat. Instead, keep your keys on you or store them in a shaded, temperature-controlled area. If you’re regularly in hot environments — such as driving in warm climates or working outdoors — consider investing in a protective silicone or leather cover. These not only shield the shell from heat exposure but also provide added protection against drops and dirt. You should also make it a habit to replace your battery once a year, even if it seems to be working fine. Batteries weakened by heat can fail suddenly, and a fresh cell ensures your key fob keeps working when you need it most. Finally, if your key fob’s shell is visibly worn or loose, replace it immediately. Many online stores, including Mr Key, offer affordable replacement shells that are easy to install and give your remote a like-new feel. Don’t wait for the damage to reach the internal electronics — by then, repair options are limited and usually more expensive. Protect Your Key, Protect Your Drive Your car key fob might be small, but it plays a huge role in your daily routine. From unlocking doors to starting your engine, it’s a modern convenience we all depend on — until it stops working. And while many drivers are careful with their car’s mechanical systems, few think twice about leaving their key fob in the heat. Now that you know how much damage summer temperatures can cause, you can take the steps needed to protect your key before it’s too late. If you’re looking for high-quality key shell replacements, batteries like the CR2032, or even complete key fobs compatible with your vehicle, Mr Key has you covered. Our online shop offers trusted parts for Peugeot, Citroën, Nissan, Suzuki, Fiat, and more — all designed to help you repair and maintain your car keys quickly and affordably.

Car Security: Protecting Your Vehicle in Today’s World
19.06.2024

Car Security: Protecting Your Vehicle in Today’s World

The Rising Need for Advanced Car Security In an era where vehicles are becoming smarter and more connected, the risks of car theft and unauthorized access are also increasing. Modern technology has enhanced both the convenience and vulnerability of cars, making robust security measures more critical than ever. This guide explores the importance of car security, the latest innovations in the field, and practical tips to ensure your vehicle stays protected. Why Car Security Matters: Understanding the Threat Car theft remains a significant concern worldwide. According to recent statistics, car-related crimes have shifted from traditional theft methods to more technologically advanced tactics. Thieves now often target vehicles equipped with keyless entry systems, using tools like relay devices to gain access. In the UK alone, over 100,000 vehicles are stolen annually, with keyless thefts—or "relay attacks"—on the rise. This growing trend highlights the importance of adopting modern security solutions to stay ahead of potential threats. Key Features of Modern Car Security Systems Modern car security systems are designed to protect against both physical and digital threats. Some of the most common and effective features include: Immobilizers Prevent the engine from starting without the correct key or transponder signal. Often included as standard in modern vehicles, reducing the likelihood of theft. Alarms Act as a deterrent by emitting loud sounds when unauthorized access is detected. Many systems also notify the owner via a smartphone app. GPS Tracking Systems Allow real-time location tracking of your vehicle in case of theft. Advanced models can remotely disable the vehicle’s engine. Dashcams Record suspicious activity around your car, providing evidence in case of an incident. Dual-camera systems monitor both inside and outside the vehicle. Emerging Trends in Car Security Technology As technology evolves, so do car security measures. Here are some of the latest innovations transforming vehicle safety: Biometric Authentication : Cars equipped with fingerprint or facial recognition systems ensure only authorized individuals can operate the vehicle. Digital Keys : Linked to smartphones, these keys allow remote access and control, but also require robust cybersecurity measures to prevent hacking. Geofencing Alerts : Some advanced systems notify owners if their car leaves a predefined area, adding an extra layer of protection. These advancements show how car security is moving beyond traditional locks and alarms, integrating digital solutions for a smarter, safer experience. Practical Tips to Keep Your Car Safe While advanced technology can significantly improve car security, there are simple, everyday practices that can also help prevent theft and unauthorized access: Park Wisely : Always choose well-lit, secure areas or designated parking spaces. Thieves are less likely to target cars in visible locations. Keep Valuables Hidden : Items left in plain sight can attract unwanted attention. Store belongings out of view or in the trunk. Use Physical Locks : Steering wheel locks and pedal locks act as visible deterrents, even for modern vehicles. Update Software Regularly : For cars with smart systems, keeping the software up-to-date ensures optimal security against potential vulnerabilities. The Global Perspective: How Car Security Varies Worldwide Car security trends and practices vary globally, influenced by factors such as local crime rates, technological adoption, and legislation. In countries like the UK and the US, keyless entry systems and advanced alarms are standard features. However, in emerging markets, physical locks and alarms still play a critical role due to affordability and accessibility. Additionally, some nations have introduced legislation mandating anti-theft systems in new vehicles, further driving innovation in the industry. Understanding these global trends can help car owners make informed decisions when investing in security measures. Stay Ahead of the Risks Car security is no longer just about locking your doors—it’s about staying one step ahead of potential threats. With advanced technologies and practical measures, you can significantly reduce the risk of theft and ensure your vehicle remains safe. Investing in modern security systems, keeping your car’s software updated, and adopting smart habits are all part of building a comprehensive protection plan. In today’s interconnected world, proactive car security is essential for every driver. Stay informed, stay vigilant, and ensure your car stays exactly where it belongs—securely in your possession.

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