Post Name

 

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

Here’s 1 Crazy Mistake 40% of Car Owners Make

Here’s 1 Crazy Mistake 40% of Car Owners Make

When it comes to car ownership, most of us are pretty diligent. We make sure our insurance is up to date, change the oil like clockwork, and even rotate our tires to avoid any wear and tear. But there’s one crucial aspect that many car owners overlook: having a spare key . It seems like a small detail, right? Yet, nearly 40% of car owners don’t have a backup key for their vehicle. And that’s a huge risk. Why? Because losing your only car key can cause a headache you’re not prepared for—and it’s a lot more common than you might think. The Hidden Dangers of Only Having One Car Key It’s easy to get comfortable with just one key. After all, it’s always in your pocket, bag, or hanging on your keychain. But life happens. Keys get lost, misplaced, or even stolen, and when that happens, you’re looking at a nightmare scenario. Here’s why: Costly Lockouts : Lose your key, and you’re locked out of your car, stranded until you can get help. Calling a tow truck or emergency locksmith is not only frustrating but can cost you hundreds of dollars. Inconvenient Delays : Have an important meeting? Picking the kids up from school? With only one key, losing it means your entire day—or week—grinds to a halt. Damaged Key, No Backup : Keys wear down over time, and if you only have one, a damaged key could lead to ignition problems. Suddenly, your car won’t start, and now you’re stuck paying for both a repair and a replacement. Security Risk : Lost keys are more than just a hassle—they’re a potential security threat. If your key falls into the wrong hands, your vehicle becomes vulnerable. The Pricey Locksmith Option Once you’re locked out or your key is lost, your options become limited—and expensive. Going to a local locksmith is one route, but here’s what you’re facing: High Prices : Traditional locksmiths can charge anywhere from €150 to €400 just to cut and program a new car key. Depending on your car model, it could be even more. Inconvenient : Many locksmiths don’t work around your schedule, and waiting for them to arrive or driving to their location takes time you don’t have. The Smart, Affordable Solution: Mr-Key.com Fortunately, there’s an easier and much more affordable option— Mr-Key.com . Instead of paying top dollar and wasting time, here’s how you can get a spare key in just a few simple steps: Take a Picture : Simply snap a photo of your existing key. Send It to Us : Upload the picture to Mr-Key.com using our secure service. Get Your Key Delivered : We’ll cut a perfect match and deliver it right to your door at a fraction of the cost of a traditional locksmith. Don’t Wait for a Crisis—Get Your Spare Key Now! Why risk being locked out or paying hundreds when you can have peace of mind for less? Visit Mr-Key.com today and get a spare car key cut from just a picture. It’s quick, it’s easy, and it’s affordable. Don’t be part of the 40% that gambles with just one key—protect your car and your schedule with Mr-Key.com!

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

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.

The Top 5 Car Key Emergencies and How to Handle Them

The Top 5 Car Key Emergencies and How to Handle Them

When it comes to car keys , emergencies often strike at the worst possible moments. Whether you’re rushing to work, stuck at a grocery store, or stranded in an unfamiliar location, knowing how to handle these situations can save you time, stress, and money. Below are the five most common car key emergencies and practical solutions to get you back on track. 1. Locked Out of Your Car? Here’s What to Do Locking your keys inside your car is a common yet frustrating mistake. The good news? There are ways to regain access without breaking the bank—or your window. Check for Spare Keys: If you have a spare key, now is the time to use it. Always keep one in a secure but accessible location, like with a trusted friend or at home. Use a Slim Jim or Unlocking Tool: While not ideal for everyone, these tools can work if you’re familiar with their use. However, be cautious to avoid damaging your car. Call a Locksmith or Roadside Assistance: Professional services can unlock your car safely and quickly. While it might cost you, it’s often cheaper than repairing a broken window. Pro Tip: Many modern cars come with apps or key fobs that allow remote unlocking. Familiarize yourself with these features beforehand. 2. Key Stuck in the Ignition? Don’t Panic A key stuck in the ignition can leave you feeling helpless, but with the right steps, you can often fix the issue yourself. Check the Gear Position: Ensure the car is in “Park” or “Neutral.” Many cars prevent key removal unless the gear is correctly positioned. Inspect for Steering Wheel Lock: Wiggle the steering wheel gently while trying to turn and remove the key. A locked steering wheel might be the culprit. Lubricate the Lock: Use a small amount of graphite lubricant to loosen the ignition lock. Avoid oil-based lubricants as they can attract dirt. Seek Professional Help: If the key is still stuck, call a locksmith or mechanic to prevent further damage. 3. Lost Your Key Fob Without a Spare? Act Fast Losing your key fob with no backup can be a nightmare, especially if your car relies on it entirely. Contact a Locksmith: Many locksmiths can program a new key fob on the spot, often at a lower cost than going to a dealership. Order a Replacement: Some car manufacturers allow you to order a replacement key fob online. Be prepared to provide proof of ownership. Preventative Measures: Always have a spare key fob and store it in a safe location. Consider investing in a key tracker to avoid future mishaps. 4. Dealing with a Wet or Damaged Key Fob? Accidents happen—maybe your key fob went through the wash or got drenched in the rain. The good news? Not all is lost. Dry It Out: Remove the battery and place the key fob in a bag of rice or silica gel to absorb moisture. Let it sit for at least 24 hours. Replace the Battery: Water damage can short-circuit the battery, so replace it with a new one after drying the fob. Test the Fob: After reassembling, check if the fob functions properly. If not, you may need to replace it or have it repaired by a professional. 5. Dead Key Fob Battery in a Remote Location? A dead key fob battery can leave you stranded, but this issue is often easier to resolve than you might think. Check for Hidden Features: Many cars have an emergency key hidden in the fob itself. This can manually unlock the door. Push-Button Start Workaround: Some cars allow you to start the engine by holding the dead fob close to the start button. Carry a Spare Battery: Always keep a spare CR-type battery in your glove box for quick replacements. These are inexpensive and widely available. Pro Tip: Familiarize yourself with your car’s manual to learn emergency procedures for dead key fobs. General Tips to Prevent Car Key Emergencies Preparation is your best defense against car key emergencies. Follow these tips to avoid getting caught off guard: Keep a Spare Key Handy: Store it at home, with a trusted person, or in a secure, hidden location. Invest in a Key Tracker: Attach a Bluetooth-enabled tracker to your key fob for easy location via your smartphone. Regular Maintenance: Replace key fob batteries proactively and inspect your keys for wear and tear. Learn Emergency Features: Understand your car’s built-in features, such as remote unlocking or hidden keys, to save time in emergencies. Stay Prepared, Stay Calm Car key emergencies don’t have to derail your day. With a little preparation and knowledge, you can tackle these common scenarios with confidence. Whether it’s unlocking your car, replacing a battery, or dealing with a damaged key fob, taking proactive measures ensures you’re always one step ahead.

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

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

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

Chat with us