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 Top 5 Car Key Emergencies and How to Handle Them
07.01.2025

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.

Do Car Keys Have GPS? What You Need to Know About Key Tracking
24.04.2025

Do Car Keys Have GPS? What You Need to Know About Key Tracking

In an age where smartphones can locate us with pinpoint accuracy and lost luggage can be tracked halfway around the world, it’s easy to assume car keys are just as smart. But for many frustrated drivers, losing a car key feels like sending it into a black hole. The lack of a clear way to find them often leads to stress, wasted time, and sometimes costly replacements. So here’s the big question: Do car keys have GPS, and can they be tracked like other smart devices? This article explains the technology behind key tracking, compares GPS with Bluetooth, and offers practical ways to find lost keys in a connected world. The Truth About GPS in Car Keys While GPS technology has become common in many consumer devices, the vast majority of car keys do not include built-in GPS. Even the most modern remote key fobs, which allow for keyless entry and push-button start, generally lack the components necessary for GPS functionality. These components include a satellite GPS receiver, a data transmission module, and a sustainable power source—none of which are typically found in a key fob. The design of a car key prioritizes compactness, cost-efficiency, and low energy usage. Adding GPS would not only increase manufacturing costs but also introduce battery life challenges. That’s why most manufacturers have opted against including GPS tracking in car keys. GPS requires constant power and data transmission — something a small coin cell battery in a typical key fob can’t support." – Marcus Lee, Automotive Tech Analyst How Can Car Keys Be Tracked? Although your keys may not have GPS, there are other technologies that make it possible to track or locate them when they’re lost. These include Bluetooth trackers, crowdsourced networks, and GPS systems that track the vehicle instead of the key itself. 1. Bluetooth Trackers (Apple AirTag, Tile, Chipolo) These small, attachable gadgets can be added to your keychain and linked to a mobile app. They rely on Bluetooth to provide location data when within a certain range. If your keys are somewhere nearby—like in your home or office—these trackers can play a sound or show you their last known position on a map. The range is generally up to 120 meters (400 feet), and battery life can last up to a year, making them a practical, low-maintenance option for most users. 2. Crowdsourced Networks (Find My, Tile Network) If your Bluetooth tracker is out of range, some brands offer a smart workaround. Apple’s AirTag, for instance, uses the “Find My” network, which consists of millions of iPhones around the world. If someone with an Apple device passes near your lost keys, the location is anonymously and securely sent to your phone. This creates a global, decentralized tracking system that mimics GPS functionality without requiring satellites or cellular connections. 3. Car GPS Systems (Vehicle Only, Not the Key) Some high-end cars offer integrated GPS systems, but these track the vehicle, not the keys. Brands like Tesla, BMW, and Mercedes-Benz allow owners to locate their car through mobile apps. If your keys are left inside the car, you may be able to find them by locating the vehicle. However, once the keys are removed, they cannot be tracked unless equipped with a separate Bluetooth tracker. GPS vs Bluetooth: What’s the Difference? To better understand why GPS isn’t commonly included in car keys, it’s useful to compare the two technologies: GPS provides global, real-time tracking with high precision, but it’s power-intensive and costly. Bluetooth, while more limited in range, is ideal for small items and short distances, offering a cost-effective solution for everyday use. Global Perspectives on Key Tracking Around the world, the adoption of key tracking technologies differs based on privacy laws, tech infrastructure, and consumer behavior. In Japan and South Korea, smart home and car integration are advanced, yet GPS-enabled keys are still not the norm. In many parts of Europe, particularly in countries like Germany, Bluetooth solutions are favored due to strict data privacy regulations. In contrast, the U.S. market has embraced personal tracking devices like Apple AirTag and Tile, making them increasingly common accessories. These differences highlight how technology adoption often reflects broader cultural and legal norms, as well as the balance between convenience and privacy. Smart Tips to Keep Track of Your Keys Whether your keys have advanced tech or not, you can take simple steps to avoid losing them. Attaching a Bluetooth tracker is a great first line of defense. Keeping your keys in a consistent, designated place at home reduces the chances of misplacement. Many tracking apps also offer “left behind” alerts, which notify you if you leave your keys behind when moving out of range. It's also smart to keep a spare key somewhere safe and consider going keyless if your next car allows it. Implementing a few of these habits can save you time, frustration, and the cost of replacing a lost key. The Future of Key Tracking While car keys may not have built-in GPS, technology continues to evolve with practical alternatives. Bluetooth trackers, supported by app alerts and community networks, already provide effective ways to find lost keys. As innovation progresses, we can expect even more seamless solutions, such as Ultra Wideband (UWB) technology and Internet of Things (IoT) integrations, to become mainstream. As our tools become smarter, so must the way we use and manage them. With a little foresight and the right accessories, you'll never lose track of your keys again.

How to Take the Perfect Photo of Your Key for Easy Replacement
08.11.2024

How to Take the Perfect Photo of Your Key for Easy Replacement

When you need a replacement key , taking a clear, detailed photo of your key can make the process much faster and more accurate. A high-quality image helps key makers understand the exact specifications, cuts, and dimensions of your key, which is especially important if you don’t have a spare. In this guide, we’ll walk you through the best practices for photographing your key so you can get an accurate replacement with ease. Why a Clear Key Photo Matters Photographing a key might sound simple, but it requires a bit of attention to detail. A well-taken photo captures the key’s grooves and unique cuts clearly, helping the key cutter replicate the exact pattern. Saves Time : A high-quality photo reduces the need for multiple attempts to cut a new key. Ensures Accuracy : Clear images help capture specific details, leading to a more precise fit. Convenient Process : With just a smartphone and a few tips, you can photograph your key from home without needing special equipment. Essential Tools for Photographing Your Key To take a clear photo of your key, you don’t need much beyond a few household items. Here’s what you’ll need: Smartphone or Camera : A phone camera is usually sufficient, but a standard digital camera works well too. Plain Background : Choose a neutral, solid-colored background like a piece of white paper or a smooth table surface. Good Lighting : Natural daylight or a bright room light helps capture details without shadows. Small Object for Elevation : A coin or similar item can lift the key slightly, making it easier to photograph. Step-by-Step Guide to Taking the Perfect Key Photo Follow these steps to take a photo that ensures clarity and accuracy for key replacement. 1. Set Up the Background Place a piece of plain white paper or another smooth, light-colored surface under your key. The solid color helps the details of the key stand out without any visual distractions. Tip : Avoid backgrounds with patterns or textures, as these can obscure the key’s features. 2. Position the Key Correctly Lay the key flat on the background, with the grooves and cuts facing up. The key should be positioned horizontally to allow a clear view of all its details. Side Profile : Make sure to capture the side profile that shows the cuts and grooves. Elevate Slightly : Place a coin or small object under one end of the key to angle it slightly toward the camera. This can help reduce shadows and improve focus on the cuts. 3. Adjust Lighting Good lighting is essential for capturing details. If possible, photograph your key in natural daylight near a window or use a well-lit room. Avoid Shadows : Ensure that no shadows fall across the key, as they can obscure details. Diffuse Light : If using a lamp, consider placing a thin cloth over it to diffuse the light and reduce harsh reflections. 4. Focus and Zoom Make sure your camera or smartphone is focused directly on the key. You may need to tap the screen to bring it into sharp focus. Zoom in Carefully : If you’re using a smartphone, zoom in slightly to capture the details, but avoid over-zooming, which can blur the image. Test Multiple Angles : Sometimes a slight adjustment in angle can capture the cuts more effectively, so take a few shots from slightly different perspectives. 5. Capture Multiple Photos It’s always a good idea to take several photos to ensure you have the best one. Try different angles and lighting adjustments to capture as many details as possible. Close-Up of the Grooves : Take one close-up image focusing on the cuts and grooves of the key. Overall Image : Include one full-length photo that shows the entire key from end to end. Try Different Angles : Slightly tilt the key or move the camera to see which angle best captures the detail of the cuts. Common Mistakes to Avoid When Photographing Your Key To get the best results, steer clear of these common issues that can impact the quality of your key photo: Blurry Images : If your hand shakes, use a small tripod or prop your phone on a stable surface. Poor Lighting : Avoid taking photos in dim rooms; use bright light to ensure the key is clearly visible. Obstructed Details : Make sure the entire length of the key is visible, without any part being cut off or covered. Tips for Ensuring a Smooth Replacement Process Once you have a clear photo of your key, there are a few final steps to make the replacement process as efficient as possible. Check the Photos : Look over your photos before sending them to ensure that they’re clear and detailed. Label the Key : If you’re photographing multiple keys, label each one in the image or add a note to avoid confusion. Include Measurements : If possible, add the measurements of the key’s length and width in your notes for added accuracy. A clear, detailed photo of your key can save you time and effort when seeking a replacement. By following these simple steps, you’ll provide all the necessary details to ensure your new key is an accurate match. Remember, good lighting, focus, and capturing all the unique cuts are essential to achieving the best results. With these guidelines, you’re set to take a photo that will make your key replacement process smooth and hassle-free.

Everything You Should Know About Key Fob Battery Life, Leaks, and Temperature Effects
09.06.2025

Everything You Should Know About Key Fob Battery Life, Leaks, and Temperature Effects

The convenience of a modern car key fob is hard to overstate — it unlocks doors, starts engines, and sometimes even controls your car remotely. But at the heart of all these features lies a small coin battery, usually a CR2032, that powers your fob’s every function. Like all batteries, it doesn’t last forever, and certain conditions can shorten its lifespan or cause unexpected problems like leaks. In this guide, we’ll explore how long your key fob battery should last, what causes leaks, and how temperature plays a critical role in battery performance. How Long Do Key Fob Batteries Typically Last? Most key fobs use lithium coin batteries like the CR2032. These are designed for small electronic devices and typically last between two to four years, depending on how often you use your fob and how close it stays to your vehicle. Constant use — such as frequent locking and unlocking — can deplete the battery faster. If your smart key remains within range of your car at all times, it may draw more power passively. Another key factor is the quality of the battery. High-grade batteries like those from Panasonic usually last longer and offer more consistent voltage. You’ll know it’s time for a replacement when the fob works only at short distances, you need to press buttons more than once, or the indicator light becomes dim or fails to light up at all. Catching these early signs is important, as a simple battery replacement can prevent unexpected lockouts or costly service calls. Battery Leaks in Key Fobs: Risks and Prevention Though not as common, a leaking battery can be far more destructive than a dead one. Leakage can corrode the internal components of your key fob, sometimes making it unusable. Signs of a leak include white residue inside the battery compartment, visible corrosion on the metal contacts, or a strange smell or dampness near the battery slot. Leaks often occur in batteries that are expired, low-quality, or exposed to extreme heat or moisture. To reduce the risk of leaks, it's a good idea to replace your key fob battery every two years, regardless of performance. Always use reputable brands such as Panasonic CR2032 , and store spare batteries in a cool, dry place. Also avoid mixing new and old batteries, even temporarily. If you notice any signs of leakage, remove the battery promptly and clean the compartment using a cotton swab and isopropyl alcohol. If the corrosion is severe, replacing the key fob casing or consulting a specialist may be necessary. How Temperature Affects Your Key Fob Battery Life Ambient temperature can have a major effect on battery efficiency. In cold conditions, the chemical reactions within a lithium coin battery slow down, resulting in reduced voltage and sluggish or inconsistent performance. A key fob left overnight in freezing temperatures might stop working until it warms up. On the flip side, high temperatures accelerate battery depletion. Leaving your key fob inside a hot car or near a heat source can shorten its lifespan and, in rare cases, even cause the battery to leak. Heat can also warp internal components, especially in compact spaces like key fobs. To protect your battery, avoid exposing your key fob to direct sunlight or intense heat for long periods. Don’t store it in jackets or compartments that get hot in summer, and try to keep a spare battery handy if you live in an area with extreme seasonal swings. Choosing temperature-resistant batteries — like those from Panasonic — adds another layer of protection. Key fob batteries are small but essential parts of modern car ownership. Understanding their typical lifespan, recognizing early signs of failure or leakage, and knowing how temperature affects their performance can help you avoid unpleasant surprises. With a little foresight, you can keep your key fob working smoothly for years. Replace the battery every two to three years, choose high-quality brands, and take precautions during temperature extremes. A few minutes of care now can save you from frustration later.

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