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

How to Maintain and Extend the Life of Your Car Keys
10.07.2024

How to Maintain and Extend the Life of Your Car Keys

Your car keys are more than just tools to unlock and start your vehicle—they’re essential components for your car's convenience and security. Taking proper care of them can prevent unexpected failures and ensure they last for years. Here are seven easy and practical tips to help you keep your car keys in the best condition possible. 1. Keep Your Keys Clean and Dry Why It Matters: Moisture and dirt are the biggest enemies of car keys, particularly electronic fobs. Exposure to these elements can cause internal corrosion and failure. How to Do It: Avoid Moisture: Keep your keys away from water, rain, and high humidity. If they accidentally get wet, dry them immediately with a soft, absorbent cloth. Regular Cleaning: Gently wipe your keys with a clean cloth to remove dirt and dust. For crevices around buttons, use a cotton swab to clean hard-to-reach areas. 2. Handle Your Keys with Care Why It Matters: Dropping, tossing, or mishandling your keys can cause physical damage or misalign internal components, rendering them unusable. How to Do It: Avoid Drops: Be mindful when handling your keys. Attach them to a lanyard or key holder for better grip and to reduce accidental drops. Use a Protective Key Cover: A well-fitted key cover adds an extra layer of protection against scratches, drops, and general wear and tear. Plus, they’re available in various styles to match your preferences. 3. Replace Key Fob Batteries on Time Why It Matters: A weak battery can lead to your car key fob failing to work when you need it most, leaving you stranded or locked out. How to Do It: Watch for Warning Signs: If your key fob’s range decreases or requires multiple presses to function, the battery is likely weak and needs replacement. Replace Properly: Follow your car’s manual for step-by-step instructions on changing the battery. Using the correct battery type ensures reliable performance. 4. Protect Your Keys from Extreme Temperatures Why It Matters: Excessive heat or cold can harm the electronic components inside your key fob or damage the metal of traditional keys. How to Do It: Avoid Direct Sunlight and Heat: Don’t leave your keys exposed to the sun on your dashboard or near heaters. Extreme heat can warp materials and damage internal circuits. Keep Away from Freezing Temperatures: In colder months, avoid leaving your keys in your car or outside for prolonged periods, as freezing conditions can impact their functionality. 5. Rotate and Use Spare Keys Why It Matters: Spare keys can deteriorate if left unused for long periods. Regularly using them ensures they remain functional and ready in emergencies. How to Do It: Alternate Keys: Use your spare key occasionally to keep it in good working condition. This prevents any surprises when you actually need it. Safe Storage: Store spare keys in a dry, cool place, away from moisture, heat, or any magnetic devices that could interfere with their programming. 6. Avoid Overloading Your Keychain Why It Matters: A heavy keychain might seem harmless, but the extra weight can wear down your car’s ignition switch or damage your key over time. How to Do It: Limit What You Carry: Stick to the essentials—remove unnecessary keys, charms, or heavy accessories. Use Lightweight Keychains: Choose minimalistic and lightweight keychains to prevent undue stress on the ignition and the key itself. 7. Regularly Inspect for Wear and Tear Why It Matters: Keys, especially those with buttons or electronic components, can show signs of wear over time. Early detection helps avoid complete failure. How to Do It: Look for Physical Damage: Check for cracks, faded buttons, or scratches that might affect functionality. Seek Professional Help: If you notice significant wear or damage, consult a professional locksmith or dealership for repairs or replacement. Ignoring issues could lead to bigger, costlier problems down the line. Why Car Key Maintenance is Worth Your Effort Properly maintaining your car keys ensures they stay reliable, functional, and secure for years to come. Whether it’s a traditional key or a modern electronic fob, these small actions can save you from costly replacements or inconvenient malfunctions. Taking care of your keys isn’t just about preventing problems—it’s also about convenience, peace of mind, and getting the most out of your vehicle’s features. By following these simple tips, you’ll keep your car keys in top shape and avoid the stress of unexpected failures.

The Complete Guide to Car Key Cutting: Everything You Need to Know
19.06.2024

The Complete Guide to Car Key Cutting: Everything You Need to Know

Unlocking the Mysteries of Car Key Cutting Have you ever been in a situation where you needed a spare car key or had to replace a lost one? Car key cutting is an essential process for creating duplicate keys or replacements, but it’s often misunderstood. From traditional keys to modern transponder and smart keys, the art of key cutting has evolved dramatically with advancements in technology. This guide will walk you through the key cutting process, its types, and when professional help is required, helping you navigate the complexities of car key duplication with confidence. What Is Car Key Cutting? Car key cutting is the process of creating a new key that matches the physical shape and specifications of your vehicle’s locks and ignition. This process involves cutting the metal key blade to fit the car’s lock mechanism precisely. For modern cars, this may also include programming the electronic components of the key, such as transponder chips or remote controls. The method used for cutting a car key depends on the type of key and the car model. Traditional keys are simpler to cut, while transponder and smart keys require specialized tools and expertise. Types of Car Keys and Cutting Methods Traditional Keys These are the classic mechanical keys used in older vehicles. Cutting these keys involves duplicating the grooves and ridges of the original key using a key-cutting machine. Transponder Keys Found in most modern cars, transponder keys contain a microchip that communicates with the car’s computer. After cutting the blade, these keys must also be programmed to function. Smart Keys These advanced keys use wireless communication to interact with the car. They don’t require physical cutting but involve programming to sync with the vehicle. Each type of key requires a different approach and level of expertise, making it essential to know what kind of key you have before proceeding with duplication. The Key Cutting Process: Step by Step Identify the Key Type Determine whether you have a traditional, transponder, or smart key. This will dictate the tools and process needed for cutting and programming. Gather Required Information Provide the key cutter with details about your car, such as the make, model, and year. For some keys, a Vehicle Identification Number (VIN) may be required. Cutting the Key Blade For traditional and transponder keys, the blade is cut using a key duplicator or a laser key-cutting machine. Precision is crucial to ensure the key fits perfectly in the lock. Programming (if required) For transponder and smart keys, the key must be programmed to the car’s computer system. This step may require specialized equipment or professional expertise. When to Seek Professional Help While traditional keys can often be duplicated at local hardware stores, transponder and smart keys typically require specialized tools and knowledge. Professional locksmiths and dealerships are equipped to handle these advanced key types, ensuring proper cutting and programming. Reasons to choose a professional: Complexity: Smart and transponder keys require technical expertise. Accuracy: Professionals use precise equipment to ensure the key functions flawlessly. Programming Needs: Only trained specialists can program keys to sync with your vehicle. Cost of Car Key Cutting The cost of cutting a car key varies depending on the type of key and the service provider. Traditional keys are the most affordable, typically costing between $10 and $50. Transponder and smart keys, however, can range from $50 to $300 or more due to the additional programming required. Tips to save money: Have a spare key: This simplifies the duplication process and reduces costs. Compare prices: Contact multiple locksmiths or dealerships to find the best deal. Be Prepared for Every Key Emergency Car key cutting is a vital service for any car owner, whether you’re duplicating a spare key or replacing a lost one. Understanding the process and knowing when to seek professional help can save you time, money, and frustration. By staying informed and proactive, you can ensure that your vehicle remains accessible and secure, no matter what challenges arise.

5 Signs Your Car Key Battery Needs Replacement – Don’t Get Locked Out!
05.03.2025

5 Signs Your Car Key Battery Needs Replacement – Don’t Get Locked Out!

Have you ever pressed your car key fob multiple times without an immediate response? It’s frustrating, right? A drained key fob battery can cause unexpected issues, and if you don’t replace it in time, you might find yourself locked out of your car at the worst moment. Fortunately, there are some telltale signs that indicate your car key battery is running low – and replacing it is a quick and cost-effective fix. Your car key is one of the most essential accessories you use daily, yet we often overlook its maintenance. While it may seem small, the proper functioning of your key fob is crucial for your convenience and security. Here are five signs that it’s time to replace your key battery before it stops working completely. 1. Your Key Works Intermittently One of the first signs of a weakening battery is an inconsistent key fob response. If it works fine sometimes but requires multiple button presses at other times, the battery is likely running low. A new battery will restore the key’s normal sensitivity. This issue can be especially frustrating when you're in a hurry or carrying items and need your car to unlock instantly. If you notice your key fob working intermittently, don’t wait until you get locked out—replace the battery promptly. 2. The Signal Range Has Decreased A brand-new car key fob allows you to lock and unlock your vehicle from a considerable distance. If you’ve noticed that you now need to be much closer for the key to work, this is a clear sign that the battery is weakening. Modern key fobs can control your vehicle from as far as 15 meters or more. When you find yourself needing to be right next to the car for it to respond, it’s time to replace the battery. A weak signal can lead to access and ignition problems, which can be inconvenient in daily use. 3. You Need to Press the Buttons Harder A properly functioning car key should respond immediately to a simple press of a button. If you need to press harder or hold the button longer for it to work, the battery is no longer providing enough power to send a strong signal. Beyond just being inconvenient, this can also damage the key fob itself due to increased pressure on the electronic components. Replacing the battery will help you avoid additional wear and tear and ensure your key works smoothly without extra effort. 4. Your Car No Longer Recognizes the Key For vehicles with push-button start systems, the key fob must be close enough for the car to detect it. If your car struggles to recognize the key and you have to bring it closer to the dashboard or ignition button, this is a clear sign of a low battery. This can be particularly annoying on rainy days or when you’re in a hurry. A properly functioning key fob should allow seamless use of your vehicle without delays or the need to adjust its position. 5. The Key Stops Working Completely If your key fob suddenly stops working and you have ruled out other possible causes, such as a damaged circuit or faulty buttons, the battery is most likely completely drained. Before you panic and assume the key fob is broken, try replacing the battery first. It’s a simple and inexpensive solution that restores your key’s functionality in seconds. How to Replace Your Car Key Battery Changing your car key battery is usually a straightforward task that only requires a small screwdriver and a new CR2032 battery. Locate the seam along the key fob’s edge and carefully pry it open. Remove the old battery and observe its position, then insert the new battery in the same orientation. In less than five minutes, your key will work like new again. There’s no need to spend money on a replacement key when a battery swap is a quick and affordable fix. Don’t Wait Until It’s Too Late! Preventative maintenance is key to avoiding unnecessary hassles. If your key is showing signs of weakness, don’t ignore them! Replace the battery in time and ensure your vehicle operates flawlessly.

Common Car Key Problems and Solutions Every Driver Should Know
17.03.2025

Common Car Key Problems and Solutions Every Driver Should Know

There’s nothing quite as frustrating as standing outside your car, key in hand, only to realize something’s not working. Whether your key won’t turn, the remote isn’t responding, or the key itself has seen better days, car key problems seem to happen at the worst possible moment. The good news? Most of these issues are avoidable or fixable, and knowing what to expect can save you both time and stress. 1. Worn-Out Key Blades You might not notice it happening, but over time, your key blade wears down. Each time you insert it into the lock or ignition, tiny grooves and cuts on the blade experience friction. After years of use, the edges get smooth, and the key may stop fitting snugly. Suddenly, you find yourself jiggling or forcing it, risking more damage. The solution here is simple: if you start noticing that the key feels loose or takes a few tries to turn, it’s time to get a replacement cut based on the original code, not by copying the worn-out key. A fresh, precisely cut key blade will fit and function perfectly, preventing damage to your lock cylinder. 2. Dead Key Fob Battery Modern cars often come with remote keys or keyless entry systems, and while they offer convenience, they also rely on tiny batteries. One day, you press the button, and nothing happens—no lights, no unlock sound, no response. Before assuming the worst, check the battery. Typically, key fob batteries (like CR1620 or CR2032 types) are inexpensive and easy to replace. A quick change will often restore full functionality. Make it a habit to change your key battery every 1-2 years, especially if you notice reduced range or need to press the button multiple times. 3. Key Not Turning in the Ignition You get into your car, insert the key, and suddenly it won’t turn. You might try wiggling the steering wheel or pushing the key harder, but nothing works. More often than not, the problem is either with the steering lock mechanism being engaged or dirt buildup inside the ignition cylinder. First, try gently moving the steering wheel side-to-side while turning the key—sometimes the wheel locks under tension, and this simple trick unlocks it. If the problem persists, there could be debris inside the ignition. Using a can of compressed air to blow out dust and tiny particles can help, but if it continues, a professional cleaning or inspection might be necessary before the key or ignition gets damaged. 4. Broken or Bent Keys You might not think twice when you use your key to open a package or pry something open—but keys aren't made for multitasking. Over time, rough handling, bending, or dropping your key can weaken the metal. Eventually, you could end up with a bent key that struggles to fit, or worse, a snapped key stuck in your lock. If your key has visible bends or cracks, don’t wait. Replacing it before it breaks entirely can save you the headache of needing an extraction service. Also, always carry a spare key, just in case. 5. Key Programming Issues If your car uses a transponder key or a smart key, there’s more than just a metal blade involved. Inside is a chip programmed to communicate with your car’s immobilizer system. If your key loses synchronization—maybe after battery replacement, an electrical issue, or accidentally resetting your system—it can leave you unable to start your vehicle. In these cases, reprogramming the key is necessary. Some cars allow you to do this manually following specific sequences (like turning the ignition on and off), but others require specialized diagnostic tools. Familiarizing yourself with your car’s manual or researching the process beforehand helps avoid surprises. 6. Water Damage Dropped your key in water or left it exposed to rain? Electronics inside remote keys and smart keys aren’t waterproof. Moisture can short-circuit internal components, causing the key to stop functioning entirely. If this happens, act fast. Remove the battery immediately and dry out the key as thoroughly as possible. You can use silica gel packets or place the key in a bowl of rice overnight to absorb moisture. However, water damage isn’t always reversible, so keeping your key away from wet environments is the best precaution. Car key problems often feel like an emergency when they strike, but most of them are preventable or quickly fixable with a little know-how. Paying attention to the warning signs—whether it’s a key that’s worn, a fob that’s sluggish, or a key that won’t turn—allows you to act before things escalate. Understanding how your key works and handling it with care will save you from unnecessary stress (and unexpected expenses) down the road. So next time something feels off with your key, remember: a little attention now can prevent a major hassle 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