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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 flaps:

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.

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

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. 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Key Fob vs. Transponder vs. Smart Key: What’s the Difference?

Key Fob vs. Transponder vs. Smart Key: What’s the Difference?

Unlocking the Modern Car Key In the past, a car key was a simple piece of metal. You inserted it into the door, turned it, and the car unlocked. You repeated the process in the ignition to start the engine. Today, however, a car key might be a sleek device that never even leaves your pocket. It may unlock your doors remotely, start the car with a button, or communicate with your vehicle without you even touching it. This evolution in key technology has introduced convenience, security, and — for many drivers — a bit of confusion. What kind of key do you actually have? Is it a transponder key , a key fob , or a smart key ? And why does it matter? In this blog, we break down each type of modern car key, explain how they work, and highlight what makes them different — so you can better understand, maintain, and protect the device that starts your vehicle. What Is a Transponder Key? The transponder key was the first major step toward electronic vehicle security. 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Most modern fobs include buttons for locking and unlocking the doors, opening the trunk, and triggering a panic alarm. Some also support remote engine start. In many vehicles, the fob is attached to — or integrated with — a mechanical key that includes a transponder chip. Others are "flip keys," with a metal blade that folds inside the fob casing. Key fob features: Enables remote locking/unlocking May include a transponder chip Often includes a mechanical backup key Battery-powered (usually coin cell batteries) May include passive entry on some models Key fobs offer a balance between convenience and control. While you still need to press buttons or insert a key in many cases, they streamline the process and add useful features. What Is a Smart Key? The smart key is the most advanced and convenient type of car key available today. It communicates with your vehicle wirelessly using radio frequency or low-energy Bluetooth. As long as the smart key is within range — often in your pocket or bag — the car will unlock automatically when you touch the handle, and start when you press the ignition button. Unlike a key fob, there’s no need to press buttons or insert anything into the ignition. The system detects the key’s presence and grants access and engine start as needed. Smart key features include: Passive keyless entry (PKE) Push-button start Proximity detection Fully hands-free operation Often includes comfort access features like memory seating and climate control However, smart keys also introduce new considerations. They rely entirely on battery power, so a dead battery can temporarily disable key functions. Because smart keys are always transmitting a signal, they are also vulnerable to relay attacks , in which thieves use signal amplifiers to trick the car into unlocking. 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How Long Does a Car Key Battery Last? Can You Use a CR2025 Instead of a CR2032?

How Long Does a Car Key Battery Last? Can You Use a CR2025 Instead of a CR2032?

When was the last time you thought about the battery inside your car key? For most drivers, the answer is probably never—until the key suddenly stops working. A car key battery is a small but essential part of modern driving. It powers keyless entry, remote locking, and in many cases, keyless ignition systems. When the battery fails, it can leave you locked out of your car or stranded in inconvenient situations. Understanding how long a car key battery typically lasts and knowing when and how to replace it can save you time, money, and unnecessary frustration. In this detailed guide, you will learn how long a typical car key battery lasts, what factors shorten its life, the most common signs that your battery needs replacement, and whether you can substitute a CR2025 for a CR2032 battery in your car key fob. How Long Does a Car Key Battery Last? The average car key battery lasts between two to four years. However, the actual lifespan of your key battery depends on several factors, including how often you use the key, whether your car uses a proximity key system, the type of battery installed, the climate where you live, and the quality of the battery brand. If your car has a keyless entry system or keyless ignition that constantly communicates with your vehicle when nearby, your battery may drain more quickly. Frequent use—such as multiple lock and unlock cycles each day—also leads to faster battery depletion. What Can Shorten the Life of Your Car Key Battery? Frequent Use: Keys that are used many times per day will naturally consume more battery power. Keyless Proximity Systems: Smart keys that communicate continuously with the vehicle tend to use more energy. Extreme Temperatures: Exposure to both heat and cold can degrade battery performance and lifespan. Low-Quality Batteries: Cheap, no-name batteries often have a shorter life and can fail unexpectedly. Many drivers wait for their key to stop working before replacing the battery, but it is recommended to replace it proactively every one to two years to avoid surprise failures, especially before long trips or the winter season. Signs That Your Car Key Battery Is Failing Your car key usually gives warning signs before the battery completely dies. Knowing these symptoms can help you avoid being caught in an inconvenient situation. Reduced Range: You may need to stand closer to your car for the key to work properly. Delayed Response: The car may not immediately lock or unlock when you press the button. Intermittent Operation: Sometimes the key works, sometimes it does not. Dashboard Alerts: Some vehicles display a "low key battery" warning on the dashboard. Complete Failure: If ignored, the key will eventually stop working entirely. If you notice any of these warning signs, it is best to replace the battery immediately to ensure continuous, reliable operation. When Should You Change Your Car Key Battery? The best time to change your car key battery is before it fully fails. Most experts recommend replacing the battery every two years as preventive maintenance. You should also replace the battery immediately if you notice that your key’s range has reduced or if it sometimes stops working without warning. Seasonal changes also play a role. During winter, cold temperatures can reduce battery performance significantly, which is why it is wise to replace your battery before the onset of cold weather. Additionally, if you are planning a long trip or vacation, it is a good idea to install a new battery beforehand to avoid potential inconvenience. Can You Use a CR2025 Instead of a CR2032 Battery in a Car Key? One of the most common questions drivers ask is whether a CR2025 battery can be used as a substitute for a CR2032 in a car key fob. Although the two batteries are similar in many ways, there are critical differences to consider. CR2025 vs. CR2032: What Is the Difference? Both the CR2025 and CR2032 batteries are 3-volt lithium coin cells and have the same diameter of 20 millimeters. However, their thickness and capacity differ. Feature CR2025 CR2032 Diameter 20 mm 20 mm Thickness 2.5 mm 3.2 mm Voltage 3 volts 3 volts Capacity Approximately 150 mAh Approximately 220 mAh The CR2032 is thicker and has a higher energy capacity, meaning it will typically last longer than a CR2025 in the same device. Can a CR2025 Fit in a CR2032 Slot? Technically, a CR2025 can physically fit into a car key fob designed for a CR2032 battery because they have the same diameter. However, because the CR2025 is thinner, it may not make stable contact with the battery terminals inside the key. Some people attempt to compensate for the thinner battery by adding a small piece of paper, cardboard, or aluminum foil to hold it in place. Although this may temporarily restore functionality in an emergency, it is not a reliable or recommended solution for long-term use. Should You Use a CR2025 Instead of a CR2032? The short answer is that using a CR2025 in place of a CR2032 is acceptable as a temporary, emergency solution but is not advisable as a permanent fix. Using the incorrect battery size can lead to poor contact, inconsistent performance, and a much shorter operating life. Risks of Using the Wrong Battery: Unstable contact may cause the key to work intermittently. Lower battery capacity means the key will require more frequent battery replacements. A loose battery inside the fob can shift during handling, potentially damaging the internal components. For long-term reliability and to protect your car key from unnecessary wear, it is always best to use the exact battery size specified for your key fob. Where to Buy the Right Car Key Battery If you are looking for a high-quality CR2032 battery for your car key, Mr Key offers reliable options from trusted brands such as Panasonic. Choosing a premium battery will ensure your key functions properly for as long as possible and reduces the risk of sudden failure. Mr Key also provides a wide range of car key shells, key fobs, and accessories compatible with popular brands like Peugeot, Citroën, Nissan, Suzuki, Fiat, Ford, and more. Whether you need to replace the battery, the shell, or the entire key, Mr Key can help you find the right product at an affordable price. You can browse the full selection in the Mr Key online store and get the parts you need delivered directly to your door. Car key batteries are often forgotten until they stop working, but with proper care and timely replacement, you can avoid the inconvenience of being locked out or dealing with a non-functional key. Understanding how long a car key battery typically lasts and knowing the signs of failure can help you stay ahead of the problem. While a CR2025 battery can sometimes be used in an emergency, the CR2032 is the correct and recommended option for most car key fobs due to its longer life and better fit. Using the right battery size ensures that your key works reliably, protects your key's internal components, and provides peace of mind. Regularly check your key, replace the battery proactively, and always use the correct parts for the best performance. When you need a new battery or key shell, Mr Key is your trusted partner for fast, easy, and affordable car key repairs.

The Importance of Having a Spare Car Key: What Every Driver Should Know

The Importance of Having a Spare Car Key: What Every Driver Should Know

When it comes to car ownership, many of us take pride in maintaining our vehicles. We keep up with oil changes, tire rotations, and insurance renewals. But there’s one crucial aspect that many drivers overlook: having a spare car key. It might seem like a small detail, but nearly 40% of car owners don’t have a backup key for their vehicle. That’s a risk you might not want to take. Let’s explore why having a spare car key is so important and how it can save you time, money, and frustration. The Hidden Risks of Having Only One Key You may think that having just one car key is fine—after all, you always know where it is, right? But life has a funny way of surprising us, and car keys get lost or damaged more often than you might think. Here are some common risks you face when relying on just one key: Lost Keys : Losing your only car key can leave you stranded. Whether you're in a rush for work or on your way to an important event, misplacing your key means you're stuck until you find it—or worse, until you get a replacement. Key Damage : Keys, like anything else, wear out over time. A bent or broken key can cause problems with your car’s ignition, and if it's your only one, you’re in for a headache. Lockouts : It’s easy to accidentally lock your keys inside your car. Without a spare key, you’ll need to figure out how to regain access—both costly and inconvenient. Theft : If someone steals your key, not only are you locked out of your car, but you also face a potential security risk. A spare key can give you quick access and peace of mind while you handle the situation. Why a Spare Key Is a Lifesaver Having a spare key is more than just a backup plan; it’s a practical solution that can save you in many situations. Here’s why having a spare key should be on your to-do list: Saves You Time : If you’ve ever lost a key, you know how time-consuming it can be to get a replacement. With a spare key, you can avoid the wait and get back on the road quickly. Prevents Expensive Lockouts : Getting locked out of your car is stressful and costly. Emergency situations like this can cost you not just time but money, and depending on the circumstances, you might even need additional assistance. Convenience for Multiple Drivers : If you share your car with a spouse, roommate, or family member, having a spare key allows both of you to have access without needing to coordinate every trip. Peace of Mind : With a spare key, you won’t have to worry about the “what if” scenarios. It’s a simple safety net that ensures you’re never completely stranded. Affordable Solutions for Replacing Your Car Key You might be wondering how to go about getting a spare key. Fortunately, the process has never been easier or more affordable. Gone are the days when you had to rely on expensive or complicated processes to secure a replacement key. Here are some practical ways to get a spare key: Online Key Replacement Services : Many services offer easy, affordable options for getting a spare car key. Simply upload a photo of your key, and you’ll receive a replacement. Automotive Dealerships : Dealerships provide spare keys for almost any car make or model. However, this option is often more costly and may require you to bring the car in for verification and programming. How to Choose the Right Key Replacement Option When deciding on how to get a spare key, consider these factors: Cost : Depending on the service or method you choose, prices can vary. Evaluate your budget and the type of key your car requires before proceeding. Convenience : For some, the most convenient option is one that doesn’t require in-person visits. Research which option offers the best balance between time and convenience for your needs. Speed : Depending on your urgency, choose an option that fits your timeframe. Some services offer express options, while others may take longer. Don’t Wait Until It’s Too Late Many car owners don’t think about getting a spare key until they’re faced with an emergency. Don’t let that be you. Having a backup key is a small investment that can save you from significant stress and financial strain down the line. Take action today and make sure you have a spare key for your vehicle. Whether it’s for a just-in-case moment or for daily convenience, having that extra key can make all the difference when you need it most.

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