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
28.05.2024

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 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.

Related Posts

Comprehensive Guide: Common Car Key Problems and How to Solve Them
30.06.2025

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.

How to identify the correct BMW key case?
17.11.2025

How to identify the correct BMW key case?

Ordering the wrong BMW key case leads to delays, extra cost, and keys that won’t start your car. BMW has used multiple key designs across generations , so identifying your key type before buying is essential. This guide shows you how to correctly identify your BMW key case and avoid costly mistakes. Why Accurate Key Identification Matters BMW keys are part of the vehicle’s immobilizer system. If you choose the wrong case, your internal electronics and transponder chip may not fit correctly, leaving you with a remote that won’t start your engine. Many BMW key fobs look similar but differ in frequency, board layout, and blade type. Dealerships confirm keys by VIN and part number because BMW key components are not universal . Independent key services require the same accuracy. BMW Key Types (Quick Identification) BMW Key Style Model Years (Approx.) Identification Clues Classic metal key Pre-1995 No remote buttons, some have a small built-in torch light Diamond key (EWS) 1995–2005 Diamond shape, 3 buttons, no battery door , rechargeable inside ignition Slot-in rectangular key (CAS) 2004–2010 Flat fob, removable emergency key blade , sliding battery cover Comfort Access key (Keyless) 2010–2019 Keyless start, similar shape to slot key, CR2032 battery BMW Display Key 2016+ (high-end models) LCD touchscreen on fob Example model guidance: E46, E39, E53 X5: Diamond key E90, E60, E70, E87: Rectangular slot key F10, F30, F25: Comfort Access style G11 7-Series, i8: Display Key For model confirmation, use a free BMW VIN decoder such as the one referenced on the BMW Owners Portal . Step-by-Step: Confirm Your Correct BMW Key Case 1) Check physical shape and buttons Count buttons, note shape, and check for removable blade or battery hatch. 2) Look for FCC ID / Part Number Inside the shell or on the back you may find codes like: FCC ID: KR55WK49127, NBGIDGNG1 BMW part numbers starting with 66 12… Matching part numbers ensures correct fit, even for look-alike shells. 3) Confirm blade type (if applicable) Common BMW blade profiles: HU58, HU92, HU100 . 4) Cross-check model and production year BMW changed key systems by chassis generation. If unsure, a BMW dealer can confirm via VIN — per BMW policy, keys are VIN-matched for security. Ordering & Cutting Your BMW Key When you order a BMW key case online, you will either: ✔ Transfer your existing electronics No immobilizer programming required if you keep your transponder. ✔ OR get a new blade cut Professional cutting can be done by photo or by key code , allowing fast remote service without visiting a locksmith. Most BMW keys can be cut accurately from a high-resolution photo using digital bitting extraction, a process also documented in locksmith standards. Important: Shell-only replacements do not program the transponder; if you need a new key, a locksmith or dealer must program it to the vehicle. BMW Key Replacement FAQ Can I replace only the case? Yes. If electronics work, transfer them into a matching case. Do I need programming? Not if you keep the same transponder chip. New keys require programming. Can BMW keys be cut by photo? Yes. High-accuracy digital decoding allows cutting from an image. How long is BMW key delivery when ordering online? Typically 3-4 days depending on region and shipping speed. Do Comfort Access keys use a special case? Yes. Ensure the case is specified as Comfort Access compatible . Ready to Order the Correct BMW Key Case? If you’re unsure, send photos of your key and vehicle model details — our specialists will help identify the correct case before purchase. ✓ BMW key cases for all generations ✓ Key cutting via photo or code ✓ Fast worldwide BMW key delivery ✓ Secure and privacy-verified ordering Visit our shop at MR-KEY.com to identify and order the correct BMW key case.

How to Easily Find Your Key Code for a Hassle-Free Replacement
04.11.2024

How to Easily Find Your Key Code for a Hassle-Free Replacement

When it comes to replacing a car key , knowing your key code is essential. This code allows you to obtain a precise duplicate, ensuring that your new key fits seamlessly without any issues. Whether you've lost your key, broken it, or simply need a spare, understanding where to locate this code can make the replacement process faster and more affordable. In this guide, we’ll walk you through what a key code is, where to find it, and tips to ensure a smooth replacement process. Why Is the Key Code Important? A key code is more than just a number; it's a unique identifier that tells a key cutter exactly how to replicate your key. Without it, the process can be longer, more complicated, and potentially costly if the key doesn’t match your vehicle’s lock. Ensures a Perfect Fit : The key code guarantees that your new key will be cut to match your original one precisely. Saves Time and Money : With the correct code, you can avoid trial and error, reducing the risk of needing multiple key replacements. Improves Security : Knowing the exact specifications of your key can prevent unauthorized duplicates. Types of Key Codes Key codes come in different types depending on the key and vehicle model. Here are the main types: Direct Code : Often a 4 to 8-digit code, this code can be entered directly into a key-cutting machine for accurate replication. Indirect Code : This type of code requires a conversion chart to find the direct key code. Though indirect codes aren’t as common, they may still appear on some older models. Blind Code : Sometimes, the code may not be directly readable or is hidden in the key's design. These require decoding using a specialized tool or software. Understanding which type of code you have can make the process smoother when you’re ready to replace your key. Common Locations for Key Codes Finding the key code isn’t always straightforward, but with a few tips, you can track it down more easily. Here are the most common places to check: 1. Vehicle Manual Your vehicle’s manual often contains useful information, including the key code. It’s usually found in the section detailing the vehicle’s locking system. The manual may also provide guidance on other important security features, so it’s a great place to start. Tip : If you can’t find it in the manual, try looking in the index under “keys” or “security.” 2. Key Fob or Key Itself For some keys, the code is printed directly on the key or key fob. Look closely at the metal part of the key or the plastic casing for a small series of numbers. This code may be faint, so you may need a magnifying glass or good lighting. Tip : Be cautious when handling the key to avoid damaging the code. A worn key can sometimes obscure the code, so check carefully. 3. Vehicle Registration and Documents Some vehicle documents, especially those you receive when you first purchase the car, may include the key code. Check any paperwork related to the purchase, including sales documents, registration, and the car title. Tip : Keep these documents safe as they contain essential information for ownership and replacement needs. 4. Original Key Packaging If you have access to the original packaging of the key, such as a bag or box, the key code is sometimes printed there. This is especially common if the key came from a dealer or as part of a new car purchase. Tip : Always save key packaging, as it can provide helpful information for future reference. 5. Contacting the Dealership If you’re unable to locate the code yourself, you can reach out to the dealership where you purchased the vehicle. Dealerships often keep records of key codes, especially if the vehicle is still under warranty. Some may provide the code for free, while others might charge a fee. Tip : Have your vehicle identification number (VIN) handy when contacting the dealership, as it can help verify your ownership. Tips for Safe Key Code Storage Once you have located your key code, it’s important to keep it safe to make future replacements easier. Here are some tips: Store Digitally : Save the code in a secure document on your phone or computer. You can even use a password-protected note or cloud storage. Keep a Physical Copy : Write down the code and store it with other important vehicle documents, like your insurance and registration. Avoid Sharing the Code : Treat the key code like a password; only share it with trusted professionals when necessary for replacements. What to Do if You Can’t Find the Code If your search for the code has been unsuccessful, don’t worry—there are still options. Here’s what to do: Contact a Professional : Some professionals can create a new key by decoding the lock without needing the original key code. This is particularly helpful if you’ve lost all copies of your key. Request Assistance from the Manufacturer : In some cases, you can contact the vehicle’s manufacturer for support. They may ask for documentation proving ownership and might provide the code directly or guide you through the next steps. Benefits of Knowing Your Key Code Having the key code at your fingertips offers several advantages, whether you need a quick replacement or simply want peace of mind. Saves Time in Emergencies : If you lose your key unexpectedly, having the code handy allows for faster replacements. Lower Replacement Costs : With the exact code, key makers can avoid unnecessary recutting, saving you money. Simplifies Multiple Key Requests : If you need multiple copies, the code makes it easy to obtain several accurate replacements without errors. Locating and safely storing your key code can simplify the replacement process significantly. By knowing exactly where to look for the code and keeping it secure, you can avoid potential stress and save both time and money when the need for a replacement arises. Taking these steps now ensures that, should you ever need a new key, the process will be as smooth and efficient as possible.

How to Spot a Car Key Cloning Scam: Warning Signs and Prevention Tips
30.04.2025

How to Spot a Car Key Cloning Scam: Warning Signs and Prevention Tips

How to Spot a Car Key Cloning Scam: Warning Signs and Prevention Tips Car theft doesn’t always involve smashing windows or forced ignition anymore. These days, all it might take is a thief standing a few feet away from you — equipped with a small electronic device and a plan to clone your car key without ever touching it. Welcome to the age of car key cloning . Fast, silent, and nearly untraceable, this high-tech method of theft is on the rise, and many drivers don’t even know it exists. In this article, we’ll walk you through how it works, what red flags to watch for, and how to protect yourself from becoming the next victim. What Is Car Key Cloning and How Does It Work? Car key cloning is the process of copying the signal emitted by your key fob and using that signal to unlock and even start your car. Thieves use tools like signal amplifiers, cloning software, or plug-in programming devices to mimic the electronic code stored in your key. In most cases, they don’t even need to touch your key. They just need to be close enough — in a parking lot, next to your front door, or even in a restaurant — to intercept the signal when you lock or unlock your car. That signal is then copied and stored on another device or blank key fob. In some instances, criminals will break into your car and access the OBD port (the vehicle’s diagnostic system) to directly program a new key. This means they can drive off in your car with a cloned key, and you may not even know how they got in. Why This Scam Is Spreading So Quickly Key cloning was once limited to high-end criminal operations, but now the tools are cheap, easy to find , and widely available online. Some fob cloning devices are openly sold on marketplaces, making it simple for even low-level criminals to learn the trade. A cloned key leaves no trace of forced entry, no damage, and often no evidence — making it harder for insurance claims to be validated and for stolen cars to be recovered. The rise in keyless entry systems means millions of drivers are potential targets, whether they realize it or not. According to The Sun, cloning devices sold online can program new keys in under 30 minutes. 5 Warning Signs You May Be Targeted Strange behavior from your key fob – If the range suddenly becomes shorter or the buttons stop responding consistently, your signal may have been intercepted. Unfamiliar devices or people near your car – Be cautious if you see people lingering nearby with phone-like devices or bags near your car. Your car unlocks by itself – This could mean someone nearby is mimicking your key’s signal. You find marks or loose panels near the OBD port – Some thieves break in to plug in programming devices. You lose access to your spare key – It’s possible a third key was added to your system, locking the others out. How to Prevent Car Key Cloning While key cloning can be hard to detect, it's relatively easy to prevent if you're proactive. Here’s how to stay protected: Use a Faraday pouch : These small, signal-blocking cases prevent your key’s signal from being intercepted when not in use. Don’t store keys near doors or windows : Keep your keys at least 5–10 meters from exterior walls. Disable keyless entry if possible : Some vehicles allow you to turn off proximity unlocking in the settings. Invest in physical security : Steering wheel locks, OBD port locks, and even wheel clamps act as strong deterrents. Audit your key system : A locksmith can check how many keys are programmed to your vehicle and delete unauthorized ones. If you're ever in doubt, replace your key and reprogram your system. It may cost a bit up front, but it's cheaper than replacing a stolen car. Need a secure replacement key or a Faraday pouch? Browse our car key and accessories collection for trusted, secure options. Know the Risk, Beat the Scam Car key cloning scams are evolving — and fast. The combination of wireless technology, smart cars, and openly available tools has created the perfect storm for high-tech theft. But with a little awareness and some simple precautions, you can stay one step ahead. Don’t wait until it happens to you. Know the signs, protect your keys, and take action now — because in a world of silent theft, what you don’t see can hurt you .

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