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

How to Choose the Correct Key for Your Westfalia Towbar
27.08.2024

How to Choose the Correct Key for Your Westfalia Towbar

Westfalia towbars are a common choice for many car owners due to their reliability and ease of use. However, because you may use your Westfalia towbar key sporadically throughout the year, it’s not uncommon to misplace it, often at the most inconvenient times—like when you're about to go on vacation. If you've lost your key , you might not know the number of the key you need to order a replacement. Fortunately, there is a way to determine this, depending on whether your towbar lock has a 3-digit or a 5-digit number. Step 1: Check the Number on Your Towbar Lock The first step is to inspect your towbar lock to see if it has a 3-digit or 5-digit number. Here’s what to do next: Sample picture of how 5-digits lock number looks like. If you have a 3-digit number: Unfortunately, the key code remains unknown based on this number alone. We can only manufacture a new key if you have at least one original key and can provide us with the W** or 2W** code from it. If you have a 5-digit number: You're in luck! You can easily determine the correct key code. The key code is based on the last two digits of the 5-digit lock number, prefixed with "2W". Step 2: Calculate Your Key Code If your towbar lock has a 5-digit number, simply ignore the first three digits and use the last two digits. Prepend "2W" to these digits to form the key code. For example, if the code on your lock is 33322 , then your key code is 2W22 . This code will be the number you provide when ordering a replacement key. Even if your 5-digit lock code starts with a different set of three digits, the method remains the same—ignore the first three and focus on the last two digits. For your convenience, we include our key code generator below. What to Do If You’ve Lost All Your Keys If you have lost all your keys and only have the 5-digit number on the lock, you can still determine the correct key using the method described above. Unfortunately, if your lock only has a 3-digit number, the specific key code cannot be determined based on the number alone. Remember, the key code is crucial for obtaining a replacement key. If the towbar was manufactured after 2008, the 5-digit code on the lock cylinder will allow you to identify the correct key. Simply use the last two digits and prefix them with "2W" to get the key code. If you're ever unsure, it's always a good idea to reach out to the manufacturer or a professional who can assist in identifying the correct key. Conclusion Choosing the correct key for your Westfalia towbar is straightforward if you know what to look for. By following these steps, you can quickly determine the correct key code and ensure you're never stuck without access to your towbar when you need it most. Be sure to keep your key code information safe, and consider having a spare key made to avoid future issues. Click Here To Order Your Westfalia Towbar Key >>

The Environmental Impact of Car Manufacturing: A Deep Dive into Its Global Consequences
24.02.2025

The Environmental Impact of Car Manufacturing: A Deep Dive into Its Global Consequences

The automobile industry has long been a driving force of economic growth and technological advancement. However, beneath its sleek exteriors and high-speed innovations lies a significant environmental footprint. From the extraction of raw materials to the assembly line and eventual disposal, every stage of a car's life cycle carries substantial ecological consequences. As the world grapples with climate change and resource depletion, it is imperative to assess the environmental impact of car manufacturing and explore sustainable alternatives. Resource Extraction: The Hidden Cost of Manufacturing Before a car even reaches the production line, the journey begins with the extraction of raw materials. The automotive industry relies heavily on metals such as steel, aluminum, and lithium, all of which require energy-intensive mining operations. Steel and aluminum production involve large-scale mining activities that contribute to deforestation, soil degradation, and biodiversity loss. The World Steel Association estimates that steel production alone accounts for 7-9% of global CO2 emissions. The demand for lithium and cobalt, key materials in battery production, has led to extensive mining operations in countries like Chile and the Democratic Republic of Congo. These activities have been linked to water shortages, toxic waste, and human rights violations. The environmental impact of resource extraction does not end at the mines. Refining these materials also emits significant greenhouse gases and pollutants that affect both the atmosphere and local ecosystems. Energy Consumption and Carbon Footprint in Production The manufacturing process itself is a major contributor to carbon emissions. Producing a single vehicle requires immense amounts of energy, primarily derived from fossil fuels. Car factories depend on energy-intensive machinery for stamping, welding, painting, and assembling components, with most facilities still relying on non-renewable energy sources, exacerbating their carbon footprint. According to the International Energy Agency (IEA), the automotive industry accounts for roughly 10% of total global CO2 emissions. While traditional internal combustion engine (ICE) vehicles release an average of 4.6 metric tons of CO2 annually, even EV production is not emission-free due to battery manufacturing. Water Usage and Pollution in Car Manufacturing Water is a crucial resource in vehicle production, used for cooling systems, paint shops, and cleaning processes. On average, it takes up to 151 cubic meters of water to manufacture a single car. This excessive water consumption poses a severe strain on local water supplies, especially in arid regions. Furthermore, wastewater from factories often contains hazardous chemicals, heavy metals, and microplastics. If not properly treated, these contaminants can seep into local water bodies, affecting marine ecosystems and public health. Air Pollution and Toxic Emissions Beyond CO2, car manufacturing emits various pollutants that contribute to poor air quality and respiratory illnesses. The painting and coating processes release volatile organic compounds (VOCs), which contribute to smog formation and have been linked to lung diseases. Emissions from factory operations and power plants used to supply energy to car manufacturing facilities contribute to nitrogen oxides (NOx) and particulate matter pollution, leading to acid rain and cardiovascular diseases. Waste Generation and Recycling Challenges The car manufacturing process generates vast amounts of waste, from metal scraps and plastic components to hazardous chemicals and non-recyclable materials. While a large percentage of scrap metal can be recycled, many plastic and composite materials used in modern cars are difficult to process. With the rise of EVs, battery disposal is a growing concern. Many lithium-ion batteries contain toxic elements like lead and cadmium, posing environmental hazards if not properly recycled. Global Efforts Toward Sustainable Car Manufacturing Recognizing the urgency of reducing their ecological impact, car manufacturers are gradually shifting toward greener alternatives. Companies like Tesla and BMW are integrating solar and wind power into their production facilities to reduce reliance on fossil fuels. Some automakers are exploring the use of recycled aluminum, biodegradable plastics, and sustainable textiles to minimize waste. Many factories are implementing closed-loop water recycling systems to reduce water consumption and prevent pollution. Efforts to promote sustainability in the industry include: The use of renewable energy sources such as solar and wind in manufacturing plants. Innovative recycling programs that repurpose old car parts and materials. Improvements in energy efficiency within production lines to reduce emissions. Adoption of cleaner, alternative materials for car interiors and body structures. Electric Vehicles: A Double-Edged Sword? While EVs are often touted as the future of sustainable transportation, their production still presents environmental challenges. The extraction and refining of lithium, nickel, and cobalt require vast amounts of energy and water, sometimes offsetting the carbon savings of driving an EV. An EV’s overall sustainability depends on the energy grid it charges from. In coal-dependent regions, EVs may not offer a significant reduction in emissions compared to efficient hybrid vehicles. The Road Ahead for a Greener Auto Industry The environmental impact of car manufacturing is a multifaceted challenge that requires a collaborative effort from governments, corporations, and consumers. Transitioning toward sustainable production practices, investing in recycling infrastructure, and promoting clean energy solutions are crucial steps in mitigating the industry's ecological footprint. As consumers, we can contribute by supporting manufacturers committed to sustainability, opting for fuel-efficient or electric vehicles, and advocating for stricter environmental policies. The road to a greener automotive industry is long, but with continued innovation and commitment, a more sustainable future is within reach.

Car Ignition Switch Problems: Symptoms, Causes, and Replacement Guide
19.11.2025

Car Ignition Switch Problems: Symptoms, Causes, and Replacement Guide

The ignition switch is one of the most important electrical components in any car. When it starts to fail, the symptoms can appear suddenly, seem unrelated, and quickly leave you stranded. This guide explains the real-world signs , the common causes , the most accurate diagnosis steps , and a clear ignition switch replacement guide that helps any driver understand what’s happening and what to do next. If you’re dealing with car ignition lock problems , this article gives you the clarity you need to fix the issue fast and safely. What the Ignition Switch Actually Does The ignition switch has two critical jobs: 1. Electrical power distribution It sends power to the dashboard, fuel pump, ignition system, starter motor, and electronic modules. 2. Starting the engine When you turn the key (or press the button), it bridges electrical circuits, enabling the starter motor to crank the engine. When the ignition switch begins failing, even slightly, it disrupts these circuits. That’s why symptoms can range from flickering dash lights to complete engine shutdown. Symptoms of a Failing Ignition Switch These are the most common, proven symptoms that mechanics use to identify ignition switch problems. 1. Car Won’t Start or Cranks Intermittently If turning the key does nothing—or the engine cranks sometimes but not always—the ignition switch may not be sending power consistently to the starter relay. Typical behavior includes: Silence when turning the key Clicks but no cranking Starts only after multiple attempts Total power loss during cranking This is one of the most classic ignition switch symptoms. 2. Stalling While Driving A failing ignition switch can cut power to the engine while you’re moving . Common signs: Sudden stall for no reason All dash lights go off instantly Engine dies when hitting bumps Engine cuts out but restarts immediately This is dangerous and needs urgent attention. 3. Dashboard Lights Flickering or Turning Off When the internal contacts inside the switch wear out, they create tiny power interruptions. You may see: Speedometer drops to zero Warning lights randomly appear Interior electronics momentarily cut out Radio resets or flickers These short power losses are a major red flag. 4. Key Feels Hot or Hard to Turn If the key is warm after driving, the switch may be overheating internally. If the key becomes difficult to rotate, the ignition cylinder (mechanical part) may be worn — which often leads to switch failure later. 5. Accessories Don’t Work in ACC Mode If turning the key to ACC does not activate: radio wipers power windows heater fan …the accessory circuit inside the switch may be failing. 6. No Sound from the Fuel Pump When Turning the Key You should hear a soft humming for 1–2 seconds. If you don’t, it may mean the ignition switch isn’t powering the pump relay. What Causes Ignition Switch Problems? Ignition switches fail for predictable and well-documented reasons. 1. Internal Wear Over Time Inside the ignition switch are metal contact plates . After thousands of cycles, these contacts burn, corrode, or lose tension. Symptoms develop slowly: random stalling needing to wiggle the key intermittent power This is the most common cause. 2. Heavy Keychains Many drivers don’t realise this: A heavy keychain constantly pulls on the ignition cylinder. Over years, this causes: internal looseness misalignment premature switch failure If your keychain has more than a few items, it may be contributing. 3. Heat and Electrical Overload Faulty relays, worn fuel pumps, or aftermarket accessories can overload the ignition switch. Excess heat damages the internal copper contacts, causing: hot key symptoms partial circuit failure total switch burnout 4. Moisture or Dirt in the Cylinder Moisture or dust causes the mechanical part of the ignition to jam or bind. This forces extra pressure onto the switch every time the key turns. 5. Faulty Key or Worn Key Blade If your key doesn’t rotate smoothly, it can damage both the cylinder and the switch . Worn keys often lead to electrical faults later. How to Diagnose Ignition Switch Problems Accurately Before replacing parts, you should confirm the ignition switch is truly the issue. These steps follow the same logic professional mechanics use. 1. Check if Dashboard Lights Turn On Turn the key to ON without starting the engine. If: no lights come on lights flicker radio stays off …the ignition switch might not be sending voltage. 2. Try Starting with Accessories On Turn the key to ACC. If the accessories work in ACC but the engine won’t start, the “start circuit” inside the ignition switch may be failing. 3. Wiggle Test Gently wiggle the key while: trying to start with ACC on with the engine idling If wiggling makes electronics turn on/off, the switch is internally worn. 4. Bump Test While Driving If the car stalls when hitting bumps or potholes, the switch is losing internal contact momentarily. This is one of the strongest indicators of a failing switch. 5. Test Voltage at the Ignition Switch (Advanced) Using a multimeter, check for: constant power switched power accessory power start signal power If any circuit fails randomly, it confirms an ignition switch fault. If you need a safety reference for electrical testing, you can check the UK Government’s general vehicle safety guidance here: Prevention: How to Avoid Ignition Switch Problems Ignition switch failures can often be prevented with small habits. 1. Keep Your Keychain Light Remove heavy accessories. This reduces stress on the ignition cylinder and switch dramatically. 2. Avoid Resting Hands on the Key While Driving Constant pressure on the key twists the internal contacts. 3. Only Use Correct, Undamaged Keys Bent, cracked, or worn keys can damage: the cylinder the switch the steering lock If your key is worn, replace it before it causes further problems. 4. Address Electrical Problems Early A failing alternator, weak battery, or short circuits can overload the ignition switch. If you notice dim headlights or battery warnings, fix those early. 5. Keep Dust and Moisture Out of the Cylinder Avoid spraying WD-40 or household lubricants into the ignition—it attracts dust. Use proper graphite lock lubricant if needed. Ignition Switch Replacement Guide You should only replace the ignition switch if diagnosis confirms it. Below is a clear replacement overview used by both DIYers and technicians. Note: Procedures vary by vehicle, but the overall steps are similar. 1. Disconnect the Battery Always disconnect the negative terminal. This prevents: accidental airbag deployment electrical shorts damage to modules 2. Remove Steering Column Covers Most cars use simple screws underneath. Once removed, the top and bottom covers split apart. 3. Locate the Ignition Switch Module It is usually mounted behind the ignition cylinder. Depending on the car: it may be held by two screws or secured with clips or integrated into a combined steering lock module 4. Remove the Electrical Connector Ignition switches usually have one large multi-pin connector. Release the locking tab and pull it gently. 5. Remove and Replace the Switch Install the new switch in the exact orientation as the old one. Common mistakes to avoid: misaligning the switch’s internal slot tightening screws unevenly damaging wiring during removal 6. Reassemble and Test Thoroughly After reassembly, test: ACC mode ON mode engine start headlights indicators wipers radio If everything works consistently, the replacement is successful. Is It Safe to Drive with a Bad Ignition Switch? Usually no . A failing ignition switch can: stall the engine suddenly disable power steering shutdown ABS cut power to headlights at night The RAC warns that electrical failures causing engine cut-outs are a serious safety risk. If your switch is failing, get it inspected immediately. FAQ: Car Ignition Switch Problems 1. How much does ignition switch replacement cost? Most replacements cost £80–£300 depending on the vehicle. Some modern cars require coding, making the cost higher. 2. Can a bad ignition switch cause the car to stall? Yes. Loss of electrical contact in the switch can cut power to the engine instantly. 3. Is a failing ignition switch the same as a bad starter? No. A bad starter prevents the engine from cranking. A bad ignition switch prevents power from reaching the starter or other systems. 4. Can a locksmith replace an ignition switch? In many cases, yes — especially for older vehicles. For modern immobilizer systems, a vehicle technician may be required. 5. Can I drive with ignition switch problems? It’s unsafe. The engine can cut out while driving, especially on bumps or turns. 6. Does a bad ignition switch affect accessories only? It can affect: accessories engine start fuel pump dashboard power ECU communication It depends on which internal circuit fails. 7. What’s the lifespan of an ignition switch? Most last between 10–15 years , depending on usage and electrical load. 8. Do push-button cars have ignition switches? Yes — they use an electronic ignition switch module instead of a mechanical one. Failure symptoms are similar. 9. What does a worn key have to do with ignition switch problems? A badly worn key can cause mechanical strain on the cylinder, which then stresses the electrical switch linked behind it. 10. Can I prevent ignition switch issues? Yes — keep your keychain light, avoid forcing the key, and keep electrical systems maintained. For high-quality replacement automotive parts and spare key, visit our shop at mr-key.com .

KEY COVERS: WHAT DO YOU NEED TO KNOW?
05.02.2025

KEY COVERS: WHAT DO YOU NEED TO KNOW?

What is a Key Cover? A key cover , often referred to as a key shell or key case, is the outer part of your key. It houses the electronic board, chip, and battery but excludes the internal electronics themselves. If your key casing is damaged, there’s no need to replace the entire key – just changing the key cover can restore its durability and usability while saving you money. When Do You Need a New Key Cover? You might need a key cover replacement when: The buttons on your key become worn out or stop responding. The outer case cracks, exposing the internal electronics. The key mechanism no longer functions smoothly. You want to refresh the appearance of your key with a new, sturdy shell. Instead of struggling with a faulty key, simply replace the cover and extend the lifespan of your original key! How to Choose the Right Key Cover? When selecting a replacement key cover, consider the following factors: Button Layout: Ensure that the number of buttons and their symbols match your existing key. Blade Shape: If your key includes an integrated blade, make sure the new shell accommodates it correctly. Quality: A good-quality key cover ensures a snug fit, smooth functionality, and long-lasting durability. At MR-KEY , we offer a variety of key covers designed to match your specific car model perfectly, providing both aesthetics and functionality. How to Change Your Key Cover? Replacing your key cover is simple and doesn’t require professional assistance. Here’s how: Purchase a compatible key cover from our website. Open your old key case carefully. Transfer the electronic board and chip from your original key to the new key cover . Reassemble the key, ensuring all components fit securely. Test the buttons and functions to confirm everything is working properly. For step-by-step guidance, we provide video tutorials on our website, showing you exactly how to change your key shell and even replace the battery if needed. What Else Can You Change When Replacing the Key Cover? While changing your key cover, it's the perfect time to: Replace non-functional click buttons on your key’s electronic board. Change the battery since you're already disassembling the key, ensuring it lasts longer. At MR-KEY , we strive to make key replacements easy, affordable, and accessible to everyone. Explore our website to find the perfect key cover, key cutting services, and useful video guides to help you maintain your car key like a pro!

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