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

Top 10 Interesting Facts About Mercedes: A Journey of Luxury, Innovation, and Performance
24.10.2024

Top 10 Interesting Facts About Mercedes: A Journey of Luxury, Innovation, and Performance

When you think of Mercedes-Benz , images of luxury, precision engineering, and cutting-edge technology come to mind. As one of the world’s most iconic car manufacturers, Mercedes has a rich history filled with groundbreaking achievements and innovations. Whether you’re an owner or an admirer of the brand, there’s always more to learn. Let’s dive into the top 10 interesting facts about Mercedes-Benz that you might not know. 1. The First Car Ever Made Was a Mercedes-Benz Mercedes-Benz holds the distinction of having created the world’s first automobile. In 1886, Karl Benz invented the Benz Patent Motorwagen, a three-wheeled vehicle powered by an internal combustion engine. This invention marked the beginning of the modern automotive industry. A Pioneer in Mobility : Mercedes-Benz didn’t just create cars; they invented the concept of personal motorized transportation. The company’s innovative spirit started at the very dawn of the industry. 2. The Name "Mercedes" Comes from a Young Girl The name "Mercedes" comes from Mercedes Jellinek, the daughter of a wealthy Austrian businessman and car enthusiast, Emil Jellinek. Jellinek was a major investor in Daimler’s vehicles and convinced the company to use his daughter’s name for a new line of cars in 1901. A Legacy in a Name : The Mercedes brand has since become synonymous with elegance, luxury, and performance, and it all began with the name of a young girl. 3. Mercedes Introduced the First Modern Car Safety Features Mercedes has always been at the forefront of automotive safety. In 1951, the company invented the "crumple zone," a revolutionary design that allows the car to absorb impact in a collision, protecting passengers inside. Pioneering Safety : Mercedes-Benz has led the way in developing safety features that have since become standard in the auto industry, such as airbags, anti-lock brakes, and electronic stability control. 4. The Famous Three-Pointed Star Has a Unique Meaning The iconic Mercedes-Benz logo—the three-pointed star—represents the company’s vision of motorized dominance on land, sea, and air. It’s more than just a logo; it symbolizes Mercedes’ ambition to excel in all forms of transportation. A Symbol of Ambition : Each point of the star represents a different domain, showing how Mercedes is not just focused on cars but has had aspirations in all areas of engineering. 5. Mercedes-Benz Was the First to Offer Diesel Passenger Cars In 1936, Mercedes-Benz was the first automaker to introduce a diesel-powered passenger car. The Mercedes 260D was not only more fuel-efficient than gasoline cars at the time, but it also laid the foundation for diesel technology in passenger vehicles. A Milestone in Efficiency : Mercedes’ commitment to innovation is clear in their early adoption of diesel technology, which became crucial in later years for fuel efficiency and performance. 6. Mercedes-Benz Develops Eco-Friendly Technology Mercedes-Benz has been a leader in developing eco-friendly technologies. From hybrid systems to fully electric vehicles, the brand’s innovation is helping pave the way for a greener automotive future. Green Innovation : The introduction of models like the EQ series, which are fully electric, demonstrates Mercedes’ dedication to reducing carbon footprints without sacrificing luxury or performance. 7. The Gullwing Doors of the Mercedes 300SL Were a Sensation The Mercedes-Benz 300SL, introduced in 1954, became famous for its distinctive "gullwing" doors that opened upwards like the wings of a bird. This innovative design not only gave the car its iconic look but also revolutionized sports car design. A Design Icon : The 300SL is still regarded as one of the most beautiful and innovative cars ever made, and its gullwing doors are a major reason why. 8. Mercedes Has a Rich Racing History Mercedes-Benz has a storied history in motorsports, particularly Formula 1. Mercedes’ F1 team has dominated the sport in recent years, winning numerous Constructors' and Drivers' Championships. Racing Royalty : From the legendary "Silver Arrows" of the 1930s to the modern-day dominance in Formula 1, Mercedes has cemented its place as one of the top names in motorsport. 9. Mercedes Introduced the First Autonomous Driving Features Mercedes-Benz has been a pioneer in autonomous driving technology. In 2013, they introduced a self-driving concept vehicle called the S-Class Intelligent Drive. This was a major step forward in the journey towards fully autonomous cars. Leading the Future : Mercedes continues to push the boundaries with advanced driver assistance systems, leading the way towards a future where autonomous cars may become the norm. 10. Mercedes-Benz Offers Personalization Like No Other Mercedes-Benz offers a wide range of customization options through its "Designo" program, allowing customers to personalize their vehicle’s paint, interior materials, and more. This ensures that each Mercedes is as unique as its owner. Tailored to Perfection : Whether you prefer a bold exterior color or a more refined leather interior, Mercedes gives you the opportunity to create a car that reflects your personality. Mercedes-Benz—A Legacy of Innovation and Luxury Mercedes-Benz has earned its place as one of the most prestigious and innovative automotive brands in the world. From creating the first car to leading the way in safety, performance, and eco-friendly technologies, Mercedes continues to set the standard. Whether you’re fascinated by their history or drawn to their luxurious design, owning a Mercedes is about embracing a legacy of excellence. As a car owner, it’s essential to be prepared for any situation. And while Mercedes may have perfected the art of driving, having a spare key for your vehicle is one practical step to ensure you’re never caught off guard.

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!

The Essential Car Parts Guide: Understanding Your Vehicle's Core Components
21.06.2024

The Essential Car Parts Guide: Understanding Your Vehicle's Core Components

Unveiling the Anatomy of Your Car Your car is more than just a mode of transportation—it's a complex machine composed of various parts working in harmony to ensure smooth and safe driving. Understanding these essential car parts not only helps you appreciate your vehicle better but also empowers you to identify issues, perform basic maintenance, and communicate effectively with mechanics. In this guide, we’ll explore the key components that keep your car running and why they’re vital for optimal performance. 1. Engine: The Heart of Your Vehicle The engine is the powerhouse of your car, converting fuel into energy to propel the vehicle forward. There are various types of engines, including: Internal Combustion Engines (ICE): Common in most vehicles, using gasoline or diesel. Hybrid Engines: Combining a traditional engine with an electric motor for better efficiency. Electric Motors: Found in EVs, powered by rechargeable batteries. Key components within the engine include pistons, the crankshaft, and the timing belt. Regular maintenance like oil changes and timely inspections are crucial for keeping the engine in good condition. 2. Transmission: Changing Gears Made Easy The transmission system ensures that power from the engine is transferred to the wheels at the correct speed and torque. There are two main types of transmissions: Manual Transmission: Requires the driver to shift gears manually. Automatic Transmission: Shifts gears automatically, providing greater convenience. Proper transmission fluid levels are essential for smooth gear transitions and the longevity of the system. 3. Battery: Your Vehicle's Power Source The car battery supplies the electrical power needed to start the engine and operate various electrical systems, such as lights, wipers, and infotainment. Modern vehicles may also include auxiliary batteries for additional power needs. Maintenance Tip: Regularly check battery terminals for corrosion and ensure proper voltage levels, especially in extreme weather conditions. 4. Braking System: Your Lifeline on the Road The braking system ensures the vehicle slows down or stops when needed, making it a critical safety component. Key parts include: Brake Pads and Rotors: Convert kinetic energy into heat, slowing the car down. Brake Fluid: Transfers force from the brake pedal to the braking mechanism. Regular inspection of the braking system can prevent wear and ensure reliability. 5. Tires and Wheels: Where the Rubber Meets the Road Tires and wheels are vital for traction, handling, and overall vehicle stability. There are various types of tires designed for specific conditions, such as all-season, winter, and performance tires. Maintenance Tip: Regularly check tire pressure, alignment, and tread depth to ensure safe driving and optimal fuel efficiency. 6. Suspension System: Smoothing Out the Ride The suspension system absorbs shocks from uneven road surfaces, ensuring a smooth and stable ride. Key components include: Shock Absorbers: Reduce impact from road irregularities. Struts and Springs: Provide structural support and maintain balance. A well-maintained suspension system enhances comfort and handling. 7. Exhaust System: Keeping Emissions in Check The exhaust system directs harmful gases away from the engine and reduces emissions. Key components include the muffler, catalytic converter, and exhaust pipes. Environmental Note: A faulty exhaust system can increase emissions and negatively impact air quality. Regular checks are essential for compliance with emission standards. 8. Cooling System: Preventing Overheating The cooling system regulates the engine's temperature to prevent overheating. It includes components like the radiator, coolant, and thermostat. Maintenance Tip: Regularly check coolant levels and inspect hoses for leaks to ensure efficient cooling. 9. Fuel System: Delivering Energy to the Engine The fuel system stores and supplies fuel to the engine for combustion. Key parts include the fuel pump, injectors, and fuel tank. Efficiency Tip: Clean fuel injectors and replace the fuel filter as needed to maintain optimal fuel efficiency. 10. Electrical System: Powering Your Vehicle's Features From the headlights to the infotainment system, the electrical system powers numerous features in your car. It includes wiring, alternators, and fuses. Maintenance Tip: Inspect fuses and ensure the alternator is functioning properly to avoid electrical issues. Empowering Yourself Through Knowledge Understanding the essential parts of your car equips you with the knowledge to maintain your vehicle effectively and address issues proactively. By staying informed, you can extend the life of your car, save on repair costs, and ensure a safer driving experience. Whether you’re a car enthusiast or a regular driver, knowing your vehicle’s anatomy is the first step toward smarter car ownership.

How to Protect Your Car Key Fob from Relay Attacks
25.04.2025

How to Protect Your Car Key Fob from Relay Attacks

Car theft has entered the digital age — and unfortunately, so have the thieves. As car manufacturers move toward keyless technology, a new type of threat has emerged: the relay attack. Unlike traditional break-ins, this high-tech method allows criminals to steal a vehicle without touching the keys — or even breaking a window. Imagine this: your car is parked safely outside your house. Your key fob is inside, hanging on a hook by the front door. You're fast asleep. But outside, two individuals with small electronic devices are working together. One stands near your front door, scanning for a signal from your key fob. The other waits by your car. Within seconds, your key’s signal is captured, extended, and transmitted to your car. It unlocks, starts, and drives away — and you might not notice until morning. This is not science fiction. It's called a relay attack , and it's one of the fastest-growing vehicle theft methods worldwide. Why Relay Attacks Are So Effective The key to this technique is exploiting the constant communication between your car and its fob. Most keyless entry systems are designed for convenience — you don’t even need to press a button. The car automatically detects the presence of the key fob and unlocks when you approach. This convenience is exactly what makes it vulnerable. Relay devices — which are cheap, portable, and easy to use — can mimic the signal and trick the car into thinking the key is nearby, even when it’s inside your home. Security experts have raised the alarm about this method for years, but many drivers still don’t realize how easily their vehicles can be accessed. In the UK alone, keyless car theft now accounts for more than 90% of vehicle thefts involving high-end models, according to the AA. And with the rise of online tutorials and black-market tools, the problem is growing globally. So, What Can You Do to Stay Safe? Fortunately, protecting your vehicle doesn’t require advanced tech or a huge investment — just awareness and a few smart habits. One of the most effective ways to block relay attacks is also the simplest: store your keys in a signal-blocking container . Often called a Faraday pouch or Faraday box, this lined case prevents radio signals from escaping. When your keys are stored inside, they can’t be scanned or cloned, no matter how close a thief gets to your home. Placement also matters. Many drivers leave their keys near the front door or on an entryway table — spots that are easy to access from outside. Moving your keys to the center of your home, an upper floor, or even a metal box can reduce signal exposure dramatically. Some newer key fobs allow you to manually disable the signal when it’s not in use. This feature is often hidden in the manual and rarely mentioned by dealers. Taking a moment to learn whether your key supports this — and how to activate it — can make a big difference. It’s also worth checking whether your vehicle’s software is up to date. Many automakers periodically release firmware updates that strengthen encryption or reduce signal range. In some cases, updates can even detect and block suspicious unlock attempts. And while it may seem old-fashioned, physical security still works . Devices like steering wheel locks or gear shift immobilisers can be powerful visual deterrents. Even if a thief manages to unlock your vehicle, the sight of a bulky lock inside may be enough to send them looking for an easier target. If you're looking for practical solutions beyond GPS , check out our blog: Do Car Keys Have GPS? What You Need to Know About Key Tracking . In summary, here are a few key takeaways to keep your keys and vehicle safer: Store your fob in a signal-blocking pouch or metal container Keep keys away from entry points like doors or windows Disable keyless signals if your fob supports it Update your car’s firmware regularly Use visible anti-theft devices as a deterrent Looking Ahead: Smarter Cars, Smarter Drivers Relay attacks are part of a larger trend — one where modern technology makes life more convenient, but also creates new risks. Just like we’ve learned to secure our phones and passwords, we now need to think about how we secure our vehicles. As carmakers explore more secure solutions — like Ultra Wideband (UWB) tech and biometric verification — drivers still need to take responsibility for their vehicle’s safety. The tools are already out there, and many of them cost less than a meal out. It’s not just about avoiding theft; it’s about peace of mind. So next time you get home, before tossing your keys on the hallway table, take a second to think: are they really safe there?

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