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What You Need To Know About BMW Swirl Flaps and How To Solve The Problem With Them

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  • What You Need To Know About BMW Swirl Flaps and How To Solve The Problem With Them
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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.

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Guide to Identifying and Replacing Your Keys
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Guide to Identifying and Replacing Your Keys

Losing your keys can be a frustrating experience, but identifying the right replacement doesn't have to be. Whether you've lost a house key, a car key, or a key to a padlock or cabinet, understanding how to identify the key you need is crucial. This guide will walk you through the process of identifying your keys, ensuring you find the right replacement quickly and efficiently. The Importance of Key Identification Before diving into how to replace a lost key, it’s important to understand why key identification is critical. Keys come in a variety of shapes, sizes, and designs, each tailored to specific types of locks. Identifying your key correctly will save time, money, and frustration. For example, car keys often include transponder chips that need to be programmed to your vehicle, while house keys may have specific patterns that fit only one brand of lock. Step 1: Check for Key Codes and Markings The first step in identifying your key is to look for any codes or markings. These can be found on the key itself or sometimes on the lock. Key codes are often a series of letters and numbers that indicate the specific model or cut of the key. If you still have the original key, examine it closely for these codes. If not, check the lock for any inscriptions that might offer clues. Key codes are essential, particularly for high-security keys or specialized keys such as those used in commercial settings. For car keys, this code might also be found in the vehicle’s manual or on a key tag provided at the time of purchase. Step 2: Determine the Key Type Next, determine the type of key you need. Different keys serve different purposes: House Keys: Typically flat with unique grooves along the edge, these are used in residential locks. Car Keys: These may include electronic transponders and are often more complex. Padlock Keys: Usually smaller, these keys have a unique profile that fits the specific lock. Cabinet or Locker Keys: These are often smaller and may be specific to a brand or lock type. Identifying the correct key type is important because it narrows down your options when searching for a replacement. Step 3: Identify the Lock Brand If you cannot find a key code, identifying the lock brand is the next best step. The brand name is usually stamped somewhere on the lock or key. Knowing the brand will help you narrow down the options for finding a replacement key. For example, many house keys are cut to fit specific brands like Yale or Schlage. Car keys, on the other hand, are usually specific to the car manufacturer. Knowing the brand is especially useful when you need to replace a key without an original to reference. Step 4: Examine the Key Profile The profile of the key refers to the unique cuts, grooves, and ridges along its blade. This profile is what allows the key to operate a specific lock. When identifying your key, compare the profile of your key to those available through online resources or in-store at key-cutting services. If you have a high-security key, it may have a more complex profile that is difficult to replicate. In such cases, it’s best to consult a professional locksmith or the lock manufacturer for an exact match. Step 5: Utilize Online Resources There are many online resources available to help you identify and replace your lost key. Websites often offer key identification tools where you can input details such as key codes, lock brands, and key types to find a match. Additionally, many online stores specialize in replacement keys, offering a wide selection based on the information you provide. Step 6: Contact the Manufacturer If you're still having trouble identifying your key, contacting the lock or car manufacturer can be extremely helpful. Provide them with any details you have about the lock or key, and they can often guide you to the right replacement. For car keys, your vehicle identification number (VIN) can often be used by the dealership to cut a new key or program a replacement transponder key. Step 7: Professional Locksmith Assistance When all else fails, a professional locksmith is your best bet. Locksmiths have the tools and expertise to identify and replicate nearly any type of key. They can also assist with programming transponder keys for cars or creating master keys for complex locking systems. Losing a key doesn't have to be a stressful experience if you know how to identify and replace it effectively. By following these steps—checking for key codes, determining the key type, identifying the lock brand, examining the key profile, using online resources, and seeking professional help—you can ensure that you find the right replacement quickly and efficiently. Proper key identification is the first step toward restoring access and ensuring security.

DIY Guide: How to Program or Sync Your Car Key Fob at Home
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Lost Your Witter, GDW, Thule (Brink) or TowTrust Towbar Key? Here's What to Do.
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Lost Your Witter, GDW, Thule (Brink) or TowTrust Towbar Key? Here's What to Do.

Lost your towbar key right before a holiday or towing trip? You’re not alone. Detachable towbar keys are typically used only occasionally – often just before a caravan holiday or when you need to tow – which means they spend most of the year tucked away. It’s all too easy for that lost towbar key to go missing between uses. The good news is that if your key has an ACS-series code (ACS01–ACS10) engraved on it, you can order a precise replacement online in minutes and avoid throwing a wrench in your travel plans. What are ACS towbar keys? The ACS-series keys are a common type of detachable towbar key numbered ACS01 through ACS10 (for reference: ACS01, ACS02, ACS03, ACS04, ACS05, ACS06, ACS07, ACS08, ACS09, ACS10). These keys fit a specific locking system used by multiple towbar manufacturers. In fact, an ACS towbar key could belong to a detachable hitch from ACS itself or from popular brands like Witter, GDW, Thule (Brink) or TowTrust – all of whom use the same ACS lock design. 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Brink / Thule – Thule’s towing division (now Brink) uses ACS keys for many of its detachable hitches. If you have a Thule or Brink detachable towbar, check for an ACS code on the lock. (Brink/Thule locks with codes like 1D## or 2D## are a different series – but ACS## codes are common on earlier Thule/Brink models.) Witter – A very popular towbar brand, Witter uses the ACS system on their detachable swan-neck towbars. A Witter detachable with an ACS key will have “ACS” on the key or lock face. Witter towbar key replacements are readily available by code. GDW – This European towbar manufacturer also uses ACS-series keys for many detachables. If you need a GDW towbar replacement key, the process is the same: find the ACS## code and order a matching key. Tow-Trust – TowTrust (Tow-Trust) towbars, often sold in the UK and EU, utilize ACS keys as well. Tow-Trust detachable models with ACS locks will have codes ACS01–ACS10 on the keys. Other brands like PCT Automotive or Towsure have also been known to use ACS locks in some of their detachable towbar systems. The key point is that multiple brands share this ACS key design. So whether your hitch is labeled Witter, Thule, Brink, GDW, or TowTrust, if the key code starts with ACS, you can get the correct replacement towbar key by that code. This compatibility makes it easier to find spares, since one good supplier can cover many brands under the ACS series. Quick Reference: ACS Key Codes and Brands For easy identification, here’s a summary of which detachable towbars use the ACS01–ACS10 key range: Towbar Brand Detachable Key Code Series Example Key Code ACS (A50-X system) ACS01 – ACS10 ACS07 (on key/lock) Brink (Thule Towbars) ACS01 – ACS10 ACS05 Witter ACS01 – ACS10 ACS03 GDW ACS01 – ACS10 ACS09 Tow-Trust ACS01 – ACS10 ACS02 If your towbar brand is listed above and you see an “ACS*” code on the lock, you can order a new key by that code. In the example codes, the number can be any from 01 to 10. How to Order a Replacement ACS Towbar Key Online One of the great things about these keys is how simple it is to get a replacement. You don’t need to visit a dealership or locksmith in person; you can order an ACS towbar key online and have it cut to code and delivered to your door. Here’s how to do it: 1. Locate the ACS key code – As mentioned, find the engraved code on your existing key or the towbar lock barrel (e.g. ACS08). Double-check that it’s in the ACS01–ACS10 range. 2. Visit a replacement key website – Go to a trusted online key supplier that offers keys cut to code. For example, you can order from a specialized service like Mr. Key. They have a product page specifically for spare keys for ACS A50-X / Brink / Thule towbars (codes ACS01–ACS10) – this is where you’ll enter your code to get the correct key. 3. Select your key code – On the product page, choose your exact code (say, ACS04 or ACS09) from the dropdown or list. 4. Place your order – Add the replacement key to your cart and check out. These keys are very affordable (usually only a few dollars or euros each), and you can often choose expedited shipping if you’re in a hurry. 5. Receive and test the key – Shipping is typically quick (a few days within Europe). Once it arrives, test the replacement towbar key in your detachable towbar’s lock. It should turn smoothly and unlock the mechanism just like the original. Problem solved. Product Link: https://mr-key.com/product/spare-key-for-acs-a50-x-brink-thule-towbar-codes-acs01-acs10 You can order the correct replacement key here: Spare Key for ACS A50-X / Brink / Thule Towbar – Codes ACS01–ACS10. Simply select your code from ACS01 up to ACS10 and choose the key with the matching number. The new key will be cut to that code and sent to you ready to use. Ordering online is not only convenient but also ensures you get the precise key you need. These keys are cut by code using professional tools, so you don’t have to worry about tracing an old key or guesswork. As long as the code you provide is correct, the new key will fit perfectly or you can get your money back. Make a Spare Key Now to Avoid Future Stress Once you have your new key in hand (or if you still have your original), it’s time to think ahead. Don’t wait until you’ve lost the only key to take action. Cutting a spare key while you still have a working one is quick and inexpensive, and it can save you a lot of trouble down the road. Here are some benefits of having a spare towbar key: No more last-minute panic: If one key goes missing, you’ll have a backup ready. This means no frantic searches the night before your trip and no postponed travel plans due to a missing key. Avoid costly lock replacements: Losing the only towbar key can be expensive – you might be forced to drill out the lock or replace the entire detachable neck mechanism. A spare key (which typically costs under £10) is far cheaper than a new lock or towbar. Keep your holiday on track: A Thule towbar spare key or Witter towbar spare key tucked in your glove box ensures that a lost key won’t derail your caravan holiday or trailer rental schedule. You can continue towing without delay. Fast & affordable peace of mind: Ordering an extra key by code is both fast and affordable. Many drivers are surprised at how easy it is – often it’s just a couple of clicks online and a short wait for delivery. It’s a small investment for the security of knowing you’re covered. Consider ordering two keys when you get your replacement. Many suppliers even offer a deal on a second key (or include a pair by default), so you can keep one spare at home and one in the vehicle. Having multiple keys means you’re highly unlikely to ever be locked out of your own towbar again. Losing your towbar key can be a frustrating experience, especially when it happens right before you need to use it. But if your detachable towbar uses the ACS lock system (codes ACS01–ACS10), solving the problem is straightforward. With a visible ACS key code and a reliable online key-cutting service, you can quickly get a new replacement towbar key cut to code and delivered. There’s no need for costly new locks or last-minute cancellations of your towing plans. Don’t let a lost towbar key ruin your trip. Take a moment to check your towbar for an ACS code. If it’s there, you can have a new key on the way in no time. And even if your current key is in hand, think ahead – get a spare made now to save yourself stress later. With fast online ordering and prices that won’t break the bank, getting an ACS towbar key replacement is the easiest way to ensure you’re never stuck without the key to your adventures. Safe towing.

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What to Do If You Lose Your Volkswagen Key?

Losing a Volkswagen key is stressful. It usually happens at the worst possible moment—before work, during travel, or far from home. Modern VW keys are no longer simple pieces of metal. They combine electronics, immobiliser chips, and precision-cut blades. When a lost car key situation happens, knowing the right steps saves time, money, and frustration. This guide explains exactly what to do if you lose your VW key, how to secure your vehicle, and how to get a proper VW key replacement without unnecessary delays. Stay Calm and Check the Obvious First Before assuming your VW key is gone for good, pause. Keys are often misplaced, not stolen. Check: Jacket and trouser pockets Bags and backpacks Around the car, driveway, or parking area Home entry points and recent stops Many VW keys are lost nearby and found within minutes. If the key truly cannot be located, move to the next step. Secure Your Volkswagen Immediately If you suspect the key is lost in a public place, vehicle security becomes the priority. Modern Volkswagen keys communicate with the car via encrypted signals. While this offers protection, losing a key still creates risk. What to do: Lock the vehicle if possible Avoid leaving the car unattended for long periods Do not delay replacement if the key cannot be recovered The fewer active keys exist for your vehicle, the safer it remains. Identify What Type of VW Key You Lost Not all Volkswagen keys are the same. Knowing what you lost helps you choose the correct replacement. Common VW key types include: Mechanical keys (older VW models) Transponder keys (chip-based immobiliser keys) Remote flip keys Smart / proximity keys (keyless entry systems) You can usually identify your key type by: The year of the vehicle Whether it had buttons Whether the car starts with a traditional ignition or push-start This information ensures you order the correct VW key replacement. Why a Spare Volkswagen Key Matters More Than You Think Many VW owners only realise the importance of a spare after losing their only key. A spare key: Prevents vehicle immobilisation Reduces stress during travel Makes replacement faster and simpler Acts as a backup for emergencies Relying on a single key is one of the most common and avoidable mistakes VW drivers make. Replacing a Lost Volkswagen Key the Smart Way A VW key replacement does not always require the original key. At mr-key.com , you can order replacement Volkswagen keys, fobs, and key cases designed to match your exact model. Available solutions include: Replacement VW key shells and fobs New key blades cut to match your vehicle Keys cut from a photo of the original Keys cut from a code , where available This allows you to restore access even if the original key is completely lost. Important : Electronic keys may still require programming after cutting, depending on the model. How VW Keys Can Be Cut Without the Original Many drivers assume a missing key makes replacement impossible. That is not true. VW keys can often be cut: From a clear photo of the original key blade From a key code linked to the vehicle or lock This method restores the physical function of the key with high precision. It is especially useful when no spare key exists. More information on official VW security and immobiliser systems can be found on the Volkswagen website Protect Your Replacement VW Key Once you replace a lost VW key, protect it properly. Simple habits make a big difference: Use a protective key case Avoid placing keys loosely in bags or pockets Keep a spare key stored safely at home Small steps prevent repeat key loss—and repeat stress. Frequently Asked Questions Can I replace a Volkswagen key without the original? Yes. A VW key replacement is possible even without the original key. Keys can be cut from a photo or code, depending on the model. What should I do if I lose my only VW key? Secure the vehicle first. Then order a replacement key as soon as possible to avoid being locked out or immobilised. Are all VW keys the same? No. Volkswagen uses different key types depending on model and year, including mechanical, transponder, remote, and smart keys. Does a replacement VW key need programming? Some VW keys include electronic chips that require programming. Cutting the key restores physical access, while programming enables full functionality. Why is having a spare VW key important? A spare key saves time, stress, and complications if your main key is lost or damaged. For independent vehicle security standards and best practices, see guidance from recognised automotive organisations such as ADAC If you’ve lost your Volkswagen key or want to avoid future problems, explore VW key replacements , fobs , cases , and key cutting services at mr-key.com and secure your vehicle the smart way.

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