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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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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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Once you identify your key type—typically a flip key with two or three buttons—you can open the casing using a small screwdriver or plastic tool. Inside, you'll find a battery nestled within the key's internal framework. Carefully remove the old battery and insert a new CR2032, ideally a reliable model like the Panasonic CR2032 . Proper alignment is crucial; the wrong orientation can prevent the key from functioning entirely. Align the shell halves carefully and press them back together until they click into place. If your key shell is also showing signs of damage or wear, consider replacing it with this Opel 3-button key housing . Replacing the battery is a quick job, but it makes a world of difference in reliability and peace of mind. Plus, it spares you the inconvenience of getting stranded or needing dealer intervention. Common Peugeot Flip Key Issues and How to Fix Them Peugeot flip keys are compact and stylish, but frequent use can expose a few recurring problems. The flip mechanism may lose tension, buttons may stop responding, or the outer shell may crack. In many cases, the spring inside wears down, and the plastic buttons may degrade over time. Exposure to moisture, dirt, or accidental drops can also damage the key fob. These symptoms can often be resolved by replacing both the battery and the key shell. Thankfully, most replacement shells come with a new flip mechanism already installed, making the process quick and cost-effective. If you're dealing with a damaged shell or non-functional buttons, a compatible Peugeot key shell can restore both the look and performance of your key. To repair your key, begin by opening the shell using a thin screwdriver. Remove the internal circuit board and transponder chip carefully. Transfer them into the new shell, ensuring everything fits snugly. Insert a fresh CR2032 battery before closing the key shell, then test all functions. Unlike dealer replacements, this DIY approach is affordable and efficient, putting the control in your hands. Understanding Citroën Key Shell Compatibility Citroën keys often resemble Peugeot models but feature subtle design differences that can impact shell compatibility. Before purchasing a replacement shell, it's important to examine a few key details. First, confirm that the button layout matches exactly—some models include a trunk release, while others do not. Next, check the blade type, usually HU83 or VA2, and make sure your new shell supports that configuration. You’ll also need to ensure there’s a space for the transponder chip, as without it, your car won’t start. Lastly, confirm that your circuit board (PCB) fits securely in the new housing. If you're unsure, compare your key with this Citroën 3-button shell for reference. A mismatched shell can result in poor fitment, misaligned buttons, or failure to lock and unlock your car. That’s why it's important to compare your current key closely to any replacement product. Shell replacements are not one-size-fits-all—small deviations in size or design can render them useless. Going Beyond: Caring for Your Car Key Long-Term Maintaining your car key goes beyond occasional repairs. Think of it as part of your overall vehicle care routine. Keep your key clean by regularly wiping it down with a soft cloth. Avoid exposing it to moisture or extreme temperatures, which can damage the battery and internal electronics. If your key starts to feel loose or if the blade no longer flips smoothly, it's a sign that maintenance is due. Another often-overlooked aspect is the condition of your key ring. Overloaded or heavy keychains can put unnecessary strain on the ignition switch and the key’s blade over time. Keeping your key light and secure can prolong both the key and the ignition system’s lifespan. If you find yourself frequently pressing buttons or experiencing lag in signal response, don't ignore it. These early symptoms are usually signs that a new battery is needed, or the shell's contacts are worn. Addressing small problems before they escalate can save you from full key failure. Car Key Maintenance Caring for your car key doesn’t have to be a daunting task. Whether you drive an Opel, a Peugeot, or a Citroën, regular maintenance and minor DIY repairs can significantly extend the life of your key. Replacing a worn battery and upgrading a broken shell not only restores functionality but also revives the overall appearance of your key. Use quality components, take your time during repairs, and always test your key before final assembly. By taking these small steps, you can avoid costly replacements and enjoy reliable key performance for years to come. Explore trusted replacement parts and accessories online at mr-key.com to keep your car keys in top condition year-round.

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