Post Name

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 5 Interesting Facts About Audi: The Legacy Behind the Four Rings

Top 5 Interesting Facts About Audi: The Legacy Behind the Four Rings

When you think of Audi , luxury, innovation, and performance probably come to mind. But behind the sleek design and advanced technology, Audi’s story is filled with fascinating history and achievements. Whether you’re a long-time fan or new to the brand, there’s a lot to discover. In this article, we’ll uncover five of the most interesting facts about Audi that every car enthusiast should know. 1. The Meaning Behind Audi’s Four Rings At first glance, Audi’s logo—four interlocking rings—seems like a simple yet stylish design. However, these rings have deep significance. Each ring represents one of the four founding companies that came together in 1932 to form Auto Union: Audi, DKW, Horch, and Wanderer. A Rich History : This merger marked the beginning of what would eventually evolve into Audi, and the four rings symbolize the unity of these brands. It’s more than just a logo; it’s a reminder of Audi’s prestigious heritage and long-standing dedication to automotive innovation. Survival Through the Ages : Despite wars, economic downturns, and changes in the automotive landscape, the legacy of these four companies continues to live on in Audi’s cutting-edge vehicles. 2. Audi Was the First to Introduce Quattro All-Wheel Drive In 1980, Audi made waves in the automotive world by introducing the Quattro all-wheel-drive system. Originally developed for rally racing, the Quattro system was revolutionary, giving drivers improved traction, handling, and stability in all types of weather conditions. A Game-Changer for Drivers : This innovative system quickly became a staple for Audi vehicles, giving them superior control and stability. Today, the Quattro system is still a key feature, especially in models designed for performance and sport. Setting the Standard : Audi’s Quattro system not only changed the way we think about driving in tough conditions but also set the benchmark for all-wheel-drive technology, making it one of the most trusted names in the industry. 3. The Name "Audi" Has Latin Origins Did you know that the name "Audi" has an interesting linguistic history? The name comes from the Latin translation of the German word “Horch,” which means “listen.” August Horch, the founder of Audi, had to change the name of his company due to legal reasons after he left the Horch company. Rather than giving up his name completely, he chose to translate it into Latin, giving birth to the name “Audi.” An International Touch : This name change added an international flair to the brand and has since become synonymous with high performance and luxury. A Tribute to the Founder : Audi’s name serves as a lasting tribute to August Horch’s vision and his pioneering spirit in the world of automobiles. 4. Audi’s Revolutionary Win at Le Mans In 2006, Audi made history by becoming the first car manufacturer to win the prestigious 24 Hours of Le Mans race using a diesel engine. Audi’s R10 TDI was not only fast but also fuel-efficient, demonstrating the potential of diesel technology in endurance racing. Fuel Efficiency Meets Performance : The victory wasn’t just about speed; it was about showcasing how efficiency and performance could work hand in hand. This win cemented Audi’s reputation for innovation and opened the door for more advanced technologies in racing. Multiple Wins : Audi’s dominance at Le Mans didn’t stop there. Over the years, the brand has secured numerous wins at the event, further proving that Audi’s commitment to excellence extends to the world of motorsports. 5. Audi’s Focus on Lightweight Design: The Audi A8 Audi has always been at the forefront of automotive design, and the Audi A8 is a testament to that. Introduced in the 1990s, the A8 was one of the first vehicles to feature an all-aluminum body, significantly reducing its weight while enhancing performance and fuel efficiency. Aluminum Innovation : By using lightweight aluminum in place of traditional steel, Audi was able to create a vehicle that not only performed better but was also more fuel-efficient and environmentally friendly. An Industry Leader : This innovative approach to vehicle design has influenced the automotive industry as a whole, and the Audi A8 remains a leader in the luxury sedan market. Audi’s Legacy of Innovation Audi is more than just a luxury car brand—it’s a company that consistently pushes the boundaries of what’s possible in automotive technology. From pioneering all-wheel-drive systems to revolutionizing motorsports, Audi has proven time and time again that it’s a brand dedicated to innovation, performance, and quality. As a car owner, whether you’re drawn to Audi for its history or its cutting-edge technology, it’s important to ensure you have reliable and convenient solutions for every aspect of car ownership, including your car keys. Audi’s legacy of innovation can serve as a reminder that planning ahead—whether in technology or practical matters like having a spare key—can save you from unexpected hassles down the road.

The Top 5 Car Key Emergencies and How to Handle Them

The Top 5 Car Key Emergencies and How to Handle Them

When it comes to car keys , emergencies often strike at the worst possible moments. Whether you’re rushing to work, stuck at a grocery store, or stranded in an unfamiliar location, knowing how to handle these situations can save you time, stress, and money. Below are the five most common car key emergencies and practical solutions to get you back on track. 1. Locked Out of Your Car? Here’s What to Do Locking your keys inside your car is a common yet frustrating mistake. The good news? There are ways to regain access without breaking the bank—or your window. Check for Spare Keys: If you have a spare key, now is the time to use it. Always keep one in a secure but accessible location, like with a trusted friend or at home. Use a Slim Jim or Unlocking Tool: While not ideal for everyone, these tools can work if you’re familiar with their use. However, be cautious to avoid damaging your car. Call a Locksmith or Roadside Assistance: Professional services can unlock your car safely and quickly. While it might cost you, it’s often cheaper than repairing a broken window. Pro Tip: Many modern cars come with apps or key fobs that allow remote unlocking. Familiarize yourself with these features beforehand. 2. Key Stuck in the Ignition? Don’t Panic A key stuck in the ignition can leave you feeling helpless, but with the right steps, you can often fix the issue yourself. Check the Gear Position: Ensure the car is in “Park” or “Neutral.” Many cars prevent key removal unless the gear is correctly positioned. Inspect for Steering Wheel Lock: Wiggle the steering wheel gently while trying to turn and remove the key. A locked steering wheel might be the culprit. Lubricate the Lock: Use a small amount of graphite lubricant to loosen the ignition lock. Avoid oil-based lubricants as they can attract dirt. Seek Professional Help: If the key is still stuck, call a locksmith or mechanic to prevent further damage. 3. Lost Your Key Fob Without a Spare? Act Fast Losing your key fob with no backup can be a nightmare, especially if your car relies on it entirely. Contact a Locksmith: Many locksmiths can program a new key fob on the spot, often at a lower cost than going to a dealership. Order a Replacement: Some car manufacturers allow you to order a replacement key fob online. Be prepared to provide proof of ownership. Preventative Measures: Always have a spare key fob and store it in a safe location. Consider investing in a key tracker to avoid future mishaps. 4. Dealing with a Wet or Damaged Key Fob? Accidents happen—maybe your key fob went through the wash or got drenched in the rain. The good news? Not all is lost. Dry It Out: Remove the battery and place the key fob in a bag of rice or silica gel to absorb moisture. Let it sit for at least 24 hours. Replace the Battery: Water damage can short-circuit the battery, so replace it with a new one after drying the fob. Test the Fob: After reassembling, check if the fob functions properly. If not, you may need to replace it or have it repaired by a professional. 5. Dead Key Fob Battery in a Remote Location? A dead key fob battery can leave you stranded, but this issue is often easier to resolve than you might think. Check for Hidden Features: Many cars have an emergency key hidden in the fob itself. This can manually unlock the door. Push-Button Start Workaround: Some cars allow you to start the engine by holding the dead fob close to the start button. Carry a Spare Battery: Always keep a spare CR-type battery in your glove box for quick replacements. These are inexpensive and widely available. Pro Tip: Familiarize yourself with your car’s manual to learn emergency procedures for dead key fobs. General Tips to Prevent Car Key Emergencies Preparation is your best defense against car key emergencies. Follow these tips to avoid getting caught off guard: Keep a Spare Key Handy: Store it at home, with a trusted person, or in a secure, hidden location. Invest in a Key Tracker: Attach a Bluetooth-enabled tracker to your key fob for easy location via your smartphone. Regular Maintenance: Replace key fob batteries proactively and inspect your keys for wear and tear. Learn Emergency Features: Understand your car’s built-in features, such as remote unlocking or hidden keys, to save time in emergencies. Stay Prepared, Stay Calm Car key emergencies don’t have to derail your day. With a little preparation and knowledge, you can tackle these common scenarios with confidence. Whether it’s unlocking your car, replacing a battery, or dealing with a damaged key fob, taking proactive measures ensures you’re always one step ahead.

How to Program a Car Key: A Step-by-Step Guide

How to Program a Car Key: A Step-by-Step Guide

Lost Your Car Key Programming? Here's What to Do Have you ever lost your car keys or found yourself with a spare key that doesn’t start your vehicle? While the process of programming a car key might seem intimidating, it’s often simpler than you’d expect. In many cases, car owners can program keys themselves without needing a visit to a dealership. This guide walks you through the essentials of car key programming, helping you save time, effort, and potentially a significant amount of money. Understanding Car Key Programming: The Basics Car key programming is the process of syncing a key with a car's internal computer so it can communicate securely. Modern vehicles use transponder keys or smart keys equipped with chips that emit a unique signal. Without proper programming, these keys won’t function, even if they fit perfectly into the ignition. While older mechanical keys didn’t require programming, today’s advanced systems add a layer of security, reducing the risk of car theft. However, this added sophistication means that replacing or reprogramming a key is no longer as simple as cutting a piece of metal. Quick Tip: Check your vehicle’s owner manual to see if programming your car key is a DIY-friendly process, as some models allow self-programming, while others require professional tools. Step-by-Step Guide to Programming a Car Key Before starting, ensure you have all necessary tools and information: The vehicle’s owner manual. All keys that need programming, including the functional ones. Step 1: Access Programming Mode Start by sitting in the driver’s seat with all the doors closed. Insert the already functional key into the ignition and turn it to the “on” position (do not start the engine). Some vehicles require you to cycle the key between “on” and “off” positions a specific number of times to enter programming mode. Step 2: Add the New Key Once in programming mode, remove the functional key and quickly insert the new key into the ignition. Turn it to the “on” position. The vehicle’s security light may flash to indicate the key has been successfully programmed. Step 3: Test the Key After programming, remove the new key and test it to ensure it can start the car and unlock the doors. Note: Each car manufacturer has unique programming steps. Be sure to consult your owner’s manual or the manufacturer’s website for specific instructions. When Professional Help Is Needed While many vehicles allow for DIY key programming, others require specialized equipment or software that only dealerships or locksmiths can access. This is particularly true for luxury or high-end cars with advanced encryption and security features. If your DIY efforts fail, it’s best to seek help from a certified professional. Visiting a dealership is a reliable, albeit more expensive, option. Alternatively, professional locksmiths often provide programming services at a lower cost, making them a practical choice for many drivers. Costs and Considerations The cost of programming a car key varies significantly based on the vehicle’s make and model. For basic models, self-programming might cost nothing if you already have a functional key. However, professional programming can range from $50 to $300 or more, especially for smart keys or proximity fobs. To minimize costs: Have a spare key : Always keep a functional spare to simplify programming if a replacement is needed. Research costs : Call local locksmiths or dealerships to compare pricing. Empower Yourself with Knowledge Programming a car key doesn’t have to be a daunting task. With the right tools and information, many car owners can handle the process themselves, saving time and money. However, it’s essential to recognize when professional assistance is necessary, particularly for complex key systems. By understanding the basics of car key programming and following a step-by-step approach, you can ensure your vehicle remains secure and functional. So, whether it’s a spare key or a replacement, you now have the confidence to tackle the task or know where to turn for help.

How to Upgrade Your Car Key: A Step-by-Step Guide

How to Upgrade Your Car Key: A Step-by-Step Guide

Upgrading your car key can significantly improve your vehicle’s security and make your daily routine more convenient. Whether you’re upgrading from a basic key to a remote key or stepping up to a smart key, this guide will take you through the entire process, step by step, ensuring a smooth transition. Understanding Your Key Type Before you start the upgrade process, it’s important to know which type of key you currently have. Here are the most common key types: Traditional Metal Keys : These are basic, mechanical keys, common in older vehicles. They don’t have any electronic components. Transponder Keys : These have an electronic chip inside the key head that communicates with the vehicle’s computer system for added security. Remote Keys : These keys have buttons to lock/unlock the doors remotely and usually have a physical blade as a backup. Understanding your current key type will help guide your decision on the best upgrade path. Choosing the Right Upgrade Once you know what type of key you have, you need to decide what features you want in your upgraded key. Some options to consider are: Remote Locking : Allows you to lock/unlock the doors from a distance. Keyless Entry : Lets you unlock the car without taking the key out of your pocket. Smart Key : Offers advanced functions such as proximity unlocking, push-button start, and remote engine start. Take some time to research the options available for your specific car model. Many car manufacturers offer compatible upgrades for different key types, so it’s important to consult your dealership or a trusted locksmith for recommendations. Gathering What You’ll Need Before starting the upgrade process, make sure you have the following materials: The New Key : This could be a transponder key, remote key, or smart key. Your Original Key : You’ll need this as a reference throughout the process. Key Programming Device : Some keys require a special device to pair the key with your car. Car Manual or Programming Guide : It’s always a good idea to have your car’s manual handy for specific instructions. Having everything ready will make the process much smoother. Step-by-Step Upgrade Process Purchase the New Key Start by purchasing your new key. You can buy it from your car’s dealership, a certified locksmith, or a trusted online retailer. Make sure that the key is compatible with your vehicle’s make and model. Transfer Electronics (if necessary) If your new key is just a shell, you will need to transfer the internal components from your old key. This includes the transponder chip and, if applicable, the key blade. Be careful when transferring the electronics to avoid any damage. Program the Key Programming the new key is crucial for it to work with your vehicle. Here’s a general guide: Insert the original key into the ignition and turn it to the ON position. Quickly remove the original key and insert the new key. Turn the new key to the ON position and wait for the security light to turn off. This might take a few minutes. Test the New Key After programming, it’s important to test the new key to ensure everything works properly. Check the following functions: Locking and unlocking the doors Starting the engine Any additional functions like remote trunk opening or proximity unlocking Troubleshooting Common Issues If your new key isn’t working as expected, don’t worry! Here are some common problems and their solutions: Key Not Recognized : Check if the transponder chip is properly placed in the key. Key Doesn’t Start the Car : Double-check the programming steps to ensure everything was done correctly. Buttons Don’t Work : Verify that the battery in the new key is properly installed and functional. If the problem persists, it’s best to consult a professional locksmith or visit your dealership for further assistance. Upgrading your car key is an excellent way to improve both the security and convenience of your vehicle. By following these steps, you’ll be able to transition smoothly to your new key. If you run into any issues, don’t hesitate to reach out to a professional locksmith who can help you along the way. Enjoy the benefits of your new car key and the added peace of mind that comes with enhanced security.

Chat with us