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 Long Does a Car Key Battery Last? Can You Use a CR2025 Instead of a CR2032?
23.06.2025

How Long Does a Car Key Battery Last? Can You Use a CR2025 Instead of a CR2032?

When was the last time you thought about the battery inside your car key? For most drivers, the answer is probably never—until the key suddenly stops working. A car key battery is a small but essential part of modern driving. It powers keyless entry, remote locking, and in many cases, keyless ignition systems. When the battery fails, it can leave you locked out of your car or stranded in inconvenient situations. Understanding how long a car key battery typically lasts and knowing when and how to replace it can save you time, money, and unnecessary frustration. In this detailed guide, you will learn how long a typical car key battery lasts, what factors shorten its life, the most common signs that your battery needs replacement, and whether you can substitute a CR2025 for a CR2032 battery in your car key fob. How Long Does a Car Key Battery Last? The average car key battery lasts between two to four years. However, the actual lifespan of your key battery depends on several factors, including how often you use the key, whether your car uses a proximity key system, the type of battery installed, the climate where you live, and the quality of the battery brand. If your car has a keyless entry system or keyless ignition that constantly communicates with your vehicle when nearby, your battery may drain more quickly. Frequent use—such as multiple lock and unlock cycles each day—also leads to faster battery depletion. What Can Shorten the Life of Your Car Key Battery? Frequent Use: Keys that are used many times per day will naturally consume more battery power. Keyless Proximity Systems: Smart keys that communicate continuously with the vehicle tend to use more energy. Extreme Temperatures: Exposure to both heat and cold can degrade battery performance and lifespan. Low-Quality Batteries: Cheap, no-name batteries often have a shorter life and can fail unexpectedly. Many drivers wait for their key to stop working before replacing the battery, but it is recommended to replace it proactively every one to two years to avoid surprise failures, especially before long trips or the winter season. Signs That Your Car Key Battery Is Failing Your car key usually gives warning signs before the battery completely dies. Knowing these symptoms can help you avoid being caught in an inconvenient situation. Reduced Range: You may need to stand closer to your car for the key to work properly. Delayed Response: The car may not immediately lock or unlock when you press the button. Intermittent Operation: Sometimes the key works, sometimes it does not. Dashboard Alerts: Some vehicles display a "low key battery" warning on the dashboard. Complete Failure: If ignored, the key will eventually stop working entirely. If you notice any of these warning signs, it is best to replace the battery immediately to ensure continuous, reliable operation. When Should You Change Your Car Key Battery? The best time to change your car key battery is before it fully fails. Most experts recommend replacing the battery every two years as preventive maintenance. You should also replace the battery immediately if you notice that your key’s range has reduced or if it sometimes stops working without warning. Seasonal changes also play a role. During winter, cold temperatures can reduce battery performance significantly, which is why it is wise to replace your battery before the onset of cold weather. Additionally, if you are planning a long trip or vacation, it is a good idea to install a new battery beforehand to avoid potential inconvenience. Can You Use a CR2025 Instead of a CR2032 Battery in a Car Key? One of the most common questions drivers ask is whether a CR2025 battery can be used as a substitute for a CR2032 in a car key fob. Although the two batteries are similar in many ways, there are critical differences to consider. CR2025 vs. CR2032: What Is the Difference? Both the CR2025 and CR2032 batteries are 3-volt lithium coin cells and have the same diameter of 20 millimeters. However, their thickness and capacity differ. Feature CR2025 CR2032 Diameter 20 mm 20 mm Thickness 2.5 mm 3.2 mm Voltage 3 volts 3 volts Capacity Approximately 150 mAh Approximately 220 mAh The CR2032 is thicker and has a higher energy capacity, meaning it will typically last longer than a CR2025 in the same device. Can a CR2025 Fit in a CR2032 Slot? Technically, a CR2025 can physically fit into a car key fob designed for a CR2032 battery because they have the same diameter. However, because the CR2025 is thinner, it may not make stable contact with the battery terminals inside the key. Some people attempt to compensate for the thinner battery by adding a small piece of paper, cardboard, or aluminum foil to hold it in place. Although this may temporarily restore functionality in an emergency, it is not a reliable or recommended solution for long-term use. Should You Use a CR2025 Instead of a CR2032? The short answer is that using a CR2025 in place of a CR2032 is acceptable as a temporary, emergency solution but is not advisable as a permanent fix. Using the incorrect battery size can lead to poor contact, inconsistent performance, and a much shorter operating life. Risks of Using the Wrong Battery: Unstable contact may cause the key to work intermittently. Lower battery capacity means the key will require more frequent battery replacements. A loose battery inside the fob can shift during handling, potentially damaging the internal components. For long-term reliability and to protect your car key from unnecessary wear, it is always best to use the exact battery size specified for your key fob. Where to Buy the Right Car Key Battery If you are looking for a high-quality CR2032 battery for your car key, Mr Key offers reliable options from trusted brands such as Panasonic. Choosing a premium battery will ensure your key functions properly for as long as possible and reduces the risk of sudden failure. Mr Key also provides a wide range of car key shells, key fobs, and accessories compatible with popular brands like Peugeot, Citroën, Nissan, Suzuki, Fiat, Ford, and more. Whether you need to replace the battery, the shell, or the entire key, Mr Key can help you find the right product at an affordable price. You can browse the full selection in the Mr Key online store and get the parts you need delivered directly to your door. Car key batteries are often forgotten until they stop working, but with proper care and timely replacement, you can avoid the inconvenience of being locked out or dealing with a non-functional key. Understanding how long a car key battery typically lasts and knowing the signs of failure can help you stay ahead of the problem. While a CR2025 battery can sometimes be used in an emergency, the CR2032 is the correct and recommended option for most car key fobs due to its longer life and better fit. Using the right battery size ensures that your key works reliably, protects your key's internal components, and provides peace of mind. Regularly check your key, replace the battery proactively, and always use the correct parts for the best performance. When you need a new battery or key shell, Mr Key is your trusted partner for fast, easy, and affordable car key repairs.

How to Program a Spare Car Key: Should You DIY or Call a Pro?
31.03.2025

How to Program a Spare Car Key: Should You DIY or Call a Pro?

You’ve got a spare car key in your hand and one big question on your mind: can you program it yourself, or should you visit a locksmith or dealer? The answer depends on your car and the key. In this guide, you'll discover when DIY programming is possible, when it's not, and how to avoid common mistakes. Whether you're aiming to save money or just want a backup key for peace of mind, here's everything you need to know. Types of Car Keys: What You’re Working With Not all car keys are the same—and that matters. Older vehicles often use simple metal keys or basic transponder keys, while modern cars rely on electronic fobs and smart keys with encrypted chips. If your car was built before the early 2000s, there’s a good chance you can program a spare yourself without any special tools. Newer vehicles, however, might require dealer-level software or diagnostic equipment to complete the job. Basic key types include: Non-transponder metal keys : can be copied at any key-cutting service. Transponder keys : contain a chip that communicates with your car’s immobilizer. Remote key fobs : combine keyless entry with a transponder chip. Smart/proximity keys : high-tech, often require dealer programming. How DIY Key Programming Works If your car supports on-board programming, you're in luck. Here’s how a common DIY method looks: Insert your original (master) key into the ignition and turn it to “on” (don’t start the engine). Leave it for five seconds, then remove it. Quickly insert the new spare key and turn it to “on.” Wait for the security light to blink or turn off—this confirms successful programming. Test the spare key by starting the engine. Note: This process varies by vehicle. Always consult your owner's manual or search for your specific make, model, and year online before starting. When You’ll Need a Professional DIY isn’t always an option. If your car uses advanced keyless systems, push-button start, or encrypted communication, programming usually requires access to manufacturer software and security codes. In these cases, a qualified locksmith or dealership is your best (and safest) bet. Also, if your vehicle requires a unique PIN to program a new key—and you don’t have it—don’t guess. Incorrect attempts could lock the system and result in costly reprogramming. Choosing the Right Spare Key Buying the correct spare key is critical for success. You’ll need: The correct transponder chip type (e.g., ID46, ID48, PCF7946 ) Matching blade shape or key profile The correct frequency (commonly 433MHz or 868MHz ) Avoid cheap generic blanks unless you're certain they’re compatible. Poor-quality keys may not accept programming or may fail shortly after. Quick DIY Checklist: Are You Ready? You already have a working master key Your vehicle supports on-board key programming The spare matches in chip, frequency, and blade You’re comfortable following time-sensitive steps You’re okay calling a pro if things don’t work If you checked most of those, DIY might be a great fit. If not, you’re better off with professional help—it could save you time, frustration, and possibly money in the long run. Be Smart with Your Spare Key Having a backup key is more than convenient—it’s essential. From lost keys to unexpected lockouts, a properly programmed spare key can save the day. If your vehicle allows DIY programming, take your time, follow instructions carefully, and double-check compatibility. If you hit a wall, don’t force it. Pros are there for a reason. No matter which route you take, you’ll thank yourself later for being prepared. Because when it comes to your car keys, one really isn’t enough.

How to Know If Your Car Key Has a Hidden Transponder Chip
29.04.2025

How to Know If Your Car Key Has a Hidden Transponder Chip

Modern car keys are more than just simple tools to unlock doors—they're powerful components of your vehicle’s security system. Hidden inside many keys is a small yet crucial piece of technology known as a transponder chip . But how can you tell if your car key has one? Whether you’ve lost your key, are looking to replace it, or simply want to understand your vehicle better, knowing if your key contains a transponder chip is essential. This guide will explain what a transponder is, why it matters, and how you can easily check if your key is equipped with one. What Is a Transponder Chip? A transponder chip, short for "transmitter + responder," is a small electronic microchip embedded inside the plastic head of the car key or within a smart key fob. When you insert the key into the ignition—or have it nearby in a push-button start system—the chip emits a unique signal. The vehicle’s onboard computer must recognize this signal before it will allow the engine to start. Without the correct signal, even if the key physically fits into the ignition, the car won’t move. Transponders have been a game-changer in reducing car theft, and today, nearly all vehicles produced after the late 1990s are equipped with them. Learn more about how modern keys work and find replacement options in our car keys collection. Why It’s Critical to Know If Your Key Has a Chip If your key has a hidden transponder chip, replacing it is more complicated than simply cutting a new metal key. You will need a key that not only matches the cut but also includes the correct programming to communicate with your car’s immobilizer system. Failing to recognize this can lead to frustration, extra dealership fees, or even being stranded. Moreover, understanding your key's technology helps you make smarter choices when buying a spare, upgrading your security setup, or troubleshooting ignition issues. How to Check If Your Car Key Has a Transponder Chip Fortunately, you don’t need expensive equipment to find out. Start by considering the age of your vehicle: if your car was manufactured after 1995 (in Europe) or 1998 (in the USA), chances are very high it uses a transponder system. Next, examine the physical key. Keys with large, bulky plastic heads usually house a chip inside. In contrast, purely metallic keys without plastic parts tend to belong to older, non-transponder vehicles. You can also perform a simple foil test. Wrap the head of your key in aluminum foil and try to start the car. Since foil blocks radio frequencies, if the car refuses to start, it’s likely that a transponder chip is present. If you want absolute certainty, consult your vehicle’s manual or speak with a professional locksmith. Many locksmiths use specialized tools to detect whether a chip exists. For additional technical explanation, you can refer to this guide on how immobilizer systems work. What Happens If the Transponder Signal Is Missing? If you try to start your car without the proper transponder signal, the immobilizer system kicks in. Most vehicles will either not crank at all or crank without allowing the engine to fire. Some models will display a warning light on the dashboard, often shaped like a padlock or a car with a key icon. Without a valid transponder signal, you won't be going anywhere—no matter how new or well-cut the key is. Can You Program a Transponder Key Yourself? Depending on the make and model of your car, some basic keys can be programmed at home—especially if you already have one working key available. However, many newer vehicles require professional diagnostic tools connected directly to the car’s computer to program keys securely. Attempting DIY programming on these systems without the right knowledge can lock your car’s immobilizer and lead to expensive repairs. Always consult your car’s manual or seek professional help before attempting any programming yourself. Knowledge = Protection Understanding whether your car key contains a hidden transponder chip isn’t just a fun fact—it's essential for protecting your vehicle and saving yourself time, money, and hassle. Whether you're planning to replace a worn-out key, add a backup, or upgrade your security, knowing what’s inside your key helps you make better, safer decisions. If you ever need a spare key, a battery replacement, or advice on key maintenance, you can explore more in our online store at Mr Key . Remember: a smart driver is a secure driver. Stay informed, stay prepared, and you'll always stay one step ahead.

How to Rescue Your Car Key After It Gets Wet: A Practical Guide
11.02.2025

How to Rescue Your Car Key After It Gets Wet: A Practical Guide

The Modern Dilemma: Wet Car Keys and How to Fix Them Imagine this: you’re caught in an unexpected downpour, and your car key slips from your hand, landing straight into a puddle. Or perhaps you accidentally leave your keys in your pocket while diving into a swimming pool. Whatever the scenario, the moment you realize your car key has been submerged in water can be panic-inducing. With modern car keys embedded with electronic chips and sophisticated technology, exposure to moisture can mean more than just a temporary inconvenience—it could leave you locked out or facing expensive repairs. But before you rush to replace your key, there are several steps you can take to salvage it. Understanding the Risks: What Happens When a Car Key Gets Wet? Car keys today are more than just metal; many include electronic transponders and remote control systems that communicate with the vehicle’s ignition. Water exposure can lead to: Short circuits: Moisture can cause electronic components to malfunction or fail entirely. Corrosion: Over time, water can lead to rust and degradation of internal circuits. Battery failure: Many car keys contain small batteries, and water exposure can lead to leakage or loss of function. While traditional metal keys are less affected by water, smart keys and key fobs are vulnerable. Acting quickly can often save your key from irreparable damage. Immediate Steps to Take When Your Car Key Gets Wet If your car key has been exposed to water, time is of the essence. Here’s what you need to do: Retrieve the key from the water as quickly as possible and wipe off excess moisture using a dry, absorbent cloth or paper towel. Remove the battery if possible since many car key fobs have removable batteries; check your car manual for instructions. If the battery is wet, replace it with a new one rather than attempting to dry and reuse it. Disassemble the key fob if safe to do so, carefully opening the casing to allow internal components to dry. Avoid using force or tools that might damage delicate parts. Use silica gel or rice for drying—place the key fob in a container of silica gel packets (often found in new shoe boxes or electronics packaging) for 24-48 hours; if silica gel is unavailable, uncooked rice can work as an alternative, though it may not be as effective. Avoid using direct heat—do not use hairdryers, microwaves, or ovens to speed up drying, as high temperatures can warp plastic components and damage circuits; instead, allow the key to air dry naturally in a warm, ventilated space. Finally, test the key once you’re confident it is dry by reinserting the battery and testing it on your car; if the key does not work, it may require reprogramming or replacement. When to Seek Professional Help If your key remains unresponsive despite thorough drying, it may have suffered internal damage. In such cases, consider these options: Contact your car manufacturer or dealership—they can provide a replacement key or attempt to reprogram the existing one. Visit a professional locksmith—many automotive locksmiths specialize in repairing and reprogramming electronic keys at a lower cost than dealerships. Check your car insurance policy—some policies cover lost or damaged keys, potentially reducing replacement costs. Global Trends in Key Fob Durability and Waterproofing Car manufacturers are increasingly designing key fobs to withstand water exposure. For example, Tesla’s Model 3 key card eliminates the need for traditional keys by using a waterproof RFID card, Toyota and BMW have introduced water-resistant key fobs, minimizing the risk of damage, and future innovations may include biometric key technology, reducing dependency on physical devices altogether. As technology advances, water-resistant key designs may become the norm, reducing the stress of accidental spills or submersion. Preventative Measures: How to Protect Your Car Key from Water Damage To avoid future incidents, consider these preventative steps: Use a waterproof key case: Available online, these cases provide a protective barrier against water exposure. Designate a dry storage spot: Avoid leaving keys in pockets that may go through the wash or near pools and sinks. Invest in a spare key: Having a backup key can be a lifesaver if your primary key is damaged beyond repair. Check for manufacturer upgrades: Some car brands offer upgraded, water-resistant key fobs for an additional fee. Act Quickly to Save Your Key A wet car key doesn’t necessarily mean it’s the end of the road. By acting swiftly and following proper drying techniques, you may be able to rescue your key without costly replacements. As car technology evolves, so too will key durability, but for now, a little caution and quick thinking can go a long way. If you frequently find yourself around water, taking preventative measures can save time, money, and frustration.

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