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 to Tell If Your Car Key Needs a Battery or a Full Replacement
09.07.2025

How to Tell If Your Car Key Needs a Battery or a Full Replacement

In an age where technology is at the core of almost every part of a vehicle, car keys are no longer simple pieces of metal. They’ve become compact, electronic tools that combine convenience with security — from remote locking systems to transponder chips and push-start capabilities. However, like any piece of technology, car keys are not immune to wear, damage, or electronic failure. And when they stop working, most drivers are left with one essential question: does my key just need a new battery, or is it time for a full replacement? This article dives deep into that very question. Understanding how to recognize the early signs of battery failure versus a complete key malfunction can save drivers from unnecessary frustration and expensive dealership visits. Whether you're dealing with a FIAT flip key, a HYUNDAI remote, or any modern fob, this guide will help you identify the issue and make an informed decision on what to do next. The Anatomy of a Modern Car Key To understand why a key might stop working, it’s helpful to know what’s actually inside it. Most modern car keys—especially those from brands like FIAT, Hyundai, Kia, Peugeot, or Volkswagen—are composed of several key components. At the core is a small lithium coin battery , typically a CR2032 or CR2025, which powers the key's remote functions. There's also a circuit board that contains the remote buttons and signal transmission systems. Some keys include a transponder chip , a tiny RFID device that communicates with your vehicle’s immobilizer system. Then there's the key blade —mechanical or flip-style—and the outer shell , which holds it all together and includes physical buttons. When something goes wrong, the issue can stem from any one of these components. But most commonly, the culprit is either a drained battery or damage to the internal electronics or casing . Early Warning Signs: Is It Just the Battery? Many car key issues start with subtle signs that most drivers overlook. The key may still work occasionally, or it might only respond when standing close to the car. These are common indicators that the battery is on its way out, but hasn’t failed completely yet. One of the first things a driver might notice is that the range of the remote decreases . You may find yourself needing to stand much closer to the vehicle than usual to lock or unlock it. In some cases, the key might require multiple button presses to get a response. If the key has a small LED light (common in many models), you might see it flicker weakly or stop lighting up altogether. These are signs that the battery still has some life, but it's not providing the power needed for consistent performance. The good news? Replacing the battery is often a quick and inexpensive fix, especially if there are no signs of physical damage or moisture exposure. How Long Does a Key Battery Last? The battery inside your key is designed to last between 2 to 3 years under regular use. Factors like frequent use, temperature changes, or prolonged storage can reduce that lifespan. If your key has never had a battery change and it's approaching that age, a weak battery is the most likely cause of any issues. Changing the battery is a simple task in most cases. Many key fobs can be gently pried open using a flathead screwdriver or a plastic tool. Inside, you’ll find the round battery, which can be swapped out for a new one. Always use a high-quality battery from a trusted brand like Panasonic or Maxell to ensure optimal performance. After inserting a fresh battery, the key should immediately start functioning normally again. If it doesn't, then the issue likely runs deeper. When It’s More Than Just the Battery So what happens if you've replaced the battery and the key still doesn't work? This is when it’s time to look at other possibilities. A complete key failure doesn’t just affect the remote functions—it can also affect the chip, the buttons, or even the mechanical components. For instance, if your car uses a push-to-start system and it no longer recognizes your key after a battery replacement, the issue may lie with the transponder chip . This chip is essential for starting the engine, and if it’s been damaged by a drop or water exposure, the car may not respond at all. Keys that have been exposed to moisture , such as rain or accidental washing, are also at high risk. Even small amounts of water can short out the internal electronics or cause corrosion on the contacts, rendering the key useless. Similarly, keys that have been dropped or stepped on can suffer internal damage even if the outer shell looks fine. Another common reason for total failure is button wear . Over time, the rubber buttons on a key can wear down or detach completely, making it difficult to send a signal to the car—even if the electronics are still working underneath. Shell Damage vs. Internal Failure It's important to distinguish between cosmetic damage and a true functional failure. A key with a cracked or broken shell may still work perfectly well, but using it daily becomes inconvenient—or risky, as it can fall apart further over time. In these cases, replacing only the key shell is often the most cost-effective solution. Shell replacement kits are available for most makes and models, including popular FIAT and Hyundai keys. They allow users to transfer the internal electronics and battery into a new casing, restoring the look and feel of the original key without needing reprogramming or electronic parts. However, if the circuit board inside the key is broken , or the transponder chip is no longer recognized by the vehicle , a complete key replacement will be necessary. This often requires purchasing a new key and having it programmed to your vehicle , either through a locksmith or via dealership-level tools. Identifying the Right Replacement Solution The path forward depends entirely on the root cause of the issue. Here’s how to decide: If your key works intermittently and shows no physical damage, start with a battery replacement . If the buttons are worn or the casing is cracked , but the electronics are fine, consider a shell replacement . If the key doesn’t respond at all , even with a new battery, and has no LED or signal , a full replacement is likely needed. If the mechanical blade is damaged , but the remote still functions, you can often just replace the key blade . Replacing just the parts you need can save time and money. Reliable sellers, like mr-key.com , offer a wide range of high-quality key shells, batteries, blades, and even full replacement keys—including options for programming and compatibility details. When your car key stops working, it’s natural to panic. But in most cases, the fix is far simpler than expected. A weak or dead battery accounts for the majority of key-related issues, and replacing it can restore full function within minutes. However, when the damage goes beyond the battery, identifying whether it’s the shell, chip, or internal electronics at fault will determine whether a full replacement is necessary. Being able to recognize the difference between a temporary battery issue and a deeper hardware failure empowers car owners to take quick, cost-effective action. With the right tools and parts—and a little guidance—almost anyone can resolve a car key issue without visiting a dealership. For a full range of replacement parts, including key shells, blades, batteries, and complete remote keys, visit mr-key.com and explore quality products that help restore your car key to like-new condition.

How Hot Weather Can Damage Your Car Key Fob – And What You Can Do About It
19.06.2025

How Hot Weather Can Damage Your Car Key Fob – And What You Can Do About It

When you think about how hot weather affects your vehicle, your first thoughts might go to the engine, the tires, or maybe even the air conditioning. But there’s one small, essential part of your daily driving routine that’s often overlooked — your car key fob. It might seem like a tough little device, but the truth is, it’s far more sensitive than it looks. If you’ve ever left your key fob on the dashboard, in a hot glove box, or even inside your pocket during a heatwave, you may have already caused damage without realizing it. Car key fobs are built with delicate electronics, plastic shells, and lithium coin batteries — all of which are vulnerable to extreme temperatures. In this article, you’ll learn how hot weather affects each part of your key fob, how to spot the early signs of damage, and most importantly, what you can do to protect it. Taking just a few simple steps can save you from the cost and inconvenience of a non-functioning remote, especially when you least expect it. The Plastic Shell: First to Feel the Heat One of the first things to suffer from heat exposure is the plastic casing that protects your key fob. While it’s designed to withstand everyday use — being dropped, tossed in a bag, or handled frequently — it’s not built to survive hours in a baking-hot car. The interior temperature of a parked vehicle can soar past 60 or even 70 degrees Celsius on a sunny day, especially if the key is sitting directly in sunlight. Over time, this level of heat can soften the plastic, causing it to warp, bend, or even split at the seams. You may start to notice that your key doesn’t close as tightly as it used to, or the buttons may feel soft and spongy instead of firm. Cracks might appear along the sides, or parts of the shell may become discolored. While this might seem like a cosmetic issue at first, it has serious implications — a compromised shell allows moisture, dust, and debris to enter the fob, putting the internal electronics at risk. If your key fob’s shell is already showing signs of wear, especially after a hot summer, it’s time to consider replacing the casing before the damage gets worse. Battery Breakdown: How Heat Drains Power Inside your key fob, there’s usually a small lithium battery — typically a CR2032 coin cell. These batteries are reliable under normal conditions, but they don’t respond well to high temperatures. In fact, exposure to extreme heat can accelerate chemical breakdown inside the battery, leading to faster discharge and a shorter overall lifespan. What’s worse, in severe cases, the battery can swell or leak, which can damage the internal components of your fob permanently. If you’ve ever noticed your key fob suddenly stops working or becomes unreliable during the summer, there’s a good chance the battery is struggling under heat stress. The signal may become weaker, you might have to press buttons multiple times, or the remote might stop responding altogether. Replacing the battery is a quick and inexpensive fix, but it’s important to recognize that battery issues are often just the first symptom of deeper heat-related problems. Internal Electronics: Silent Victims of the Heat While the shell and battery are easier to see and replace, the most serious damage often happens silently — deep inside the electronic circuit board. This board, often referred to as the platine, is responsible for all communication between your key and your vehicle. It’s a compact, delicate system of soldered connections and microchips, and unfortunately, it’s not designed to cope with repeated thermal stress. When your key fob is exposed to fluctuating high temperatures, the constant expansion and contraction of materials can loosen solder joints or weaken connections. Moisture that gets trapped inside the shell during humid summer months can accelerate corrosion, especially if the casing is already cracked or loose. The damage might not be immediate, but over time you may find that your key fob becomes unpredictable — sometimes it works, other times it doesn’t, and eventually, it might stop working completely. What You Can Do to Prevent Heat Damage The good news is that most heat-related damage to key fobs is preventable with just a little care and awareness. First, never leave your key fob inside a parked car for extended periods, especially not in direct sunlight. It’s easy to toss your keys into the cup holder or leave them on the dashboard while you run errands, but those few minutes can expose them to dangerous levels of heat. Instead, keep your keys on you or store them in a shaded, temperature-controlled area. If you’re regularly in hot environments — such as driving in warm climates or working outdoors — consider investing in a protective silicone or leather cover. These not only shield the shell from heat exposure but also provide added protection against drops and dirt. You should also make it a habit to replace your battery once a year, even if it seems to be working fine. Batteries weakened by heat can fail suddenly, and a fresh cell ensures your key fob keeps working when you need it most. Finally, if your key fob’s shell is visibly worn or loose, replace it immediately. Many online stores, including Mr Key, offer affordable replacement shells that are easy to install and give your remote a like-new feel. Don’t wait for the damage to reach the internal electronics — by then, repair options are limited and usually more expensive. Protect Your Key, Protect Your Drive Your car key fob might be small, but it plays a huge role in your daily routine. From unlocking doors to starting your engine, it’s a modern convenience we all depend on — until it stops working. And while many drivers are careful with their car’s mechanical systems, few think twice about leaving their key fob in the heat. Now that you know how much damage summer temperatures can cause, you can take the steps needed to protect your key before it’s too late. If you’re looking for high-quality key shell replacements, batteries like the CR2032, or even complete key fobs compatible with your vehicle, Mr Key has you covered. Our online shop offers trusted parts for Peugeot, Citroën, Nissan, Suzuki, Fiat, and more — all designed to help you repair and maintain your car keys quickly and affordably.

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 Choose the Right Car Key Shell for Your Vehicle + Why We Recommend Panasonic CR2032 Batteries
27.05.2025

How to Choose the Right Car Key Shell for Your Vehicle + Why We Recommend Panasonic CR2032 Batteries

Your car key is one of those things you don’t really think about — until it breaks. Whether it’s the worn-out buttons, a cracked shell, or a battery that gives up at the worst possible moment, an aging car key can cause more than just annoyance. But here's the good news: you can restore your key to like-new condition easily, affordably, and from the comfort of your home. In this complete guide, we’ll show you how to choose the right replacement key shell for your car and why the Panasonic CR2032 battery is a trusted choice to keep your key fob performing reliably. Part 1: How to Choose the Right Car Key Shell Think of your key shell as a protective layer. It shields the sensitive electronics inside — the buttons, circuit board, and transponder chip — all of which are essential to operating your vehicle. When the case begins to wear down or fall apart, it’s time to replace it. 1. Know Your Car's Make, Model, and Year Key shells are made to fit specific car models and years. For instance: Flip key shells for Opel are commonly used on models from 2010 to 2024. Audi smart key shells are dependent on the platform code (like A3 8Y or A4 B9). Consult your owner's manual or use a compatibility tool like this one to confirm fitment. 2. Match the Key Blade Blades come in various formats like HU162, VA2, or HU100. Even a slight variation in shape or groove pattern can render the key useless in your ignition or door locks. Carefully compare the blade on your current key to the one listed for any replacement shell. 3. Button Layout and Functionality Make sure the number and positioning of buttons on the replacement shell matches your original. If not, the rubber pads may not line up with the contact points on your key’s circuit board, making the buttons unresponsive. 4. Interior Design and Compatibility The outside might look the same, but inside layouts often differ. Ensure that your circuit board, battery slot, and chip all fit securely inside the new shell. Misalignment can cause rattling, failure to start the car, or buttons that don’t function correctly. 5. Material Quality Avoid very cheap replacements with thin plastic and soft rubber. A good quality shell should be durable, with solid construction and tactile buttons that don't wear out quickly. For example, this Opel flip key shell combines strength with excellent fit. Part 2: Why We Recommend Panasonic CR2032 Batteries When your key fob starts failing — maybe the range drops or it takes multiple presses to unlock — chances are the battery is low. Many car owners replace the shell without considering the battery, only to find the problem persists. Understanding the CR2032 The CR2032 is a 3-volt lithium coin battery, commonly used in remote keys and small electronic devices. It’s compact, stable, and specifically suited for low-power, long-term applications. What Makes Panasonic CR2032 Stand Out? Panasonic’s version of the CR2032 is known for its consistency and reliability. It offers: A stable voltage output, ensuring your key communicates with your car effectively Longer life compared to many generic brands Resistance to leaks, which protects internal circuits from corrosion Choosing a battery from a trusted manufacturer can save you from unexpected failures, especially in colder climates where battery performance matters most. We recommend the Panasonic CR2032 battery for its excellent balance of performance and reliability. Refreshing Your Car Key: A Practical Approach If your car key is showing signs of age, it's usually best to replace both the shell and the battery. The process is simple: Open the old shell carefully, using a flat tool if needed. Remove the circuit board, chip, and battery. Clean the components gently with a dry brush. Place them into the new shell, ensuring alignment. Insert a fresh CR2032 battery. Close and secure the new shell. After completing these steps, your key should be more responsive, look better, and feel sturdier in your hand.

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