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

5 Fascinating Facts About Audi That Every Car Enthusiast Should Know
17.09.2024

5 Fascinating Facts About Audi That Every Car Enthusiast Should Know

Audi is a brand that’s deeply ingrained in the world of luxury cars, known for its sleek designs, innovative technology, and unbeatable performance. Whether you're a die-hard car enthusiast or someone who just appreciates good engineering, there's more to Audi than meets the eye. Let's dive into five fascinating facts about Audi that might surprise you and give you an even deeper appreciation for this iconic brand. 1. The Meaning Behind Audi’s Four Rings: More Than Just a Logo When you think of Audi, the first thing that likely comes to mind is its distinctive four-ring logo. But did you know that each of those rings has a special meaning? The rings symbolize the four founding companies of Auto Union: Audi, DKW, Horch, and Wanderer. Back in 1932, these four automakers joined forces to create Auto Union, and each company contributed its own expertise to form what would eventually evolve into Audi. Those four rings serve as a reminder of the brand’s rich history and the combined heritage of those founding companies. So, the next time you see the iconic logo, you'll know there's a story behind it, representing decades of innovation and collaboration. 2. Audi’s Groundbreaking Win at Le Mans: Changing the Game With Diesel Power Audi has a long history of dominating motorsports, but its victory at the 2006 24 Hours of Le Mans was nothing short of revolutionary. Why? Because Audi became the first manufacturer to win the prestigious race with a diesel engine. The Audi R10 TDI wasn’t just fast—it was efficient, too. Diesel engines are known for their fuel efficiency, and Audi capitalized on this advantage, allowing the R10 to spend less time refueling and more time on the track. This win not only cemented Audi's status as a force in motorsport but also challenged the perception that diesel engines were only about fuel economy, not performance. For Audi, this victory was more than just a win; it was a statement about their commitment to innovation and pushing the boundaries of what’s possible in automotive technology. 3. What’s in a Name? The Surprising Latin Origin of ‘Audi’ Here’s a fun fact that even some Audi fans might not know: the name “Audi” has its roots in Latin. The brand’s founder, August Horch, initially used his own surname for his company. However, after a legal dispute forced him to change the name, he decided to get creative. “Horch” means “listen” in German, and August decided to translate this into Latin, which gave him the word “Audi.” The name stuck, and today Audi is synonymous with cutting-edge automotive engineering. It’s a subtle nod to the brand’s history while still looking forward to the future, a balance Audi has always managed to strike perfectly. 4. Audi’s Quattro All-Wheel Drive: Revolutionizing Rally Racing and Beyond When it comes to Audi’s technology, one word stands out: Quattro. Audi revolutionized the automotive world in the 1980s with its Quattro all-wheel-drive system. Originally developed for rally racing, Quattro provided exceptional traction and handling, especially on difficult terrains like gravel and snow. Audi introduced the Quattro system into rally racing, and it wasn’t long before they started winning championship titles. This technology was so successful that it didn’t just stay on the racetrack; it made its way into Audi’s consumer cars, where it continues to be a major selling point. Today, Quattro is still considered one of the best all-wheel-drive systems on the market, offering you a smoother, more controlled ride no matter the road conditions. For those who love the thrill of driving in all conditions, Quattro offers a unique driving experience that’s hard to beat. 5. The Audi A8: A Pioneer in Lightweight Design Audi is known for pushing the envelope when it comes to design, and the Audi A8 is a perfect example of this innovation. Launched in the 1990s, the A8 was one of the first cars to feature an all-aluminum body. Why is that important? An aluminum body is significantly lighter than traditional steel, which not only improves fuel efficiency but also enhances the car’s handling and performance. Aluminum may be lightweight, but it's incredibly strong, offering superior protection without sacrificing speed or agility. By reducing weight and increasing strength, Audi set a new standard for luxury sedans, one that many automakers have since tried to emulate. If you’ve ever had the pleasure of driving an A8, you know exactly what we’re talking about—lightweight design, power, and luxury all rolled into one. Audi’s Legacy of Innovation As you can see, Audi is much more than just a luxury car brand. From its humble beginnings as part of Auto Union to its groundbreaking Quattro technology and diesel-powered victories, Audi has continually set new standards in the automotive world. Whether it’s the iconic four rings that represent decades of collaboration or the cutting-edge engineering that defines every Audi model, this brand continues to inspire and innovate. Next time you see an Audi, you’ll know it’s not just another car—it’s a symbol of innovation, performance, and a commitment to excellence that has stood the test of time. If you’re an Audi owner or simply an admirer of fine automotive craftsmanship, these five fascinating facts give you even more reason to appreciate this iconic brand. So, what’s your favorite Audi innovation? Let us know!

TSA Locks: Why They Matter for Car Owners
05.12.2024

TSA Locks: Why They Matter for Car Owners

TSA Locks: Why They Matter for Car Owners As a car owner, you may not immediately consider the importance of a TSA-approved lock for your vehicle, especially when it comes to travel. However, these specialized locks can offer an added layer of security and convenience, particularly when you’re transporting your vehicle or luggage through airports, shipping services, or even while storing it during a trip. But what exactly is a TSA lock, and why should you, as a car owner, care about it? In this article, we break down everything you need to know about TSA locks, how they work, and why they could be beneficial for both you and your vehicle. What is a TSA Lock? A TSA lock is a special type of lock that has been designed to meet the standards set by the Transportation Security Administration (TSA). These locks are typically used for luggage, but their benefits extend to car owners who want to secure their valuables during travel. What sets TSA locks apart from standard locks is their unique feature: TSA agents can unlock these locks using a master key. This allows them to inspect your belongings if needed without damaging your lock or luggage. These locks are often used for suitcases, travel bags, and in some cases, for securing items inside a vehicle while it's being shipped or stored. Why Should Car Owners Consider TSA Locks? While TSA locks are primarily used for luggage, there are several ways car owners can benefit from them: 1. Convenience for Travel If you're shipping your car or using long-term parking at an airport, you may want to secure your vehicle's trunk or compartments. TSA-approved locks give you peace of mind knowing that any inspections required by airport security or shipping agents won't result in your lock being broken. 2. Extra Layer of Security When you’re transporting your vehicle across state lines or internationally, you’ll likely want to keep valuables like electronics, tools, or personal items in the car. A TSA-approved lock ensures that, should security personnel need to access your vehicle, they can do so without causing damage. 3. Compliance with Shipping Regulations Certain vehicle shipping services may require TSA-approved locks as part of their protocols. These locks provide an easy way for shipping carriers to inspect your vehicle without having to call you for permission every time an inspection is necessary. By using TSA-approved locks, you comply with industry regulations and simplify the process. How Do TSA Locks Work? TSA locks are equipped with a special mechanism that allows TSA personnel to unlock them using a universal key. When you use a TSA-approved lock, you set your own combination or use a key for the lock. The TSA agents have access to a master key that fits all TSA locks, allowing them to inspect the contents of your luggage or vehicle safely. These locks are typically used for things like bags, briefcases, or car storage compartments. They provide the added benefit of security, knowing that your belongings are locked but still accessible for inspection when necessary. How to Choose the Right TSA Lock for Your Vehicle If you’re considering a TSA lock for your car, there are a few things to keep in mind: Size and Fit : Make sure the TSA lock fits the compartments or storage areas you intend to secure, whether it’s the trunk, glove box, or internal storage. Durability : Look for locks made of high-quality materials, such as stainless steel or reinforced plastic, to ensure they stand up to wear and tear during transit. Ease of Use : Choose a lock that you can easily open and close but that remains secure against tampering. Approval : Always ensure that the lock you purchase is TSA-approved. You can usually find the TSA logo on the packaging or lock itself. Are TSA Locks Necessary for Every Car Owner? While TSA locks offer multiple benefits, they aren’t absolutely necessary for every car owner. If you rarely travel with your car or if you don’t need to transport it across borders, a standard lock might be sufficient for your needs. However, for those who ship their car regularly or for long-term travelers, TSA-approved locks are a great investment. Whether you're shipping your vehicle, storing it during travel, or just want an extra layer of security, TSA locks can provide the assurance that your belongings remain secure—and that airport security or shipping agents can access your vehicle if needed without causing damage. TSA locks may seem like a small detail, but for car owners who frequently travel, ship their vehicles, or store valuable items inside their cars, they can make a big difference. With the convenience, security, and compliance they offer, TSA-approved locks provide peace of mind, knowing your car and belongings are safe during the travel process. Next time you're preparing for a trip, consider investing in a TSA-approved lock to make your journey a little easier and a lot more secure. This revised blog provides an informative, engaging overview of TSA locks and their relevance to car owners. It emphasizes both convenience and security while addressing the potential benefits for those who travel or ship their vehicles regularly.

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.

The Rise of Smart Car Keys: Revolutionizing Vehicle Access and Security
17.01.2025

The Rise of Smart Car Keys: Revolutionizing Vehicle Access and Security

In today’s fast-paced world, convenience and security have become paramount, even when it comes to something as seemingly simple as car keys. Gone are the days when a physical metal key was all you needed to start your car. Smart car keys are at the forefront of a technological revolution, reshaping how we access and secure our vehicles. From push-button starts to remote access via smartphone apps, smart car keys are not just a luxury—they are rapidly becoming the standard in automotive innovation. The Evolution of the Car Key The journey of the car key from a mechanical device to a sophisticated electronic gadget mirrors the evolution of the automotive industry itself. The earliest car keys were simple mechanical tools, designed to fit into and turn a lock. By the mid-20th century, advancements introduced key fobs with remote locking and unlocking capabilities, adding a layer of convenience. Fast forward to the 21st century, and the introduction of smart keys has completely transformed the landscape. These keys leverage advanced technology like RFID (Radio Frequency Identification) and Bluetooth to communicate seamlessly with vehicles. Instead of physically inserting a key, drivers can now unlock, lock, and start their cars with just a push of a button—or even through proximity sensors. Key Features of Smart Car Keys Modern smart car keys are equipped with a host of features that enhance both convenience and security. Here are some of the most notable functionalities: Keyless Entry and Start: Proximity sensors allow you to unlock your car doors simply by approaching your vehicle. Push-button ignition eliminates the need for a traditional key turn. Remote Access: Many smart keys integrate with smartphone apps, enabling you to lock, unlock, and even start your car remotely from anywhere in the world. Enhanced Security Measures: Smart keys often use encrypted signals, making them nearly impossible to duplicate or hack. Some models include biometric authentication, such as fingerprint recognition. Theft Prevention: Advanced systems disable the car’s engine if the smart key is not detected nearby, adding an additional layer of security. These features have not only made life easier for drivers but have also raised the bar for vehicle security standards. A Global Phenomenon The adoption of smart car keys is not limited to any one region—it’s a global trend. In countries like Germany, Japan, and the United States, automotive manufacturers have embraced this technology as a standard feature in most mid-range to high-end vehicles. Emerging markets are also seeing increased adoption, with local manufacturers integrating smart key technology to remain competitive. Internationally, the demand for smart keys is driven by urbanization and the rising importance of connected devices. In Europe, for example, manufacturers are exploring how smart keys can work alongside digital infrastructure, like smart parking systems, to provide a fully integrated driving experience. Challenges and Limitations Despite their many advantages, smart car keys are not without their challenges. The most common issues include: Battery Dependency: Smart keys rely on batteries, which can fail unexpectedly, leaving drivers stranded if they don’t have a backup plan. High Replacement Costs: Losing a smart key can be expensive, as replacements often require reprogramming by a professional. Hacking Risks: While smart keys are more secure than traditional ones, they are not immune to sophisticated cyberattacks. Manufacturers and cybersecurity experts are working tirelessly to address these challenges, ensuring that the technology remains reliable and secure for users. Future Trends in Smart Key Technology The future of smart car keys promises even more exciting advancements. Here’s what to expect in the coming years: Biometric Integration: Fingerprint and facial recognition are likely to become standard features, providing an unmatched level of personalization and security. Smartphone as a Key: Many manufacturers are working on phasing out physical smart keys altogether, replacing them with app-based solutions that integrate seamlessly with your phone. Sustainability: With growing concerns about electronic waste, manufacturers are exploring eco-friendly materials and designs for future smart keys. These innovations are not only about convenience but also about creating a holistic and secure driving experience. What This Means for Car Owners For car owners, the rise of smart car keys represents a shift in how we interact with our vehicles. While the technology offers incredible benefits, it also requires a certain level of awareness and preparedness. Knowing how to maintain your smart key, replace its battery, or troubleshoot issues can save you time and money in the long run. Additionally, investing in protective cases or backup solutions, such as a spare traditional key, can help you avoid potential inconveniences. As this technology evolves, staying informed about new features and security measures will ensure that you get the most out of your smart key. Driving Into the Future Smart car keys are more than just a convenience—they are a testament to how technology can enhance everyday life. By combining cutting-edge security measures with unparalleled ease of use, these keys have redefined the driving experience. As automotive technology continues to evolve, smart car keys will likely play an even more integral role in shaping the future of transportation. Whether you’re an early adopter of the latest innovations or someone considering upgrading to a vehicle with smart key capabilities, understanding the benefits and challenges of this technology is essential. The road ahead is bright, and smart car keys are just the beginning of what promises to be an exciting journey in automotive innovation.

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