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

What Makes EV Key Fobs Different from Traditional Car Keys?
03.07.2025

What Makes EV Key Fobs Different from Traditional Car Keys?

When you think about car keys, you probably picture the classic remote fob—the one you click to lock or unlock your car from a short distance. For years, this type of key was the standard. But with the rise of electric vehicles (EVs), key fobs have changed more than you might think. They’ve become smarter, more secure, and packed with new technology that sets them apart from their traditional counterparts. So, what exactly makes an EV key fob different? Let’s dive into the world of modern keys and discover why electric vehicle fobs aren’t just an accessory—they’re a key part of the driving experience. Smarter Connections One of the most noticeable differences between EV key fobs and traditional ones is how much they actually “talk” to your car. Old-school fobs were pretty simple. They sent a basic signal to lock or unlock your doors and maybe popped the trunk if you were lucky. But EV key fobs are much more connected. Many of them communicate with the car’s internal system in real-time. When you press a button on an EV fob, you’re not just opening doors—you might be starting the climate control, checking the battery level, or even setting your seat to your personal position. Some fobs go a step further, automatically unlocking the car as you walk up or adjusting settings based on which key is nearby. It’s no longer just a key—it’s part of your driving profile. Software That Evolves Here’s something traditional key fobs can’t do: get smarter over time. EV key fobs often receive something called Over-The-Air (OTA) updates . Just like your phone or your laptop, your key fob’s software can be updated remotely. This can improve its performance, fix bugs, and even add new features. That means your EV key fob is no longer a “set it and forget it” device. It evolves with your car. Updates can make your key safer, faster, and more reliable without you ever stepping foot in a dealership. For some EV owners, their key fob today might already be more advanced than when they first got it. Stronger Security Security has always been important, but for modern EV key fobs, it’s taken to a whole new level. Traditional key fobs use basic encryption, which—unfortunately—has become easier for tech-savvy thieves to bypass. EV key fobs, on the other hand, often use advanced encrypted signals that change every time you use them. Some are even equipped with Ultra-Wideband (UWB) technology, which makes it nearly impossible for criminals to hack or clone the key’s signal. In a world where keyless car theft is becoming more common, these newer security features offer real peace of mind. Your key fob isn’t just a remote—it’s a digital handshake between you and your car that’s designed to keep you protected. A Little More Power-Hungry All these advanced features, constant communication, and longer-range signals come with a small trade-off: EV key fobs tend to use more battery power than traditional ones. You might notice that you need to replace the battery a bit more often, especially if your fob is always syncing with the car or receiving regular updates. The good news? Most EV key fobs still use common, affordable batteries like the CR2032, and replacements are quick and simple. It’s just something to be aware of if you’re used to your old key fob battery lasting for years without a second thought. The Future in Your Pocket EV key fobs are no longer just about opening doors—they’re smart devices that bring you closer to your car’s full potential. They offer more convenience, better security, and the ability to grow and improve over time. As the automotive world moves toward electric, key fobs are evolving right along with it. Whether you drive an EV today or plan to in the future, your key is becoming just as high-tech as the vehicle it unlocks. At Mr. Key , we’re here to help you keep your key fob in top condition—whether you need a battery, a new key shell, or expert advice on key maintenance. Explore our range of products and keep your smart key working like new. Visit us at mr-key.com for all your car key needs.

Everything You Should Know About Key Fob Battery Life, Leaks, and Temperature Effects
09.06.2025

Everything You Should Know About Key Fob Battery Life, Leaks, and Temperature Effects

The convenience of a modern car key fob is hard to overstate — it unlocks doors, starts engines, and sometimes even controls your car remotely. But at the heart of all these features lies a small coin battery, usually a CR2032, that powers your fob’s every function. Like all batteries, it doesn’t last forever, and certain conditions can shorten its lifespan or cause unexpected problems like leaks. In this guide, we’ll explore how long your key fob battery should last, what causes leaks, and how temperature plays a critical role in battery performance. How Long Do Key Fob Batteries Typically Last? Most key fobs use lithium coin batteries like the CR2032. These are designed for small electronic devices and typically last between two to four years, depending on how often you use your fob and how close it stays to your vehicle. Constant use — such as frequent locking and unlocking — can deplete the battery faster. If your smart key remains within range of your car at all times, it may draw more power passively. Another key factor is the quality of the battery. High-grade batteries like those from Panasonic usually last longer and offer more consistent voltage. You’ll know it’s time for a replacement when the fob works only at short distances, you need to press buttons more than once, or the indicator light becomes dim or fails to light up at all. Catching these early signs is important, as a simple battery replacement can prevent unexpected lockouts or costly service calls. Battery Leaks in Key Fobs: Risks and Prevention Though not as common, a leaking battery can be far more destructive than a dead one. Leakage can corrode the internal components of your key fob, sometimes making it unusable. Signs of a leak include white residue inside the battery compartment, visible corrosion on the metal contacts, or a strange smell or dampness near the battery slot. Leaks often occur in batteries that are expired, low-quality, or exposed to extreme heat or moisture. To reduce the risk of leaks, it's a good idea to replace your key fob battery every two years, regardless of performance. Always use reputable brands such as Panasonic CR2032 , and store spare batteries in a cool, dry place. Also avoid mixing new and old batteries, even temporarily. If you notice any signs of leakage, remove the battery promptly and clean the compartment using a cotton swab and isopropyl alcohol. If the corrosion is severe, replacing the key fob casing or consulting a specialist may be necessary. How Temperature Affects Your Key Fob Battery Life Ambient temperature can have a major effect on battery efficiency. In cold conditions, the chemical reactions within a lithium coin battery slow down, resulting in reduced voltage and sluggish or inconsistent performance. A key fob left overnight in freezing temperatures might stop working until it warms up. On the flip side, high temperatures accelerate battery depletion. Leaving your key fob inside a hot car or near a heat source can shorten its lifespan and, in rare cases, even cause the battery to leak. Heat can also warp internal components, especially in compact spaces like key fobs. To protect your battery, avoid exposing your key fob to direct sunlight or intense heat for long periods. Don’t store it in jackets or compartments that get hot in summer, and try to keep a spare battery handy if you live in an area with extreme seasonal swings. Choosing temperature-resistant batteries — like those from Panasonic — adds another layer of protection. Key fob batteries are small but essential parts of modern car ownership. Understanding their typical lifespan, recognizing early signs of failure or leakage, and knowing how temperature affects their performance can help you avoid unpleasant surprises. With a little foresight, you can keep your key fob working smoothly for years. Replace the battery every two to three years, choose high-quality brands, and take precautions during temperature extremes. A few minutes of care now can save you from frustration later.

Why Your Car Remote Isn’t Working and How to Fix It
07.01.2025

Why Your Car Remote Isn’t Working and How to Fix It

Car remotes have become an essential part of modern vehicle ownership, offering convenience and added security. However, when they stop working, it can lead to frustration and delays. If you’ve ever faced a malfunctioning car remote, don’t worry—you’re not alone. Here’s a guide to help you understand the common reasons why your car remote might fail and how you can fix the issue quickly and affordably. 1. Dead Battery: The Usual Suspect One of the most common reasons for a non-functional car remote is a dead battery. Over time, the small coin batteries in your remote lose their charge, making the remote unusable. Signs of a Dead Battery: Reduced range, inconsistent functionality, or complete failure to respond. How to Fix It: Replace the battery with a compatible CR-type coin battery. Check your car manual or the remote’s casing for the correct battery type. Pro Tip: Always keep a spare battery in your glove compartment to avoid getting stranded. 2. Signal Interference: The Invisible Barrier Signal interference can block communication between your remote and your car. This can happen in areas with high electromagnetic activity or if the remote’s signal is weakened. Common Causes: Proximity to cell towers, Wi-Fi routers, or even other key fobs . How to Resolve It: Move closer to your car and try again. Change your location if you’re in a crowded parking area. Keep your remote away from other electronic devices that might cause interference. Prevention Tip: Avoid storing your car remote near electronics when not in use. 3. Remote Needs Reprogramming Sometimes, a car remote loses its programming, which is essential for communicating with your car. This can happen after battery replacement, electrical system resets, or software glitches. Signs Your Remote Needs Reprogramming: The buttons don’t respond, or the remote only works intermittently. What You Can Do: Check your car manual for DIY reprogramming instructions. If DIY methods fail, consult a professional locksmith or your car dealer for assistance. Pro Tip: Always reprogram your remote immediately after replacing its battery to avoid compatibility issues. 4. Physical Damage: More Than Just Wear and Tear Daily use, accidental drops, or exposure to moisture can damage your car remote, leading to malfunction. The internal components, such as the circuit board, are particularly sensitive. Signs of Damage: Cracks on the casing, loose buttons, or water ingress. How to Address It: For minor issues, replace the remote casing or repair loose buttons. If the circuit board is damaged, you’ll need a replacement remote. Preventative Measures: Use a protective key cover to shield your remote from damage. Keep your remote away from water and extreme temperatures. 5. Faulty Car Receiver: The Problem Isn’t Always the Remote In some cases, the issue lies with your car’s receiver rather than the remote. If the receiver is damaged or malfunctioning, it won’t recognize signals from the remote. How to Diagnose: If multiple remotes fail to work with the same car, the receiver might be the issue. Test your remote on a similar vehicle, if possible, to rule out the remote as the problem. How to Fix It: Consult a professional mechanic to inspect and repair the car’s receiver system. General Tips to Keep Your Car Remote Functional Prevention is better than cure, especially when it comes to car remotes. Here are some tips to avoid future issues: Regular Maintenance: Inspect your remote periodically for wear and tear. Store It Safely: Keep your remote in a safe, dry place to avoid accidental damage. Backup Plan: Always have a spare key or remote handy for emergencies. Invest in a Tracker: Attach a Bluetooth tracker to your remote for easy location if it gets misplaced. When to Seek Professional Help While many car remote issues can be resolved with DIY methods, some problems require professional assistance. If your remote still doesn’t work after troubleshooting, consult a locksmith or an automotive specialist. They can help with repairs, replacements, and reprogramming at an affordable cost. Don’t Let a Faulty Remote Slow You Down A malfunctioning car remote can be a hassle, but most issues are fixable with a little know-how. Whether it’s a dead battery, signal interference, or physical damage, understanding the root cause will help you resolve the problem efficiently. With proper care and maintenance, your car remote will continue to offer the convenience and security you rely on every day.

Inside a Key Rescue: How to Salvage a Wet or Flooded Car Key
10.07.2025

Inside a Key Rescue: How to Salvage a Wet or Flooded Car Key

Water damage is one of the most common – and most stressful – problems car key owners face. Whether your key fell into a puddle, went through the wash, or was simply caught in a downpour, it can stop working in an instant. But does water exposure always mean you need to buy a new key? Not necessarily. In many cases, a quick and proper response can save your key, restore its function, and spare you an expensive replacement. This guide walks you through how to rescue a wet or flooded car key, what not to do, and how to know when it’s beyond repair. How Car Keys Get Wet Modern car keys, especially keyless remotes and fobs, aren’t designed to be waterproof. Even small amounts of moisture can cause damage if the internal components are exposed. Some of the most common causes of water-damaged keys include: Being left in clothing and run through the washing machine Falling into sinks, toilets, or puddles Exposure to rain, snow, or slush Dropped at the beach or near pools Stored in damp gym bags or jackets Once water enters the key shell, it can corrode the circuit board, damage the battery, or short-circuit the transponder chip. What to Do Immediately After Getting Your Key Wet The first few minutes after exposure are critical. Acting quickly can mean the difference between a working key and a dead one. 1. Remove the Key from the Water Take the key out of the water as quickly as possible. The longer it sits, the more damage can occur inside. 2. Open the Key Shell If your key has a removable shell, gently open it using a small screwdriver or plastic tool. This allows you to access the internal parts and dry them properly. If you’re unsure how to open it, look up a video or guide specific to your car model. 3. Take Out the Battery Immediately remove the battery. A wet battery in contact with electronics can cause short circuits and corrosion. Do not reinstall the same battery later; it may be compromised. 4. Dry the Internal Components Gently pat all visible parts dry with a lint-free cloth. Do not use paper towels, as they can leave behind fibers. Then allow the key to air-dry using one of the following methods: Option A: Use Silica Gel or Desiccant Packs Place the opened key and all components in an airtight container with silica gel packets. Leave it sealed for at least 24 to 48 hours. Option B: Use Uncooked Rice If silica gel isn’t available, uncooked rice can work as an alternative. Place the key in a bowl of rice and cover it completely. Leave it for 2 to 3 days. Do not use a hair dryer, microwave, or place the key near a heater. High heat can warp the plastic shell and damage sensitive electronics. After Drying: Will the Key Work Again? After a full drying period, insert a new battery and test the key. In many cases, it will begin working again — especially if water exposure was brief and the board was not damaged. If the key still doesn’t respond, try the following steps: Inspect the circuit board for corrosion or residue Try replacing the outer shell if buttons feel worn or unresponsive Check if the vehicle recognizes the transponder chip If none of these steps work, the internal chip or electronics may be permanently damaged. When to Replace the Key Sometimes the damage goes beyond what cleaning and drying can fix. You’ll likely need a full replacement if: The key no longer sends a signal The LED light doesn’t flash when pressing buttons There is visible corrosion on the circuit board The transponder chip fails to communicate with the vehicle Buttons are physically damaged or unresponsive The key was underwater for an extended time In these situations, replacing the key is often the most reliable solution. Don’t Wait Until It’s Too Late – Keep a Spare Key If you’ve experienced water damage once, there’s a good chance it could happen again. Keeping a backup key stored in a safe, dry location is one of the best precautions you can take. You can find replacement key shells, blades, batteries, and fully programmed keys for most vehicle brands at mr-key.com . Investing in a spare can save time, money, and stress. Final Tips for Car Key Water Damage Act fast and remove the battery as soon as possible Use silica gel or rice for slow, safe drying Avoid heat, rubbing, or shaking the electronics Replace the shell if it’s worn, cracked, or damaged If in doubt, test with a new battery before replacing the entire key Need Replacement Parts? Whether you need a new shell, battery, or a complete key, visit mr-key.com to find compatible parts for a wide range of vehicles. Our selection includes: Key shells for all major brands CR2032 batteries Key blades and electronics Fully assembled remote keys with chip and programming options If your key has been exposed to water, don’t panic. With the right steps, many keys can be rescued — and if not, we’re here to help you find the right replacement.

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