Post Name

Swirl flaps are a BMW system that has been introduced to help burn the fuel mixture in the cylinder better due to the fact that diesel engines do not have throttle valves and it is not possible to adjust the air-fuel ratio. A diesel engine without vortex valves operates between a poor and a rich fuel mixture, because the only way to regulate it is through fuel injection.

Design of the first generation swirl flaps that are made of made of metal.

Unfortunately, swirl flaps are responsible for countless damaged engines and costly repairs due to design errors or metal fatigue. Once damaged, the cylinder sucks them in and causes great damage.

This is how damaged valves damage the cylinder.

Typical swirl flaps  suction damage.

The vortex valves are positioned in the inlet and are controlled by vacuum (DDE 4.0) or electrically (DDE5.0 / DDE6.4) by the engine ECU.

Effects of malfunctioning valves:

  • Swirl valves are  stuck in open position: Deterioration of exhaust gas performance at lower speeds.
  • Swirl valves are stuck in closed position: Approximate power loss of 10% at high engine speeds.

How swirl flaps work:

Performance characteristics:

The vortex valves are in the closed position, at low engine speeds and small amounts of fuel injected (controlled by the ECU card).

They open under the following conditions:

  1. coolant temperature <14 ° C OR * fuel quantity> 24 mg OR
  2. engine speed 2250 rpm OR
  3. inlet air temperature <-5 ° C

BMW and Pierburg have decided to produce diesel engines with metal vortex valves. The speed at which the pistons in the diesel engine operate is at least 60 rpm, so a sucked vortex valve will break and cause a number of damages inside the engine.

In most cases, one or more pistons are severely damaged, as a bonus you get valves, in some cases a head or turbocharger. And this combination with a BMW engine is like a cumulative jackpot  🙂

In 2004, BMW began work on the problem and improved the design, however, a number of owners reported ongoing problems in this area.

The solution to this problem is by removing the vortex valves and plugging, which does not affect the performance of the engine and at the same time, you can safely pass the exhaust test.

Engines:

M47 (136hp VP44 fuel pump) has no valves.

M47N common rail engine (including M47N / M47TU / M47TUD20) (150hp. Face lift model from 2001 -) has valves.

M57 engines (M57D) (525d & 187hp. 330d) cars with manual transmission do not have valves, but those with automatic have.

M57N engines (M57TUD) (525d & 330d 204hp) have vortex valves.

Ruined swirl flaps:

The plugs that replace the vortex valves are easy to find on the internet, but you can also find them here on our website.

Typical plugs:
 

Disassembly of vortex valves:

The vortex valves can be safely dismantled and in most cases if they are  removed properly no loss of power is felt.

Final list of models for which vortex valves are installed:

Engine: M47N/M47TU/M47TUD20

Applications:

* 110 kW (148 hp) and 330 N·m (243 lb·ft)

o E46 320d 2001-2005

o E83 X3 2.0d (up to end of 2006)

Engine: M47TU2D20

The engine was updated again in 2004 as the M47TU2D20. Still at 1995 cc, it produced more power across the range.

Applications:

* 120 kW (161 hp) and 340 N·m (251 lb·ft)

E60/E61 520d

E87 120d

E90/E91 320d

E83 X3 2.0d (end of 2006 onwards)

Engine: M57/M57D25

M57D25 was introduced in 2000.

Applications:

* 166 PS (122 kW; 164 hp) at 4000 rpm, 350 N·m (260 lb·ft) at 2000-2500 rpm with a 4750 rpm redline, models:

2000-2003 E39 525d *Vehicles With Automatic Transmission ONLY*

Engine: M57N/M57TU/M57TUD25

M57TUD25 was introduced in 2004.

Applications:

* 177 PS (130 kW; 175 hp) at 4000 rpm, 400 N·m (300 lb·ft) at 2000-2750 rpm models:

E60/E61 525d

Engine: M57/M57D30

M57D30, also called M57D29, was introduced in 1998.

Applications:

* 184 PS (135 kW; 181 hp)@4000, 390 N·m (290 lb·ft)@1750-3200 models:

E39 530d *Vehicles With Automatic Transmission ONLY*

E46 330d/330xd *Vehicles With Automatic Transmission ONLY*

* 184 PS (135 kW; 181 hp)@4000, 410 N·m (300 lb·ft)@2000-3000 models:

E38 730d *Vehicles With Automatic Transmission ONLY*

E53 X5 3.0d

* 193 PS (142 kW; 190 hp)@4000, 410 N·m (300 lb·ft)@1750-3000 models:

E38 730d

E39 530d

Engine: M57N/M57TU/M57TUD30

M57TUD30 was introduced in 2002. It originally produced 160 kW (215 hp) at 4000 rpm and 500 N·m (370 lb·ft) at 2000-2750 rpm, but was tweaked for 150 kW (201 hp) at 4000 rpm and 410 N·m (300 lb·ft) at 1500-3250 rpm for 2003 and again for 200 kW (268 hp) at 4000 rpm and 560 N·m (410 lb·ft) at 2000-2250 rpm in 2004.

Applications:

* 204 PS (150 kW; 201 hp)@4000, 410 N·m (300 lb·ft)@1500-3250 models:

E46 330d/330Cd/330xd

E83 X3 3.0d

* 218 PS (160 kW; 215 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E53 X5 3.0d

E60/E61 530d/530xd

E65 730d

* 272 PS (200 kW; 268 hp)@4000, 560 N·m (410 lb·ft)@2000-2250

E60/E61 535d

* 245 PS (180 kW; 242 hp)@4000, 500 N·m (370 lb·ft)@2000-2250

* 286 PS (210 kW; 282 hp)@4000, 580 N·m (430 lb·ft)@2000-2250

Engine: M57TU2D30

M57TU2D30 was introduced in 2007, making its debut in the facelifted E60 and E61.

* M57TU2D30-UL: 197 PS (145 kW; 194 hp)

* M57TU2D30-OL: 235 PS (173 kW; 232 hp)@4000, 500 N·m (370 lb·ft)@2000-2750

* M57TU2D30-TOP: 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft)

Applications:

* 197 PS (145 kW; 194 hp), 400 N·m (300 lb·ft) models:

E90/E91/E92 325d

E60/E61 525d/525xd

* 231 PS (170 kW; 228 hp)@4000, 500 N·m (370 lb·ft)@2000-2750 models:

E65 730d

E90/E91 325d

E90/E91 330d/330xd

* 235 PS (173 kW; 232 hp) models:

E60/E61, BMW E70, BMW E71

* 286 PS (210 kW; 282 hp), 580 N·m (430 lb·ft) models:

E60/E61 535d

E70 X5 3.0sd

E71 X6 xDrive35d

E83 X3 3.0sd

E90/E91 335d

The above models are listed for information only if you want to to make sure your engine has valves installed, please contact a competent person.

Please note that the information described above is for informational purposes only and does not claim to be reliable. Mr-key.com is not responsible for any repair work you undertake that is related to the topic described in this article.

Related Posts

Removing Keys from Locks: A Comprehensive Guide

Removing Keys from Locks: A Comprehensive Guide

Removing a key from a lock may seem simple, but it can become tricky when dealing with stuck or broken keys. Whether you're dealing with a standard lock, padlock, or vehicle ignition, understanding the correct techniques can save you from damage and frustration. This guide will walk you through the essential steps for removing keys from various types of locks, offering practical advice and tips to ensure a smooth process. Common Scenarios and Challenges Keys can become stuck or difficult to remove for several reasons, including misalignment, wear and tear, or damage to the key or lock. Additionally, environmental factors like temperature changes can cause metals to expand or contract, making key removal more challenging. Recognizing the cause of the issue is the first step in effectively addressing it. Basic Techniques for Key Removal Gentle Wiggle and Pull: The first technique to try is a gentle wiggle and pull. Hold the key firmly and move it slightly up and down or side to side while pulling gently. This method works well if the key is simply stuck due to misalignment. Lubrication: If the key is difficult to remove, applying a small amount of graphite powder or a silicone-based lubricant into the keyhole can help. Avoid using oil-based lubricants, as they can attract dirt and grime, potentially worsening the problem. Tapping the Lock: For stubborn cases, lightly tapping the lock with a hammer while gently pulling the key can help dislodge it. This method is effective when the key is stuck due to debris or minor misalignments within the lock. Advanced Techniques for Stuck Keys Using a Key Extractor: If the key is broken off inside the lock, a key extractor tool can be very effective. Insert the tool into the keyhole, hook the broken key piece, and pull it out carefully. This method requires patience and a steady hand. Pliers and Tweezers: If part of the key is still protruding, you can use needle-nose pliers or tweezers to grip and pull the key out. Be careful not to apply too much force, as this can push the key further into the lock or damage the lock mechanism. Heat Application: In cold weather, metal contracts, which can cause the key to get stuck. Gently heating the key with a hairdryer or warm cloth can expand the metal slightly, making it easier to remove. However, avoid using an open flame, as it can damage the lock or key. Preventing Key Stuck Issues Prevention is always better than cure. Here are some tips to prevent keys from getting stuck in the future: Regular Maintenance: Keep your locks and keys clean and well-lubricated with appropriate materials. Regularly inspect for wear and tear, and replace any damaged keys or locks. Use Duplicate Keys: If you notice a key becoming difficult to use, have a duplicate made before it breaks or becomes stuck. This will save you the hassle of dealing with a stuck key. Avoid Excessive Force: Never force a key into a lock. If it doesn’t turn easily, stop and inspect both the key and the lock for damage or obstruction. When to Call a Professional While many stuck key issues can be resolved with the techniques mentioned above, there are times when professional assistance is necessary. If you’ve tried all the methods and the key remains stuck, or if you’re dealing with a high-security lock, it’s best to contact a professional locksmith. They have the tools and expertise to safely remove the key without damaging the lock or key further. Dealing with a stuck key can be frustrating, but understanding the proper techniques can save you time and prevent damage. From basic wiggling and lubrication to more advanced methods like using a key extractor, there are various approaches depending on the severity of the situation. Regular maintenance and careful handling can help prevent these issues from occurring in the first place. When in doubt, don’t hesitate to seek professional help to ensure your lock and key remain in good working condition.

Simple and Affordable Solutions for Car Key Replacement and Repairs

Simple and Affordable Solutions for Car Key Replacement and Repairs

Misplacing or damaging your car keys can be a major inconvenience, but it doesn't have to be a costly ordeal. As a car owner seeking budget-friendly and efficient solutions, understanding your options is crucial. Here's a comprehensive guide to help you navigate the process of replacing your car keys without breaking the bank. Understanding Your Car Key Type Identifying the specific type of car key you have is the first step toward an effective replacement: Traditional Metal Keys : Simple, non-electronic keys that are easy and inexpensive to duplicate. Transponder Keys : Equipped with a chip that communicates with your vehicle's ignition system for added security. Remote Key Fobs : Allow remote locking and unlocking of your vehicle, often integrated with a transponder chip. Smart Keys : Provide keyless entry and start features, utilizing advanced technology for convenience. Cost-Effective Alternatives to Dealership Key Replacement Dealerships are known for charging premium prices for key replacements. Consider these more affordable options: Professional Locksmiths : Specialize in cutting and programming various types of car keys, often at a fraction of dealership costs. Online Key Retailers : Offer replacement keys and fobs that can be purchased and then programmed either by yourself or a professional. Hardware Stores : Some stores can duplicate traditional metal keys on the spot, providing a quick and inexpensive solution. Steps to Take When You've Lost Your Car Key Losing your car key can be stressful, but following these steps can streamline the replacement process: Verify Your Vehicle Identification Number (VIN) : Locate your VIN, typically found on the dashboard or inside the driver's side door, as it is essential for key replacement. Gather Necessary Documentation : Prepare proof of ownership, such as your vehicle registration and personal identification. Contact a Professional : Reach out to a reputable locksmith or key replacement service with your vehicle details to obtain a new key. Removing a Broken Key from the Ignition or Door Lock A broken key can be a frustrating obstacle. Here's how to address it: Use Needle-Nose Pliers : If a portion of the key is protruding, gently extract it using pliers. Apply Lubricant : Spray a graphite-based lubricant into the lock to ease the removal process. Seek Professional Assistance : If the key fragment is lodged deep or these methods fail, contact a locksmith to prevent further damage. Preventative Measures to Avoid Future Key Issues Keep a Spare Key : Having a duplicate stored safely can save time and money in emergencies. Regular Maintenance : Inspect your keys and locks periodically for signs of wear and address issues promptly. Use Key Protectors : Invest in key covers or cases to minimize physical damage.

Car Won’t Start After Key Shell Change? Here’s What the Transponder Chip Does

Car Won’t Start After Key Shell Change? Here’s What the Transponder Chip Does

Modern car keys have come a long way from the traditional cut metal blades of the past. What was once a simple tool for turning an ignition has evolved into a smart, encrypted device with layers of built-in security. Among the most critical components in today’s car keys is the transponder chip — a small but vital element that could be the reason your car doesn’t start after replacing your key shell. If you've recently changed the shell or casing of your key and suddenly find that your car won’t start, you're not alone. This is one of the most common (and frustrating) issues car owners face when performing a key repair or upgrade. So let’s break down what’s really happening — and how you can fix it. What Is a Transponder and What Does It Do? A transponder chip (short for “transmitter-responder”) is a small electronic component embedded in your car key. Its purpose is to communicate with your vehicle’s immobilizer system to authorize ignition. Here’s how it works: When you insert your key and turn the ignition, your car sends out a radio signal. The transponder chip in your key responds with a coded signal unique to your car. If the code is correct, the car’s computer disables the immobilizer and allows the engine to start. If the chip is missing, broken, or the code doesn’t match — the engine won’t start, even if the key blade physically turns. This system is an anti-theft measure, and it's present in most vehicles manufactured after the late 1990s. Without a functional transponder, your key may unlock the doors but it will not allow the car to start. This ensures that even if someone manages to copy the physical blade of your key, they still can’t steal your car. Why Your Key Might Not Work After Shell Replacement Changing your key shell (also called a case or housing) can seem like a simple cosmetic repair — but it’s easy to overlook the importance of transferring the transponder chip during the process. If your key no longer starts the car after a shell replacement, the most likely reason is: You forgot to move the transponder chip into the new shell. In many keys, the chip is not part of the electronics board . It’s often a tiny black or glass capsule , sometimes hidden in a small compartment within the key shell — completely separate from the buttons and battery. If you didn’t see it, it’s probably still sitting inside the old casing. Some people assume that simply moving over the circuit board and battery is enough — but without the transponder, your key won’t be recognized by the car’s immobilizer. This results in the engine failing to start, even though the buttons may still lock and unlock the doors. Symptoms of a Missing or Misplaced Transponder If your key turns in the ignition but: The car does not crank or start You see a flashing key icon or immobilizer warning on the dashboard The central locking might still work, but the engine won’t respond You hear a clicking sound but no ignition occurs Then it’s almost certainly a transponder issue. The car's system is waiting for a valid coded signal from the key — and without it, the start command is rejected. How to Fix It: What You Need to Do Here’s how to get your car running again: 1. Check Your Old Key Shell Open the old casing and look for a small black or clear capsule (typically rice-sized). That’s your transponder chip. Some are glued in place and may require careful prying. 2. Transfer the Chip Carefully remove it and insert it into the correct compartment in your new key shell. Some aftermarket shells have a specific slot for it, while others require a bit of creativity to keep it securely in place. In some cases, adhesive putty or double-sided tape can help hold it. 3. Reassemble and Test Put your key back together and try starting the car again. If the chip is correctly placed, it should work immediately — no reprogramming needed. Always test both ignition and door lock/unlock functions. What If You Lost the Chip? Unfortunately, if the chip is damaged or lost, the key will no longer be able to start your vehicle. In this case, you’ll need to: Contact a professional auto locksmith Have a new transponder chip programmed to your car’s immobilizer system Provide proof of ownership (such as your vehicle logbook or registration) in most cases Depending on the make and model of your car, programming a new chip may cost anywhere from $50 to $250 , and it typically requires special diagnostic equipment. It’s worth noting that some dealerships may charge significantly more than independent auto locksmiths — and you may have to wait longer for service. Pro Tips When Replacing Your Key Shell Always examine the inside of your old shell carefully before throwing it away. Take photos before disassembly so you know where each component goes. If you're unsure where the chip is or how to transfer it, look for DIY videos specific to your key model. Use tweezers and caution — the chip is fragile. Avoid static electricity or contact with magnets during the transfer process. Some modern keys have transponders integrated into the circuit board , in which case no separate chip needs to be moved. If you’re working with a smart key or proximity key, additional steps may be required. These typically involve re-synchronization with the vehicle’s system and may not function correctly without professional assistance. Small Chip, Big Consequences It’s incredible how something as small as a transponder chip can control such a major function. Replacing your key shell is a great way to refresh the look and feel of your key — but it’s vital not to overlook the importance of transferring every component, especially the transponder. Many DIY repairs are abandoned or lead to confusion simply because of this overlooked step. Fortunately, it’s one of the easiest problems to fix once you understand what to look for. If your key looks brand new but your car won’t start, don’t panic. Chances are, the solution is sitting inside your old key shell — quietly waiting to be moved over.

Key Lock Standards for Ultimate Vehicle Security

Key Lock Standards for Ultimate Vehicle Security

In today’s world, where vehicle security is more important than ever, understanding the various key lock standards is crucial for protecting your car against theft. Whether you own a luxury vehicle, a family car, or a fleet of commercial vehicles, knowing how different key locking systems work and what standards are in place can ensure that your vehicle remains secure. In this article, we’ll explore the key lock standards that every car owner should know, what makes a secure system, and how they help protect your car from potential threats. Understanding Key Lock Standards Key lock systems play an essential role in vehicle security. Modern car locks are not just about preventing unauthorized entry but also about preventing the car from being started or stolen. A well-designed key lock system integrates advanced technologies that enhance the protection of your vehicle. There are several key lock standards in the automotive industry, each with its specific focus on improving security and minimizing risks. These standards include traditional mechanical key locks, transponder keys, keyless entry systems, and smart keys. Mechanical Key Locks: The Traditional Standard Mechanical key locks are the most basic and traditional form of car locking systems. For many years, these locks were the standard, and they are still widely used today, particularly in older vehicles. A mechanical key lock involves a physical key that is inserted into the door or ignition switch to gain access to the car or start the engine. While simple, mechanical locks are not as secure as newer systems. Over time, thieves have developed methods to bypass or pick mechanical locks, making them less effective for modern vehicle security. However, many vehicles still rely on these locks, and they remain a crucial part of the overall security system. Transponder Keys: A Step Up in Security In response to the vulnerabilities of mechanical key locks, the automotive industry introduced transponder keys in the 1990s. A transponder key is equipped with a microchip embedded inside the key fob. When the key is inserted into the ignition, the microchip sends a signal to the vehicle's engine control unit (ECU), verifying that the key is legitimate and authorized to start the car. Transponder keys significantly enhance vehicle security by making it much more difficult for thieves to clone the key. Without the proper code, the car won’t start, even if the thief has an exact replica of the physical key. This added layer of security has made transponder keys the industry standard in many vehicles. Keyless Entry Systems: Convenience Meets Security Keyless entry systems, also known as remote entry systems, are now common in modern vehicles. These systems allow you to unlock or lock your car without inserting a key. Instead, the car communicates wirelessly with a key fob, sending a unique signal that grants access. The key fob typically includes buttons to lock or unlock the doors and sometimes to start the engine remotely. The convenience of keyless entry is undeniable, but it also introduces certain vulnerabilities. Keyless entry systems rely on wireless signals, which can sometimes be intercepted or duplicated by thieves using sophisticated equipment. To counteract these risks, manufacturers have developed enhanced encryption protocols and rolling codes that change each time the system is used, making it more challenging to hack into the system. Smart Keys: The Next Level of Vehicle Security Smart keys represent the latest evolution in vehicle security. These keys go beyond the capabilities of traditional key fobs and keyless entry systems by offering features like proximity sensing and push-to-start functionality. Smart keys allow you to unlock and start your vehicle without physically touching the key fob. The system detects when the key fob is near the car and grants access automatically. Smart keys are highly secure, as they use advanced encryption methods and rolling codes to protect the vehicle from unauthorized access. In addition, the vehicle can be programmed to disable the engine if an unauthorized key is detected, providing an additional layer of security. International Security Standards for Vehicle Locks To ensure the security of vehicles globally, several international standards have been developed to guide manufacturers in creating secure key lock systems. Some of the most important standards include: ISO 9001 : This standard focuses on the quality management of products, including vehicle locking systems. It ensures that manufacturers meet specific quality control guidelines, which helps ensure the reliability and security of key lock systems. ISO 14298 : This is a more specific standard related to secure key management for vehicles, focusing on preventing unauthorized duplication and tampering with vehicle keys. EC Regulation 1303/2014 : This European regulation outlines the technical specifications for car security systems, including locking systems. It provides a framework to protect vehicles against unauthorized access, theft, and other security risks. Adhering to these standards ensures that vehicle manufacturers meet global security requirements and offer their customers reliable and effective security systems. Why Secure Key Locks Are Essential for Vehicle Protection With increasing car theft rates and sophisticated methods used by criminals, investing in a secure key lock system is no longer optional—it’s essential. A secure key lock system prevents unauthorized access to the vehicle and ensures that only legitimate owners or authorized individuals can use the vehicle. Each level of security, from mechanical locks to smart keys, offers a different degree of protection, and modern vehicles often incorporate multiple systems to strengthen security. The combination of these advanced technologies, alongside international security standards, provides vehicle owners with peace of mind knowing their vehicle is well-protected. Key lock standards have come a long way from the traditional mechanical locks of the past. Today’s vehicles rely on advanced technologies like transponder keys, keyless entry systems, and smart keys to provide higher levels of security. These systems are designed to make it as difficult as possible for thieves to bypass them, giving car owners confidence that their vehicles are protected. By understanding the different key lock standards and their capabilities, you can make informed decisions about your vehicle’s security and take steps to ensure that your car remains safe from theft. Whether you’re driving a new model or an older vehicle, upgrading or maintaining your key lock system can help safeguard your investment and provide peace of mind on the road.

Chat with us