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

The Top 5 Car Key Emergencies and How to Handle Them
07.01.2025

The Top 5 Car Key Emergencies and How to Handle Them

When it comes to car keys , emergencies often strike at the worst possible moments. Whether you’re rushing to work, stuck at a grocery store, or stranded in an unfamiliar location, knowing how to handle these situations can save you time, stress, and money. Below are the five most common car key emergencies and practical solutions to get you back on track. 1. Locked Out of Your Car? Here’s What to Do Locking your keys inside your car is a common yet frustrating mistake. The good news? There are ways to regain access without breaking the bank—or your window. Check for Spare Keys: If you have a spare key, now is the time to use it. Always keep one in a secure but accessible location, like with a trusted friend or at home. Use a Slim Jim or Unlocking Tool: While not ideal for everyone, these tools can work if you’re familiar with their use. However, be cautious to avoid damaging your car. Call a Locksmith or Roadside Assistance: Professional services can unlock your car safely and quickly. While it might cost you, it’s often cheaper than repairing a broken window. Pro Tip: Many modern cars come with apps or key fobs that allow remote unlocking. Familiarize yourself with these features beforehand. 2. Key Stuck in the Ignition? Don’t Panic A key stuck in the ignition can leave you feeling helpless, but with the right steps, you can often fix the issue yourself. Check the Gear Position: Ensure the car is in “Park” or “Neutral.” Many cars prevent key removal unless the gear is correctly positioned. Inspect for Steering Wheel Lock: Wiggle the steering wheel gently while trying to turn and remove the key. A locked steering wheel might be the culprit. Lubricate the Lock: Use a small amount of graphite lubricant to loosen the ignition lock. Avoid oil-based lubricants as they can attract dirt. Seek Professional Help: If the key is still stuck, call a locksmith or mechanic to prevent further damage. 3. Lost Your Key Fob Without a Spare? Act Fast Losing your key fob with no backup can be a nightmare, especially if your car relies on it entirely. Contact a Locksmith: Many locksmiths can program a new key fob on the spot, often at a lower cost than going to a dealership. Order a Replacement: Some car manufacturers allow you to order a replacement key fob online. Be prepared to provide proof of ownership. Preventative Measures: Always have a spare key fob and store it in a safe location. Consider investing in a key tracker to avoid future mishaps. 4. Dealing with a Wet or Damaged Key Fob? Accidents happen—maybe your key fob went through the wash or got drenched in the rain. The good news? Not all is lost. Dry It Out: Remove the battery and place the key fob in a bag of rice or silica gel to absorb moisture. Let it sit for at least 24 hours. Replace the Battery: Water damage can short-circuit the battery, so replace it with a new one after drying the fob. Test the Fob: After reassembling, check if the fob functions properly. If not, you may need to replace it or have it repaired by a professional. 5. Dead Key Fob Battery in a Remote Location? A dead key fob battery can leave you stranded, but this issue is often easier to resolve than you might think. Check for Hidden Features: Many cars have an emergency key hidden in the fob itself. This can manually unlock the door. Push-Button Start Workaround: Some cars allow you to start the engine by holding the dead fob close to the start button. Carry a Spare Battery: Always keep a spare CR-type battery in your glove box for quick replacements. These are inexpensive and widely available. Pro Tip: Familiarize yourself with your car’s manual to learn emergency procedures for dead key fobs. General Tips to Prevent Car Key Emergencies Preparation is your best defense against car key emergencies. Follow these tips to avoid getting caught off guard: Keep a Spare Key Handy: Store it at home, with a trusted person, or in a secure, hidden location. Invest in a Key Tracker: Attach a Bluetooth-enabled tracker to your key fob for easy location via your smartphone. Regular Maintenance: Replace key fob batteries proactively and inspect your keys for wear and tear. Learn Emergency Features: Understand your car’s built-in features, such as remote unlocking or hidden keys, to save time in emergencies. Stay Prepared, Stay Calm Car key emergencies don’t have to derail your day. With a little preparation and knowledge, you can tackle these common scenarios with confidence. Whether it’s unlocking your car, replacing a battery, or dealing with a damaged key fob, taking proactive measures ensures you’re always one step ahead.

The Evolution of the Car Key: Unlocking the Future of Mobility
16.04.2024

The Evolution of the Car Key: Unlocking the Future of Mobility

A Journey Through Time Imagine holding a car key from 1920 and trying to start a modern electric vehicle. The mere concept of what a “car key” represents has undergone a profound transformation, reflecting changes in automotive technology, security, and convenience. From simple mechanical tools to sophisticated digital devices, car keys have evolved alongside the vehicles they unlock. But how did we get here, and what does the future hold for this essential accessory? The Humble Beginnings: Mechanical Keys The car key’s story begins in the early 20th century, a time when cars were a luxury rather than a necessity. Early automobiles didn’t require keys as we know them today. Drivers used manual cranks to start the engine, a labor-intensive and often hazardous process. By the 1920s, the first generation of mechanical car keys emerged. These keys were simple, utilitarian devices used to lock the vehicle’s ignition or steering mechanisms. They marked the beginning of an era where security and convenience started to merge. Key features of early car keys included: A straightforward design, often a single-sided cut metal key. Limited security, as locks were rudimentary and easily picked. Despite their simplicity, these keys represented a revolutionary leap in vehicle security and usability. Entering the Electric Era: Ignition and Beyond The 1940s and 1950s saw a significant evolution in car keys with the introduction of ignition locks. These new systems required a key to start the vehicle, making cars both safer and easier to use. Manufacturers like Chrysler pioneered these innovations, creating a standard that would dominate for decades. The electric ignition systems introduced: A dual-purpose functionality: keys could unlock doors and start engines. Enhanced security, discouraging theft by eliminating manual starts. However, as automotive theft techniques became more sophisticated, so did the need for better security measures. The Advent of Remote Keyless Entry The 1980s and 1990s marked a pivotal period in the evolution of car keys with the introduction of remote keyless entry (RKE) systems. These keys included a built-in transmitter, allowing drivers to lock and unlock their cars with the push of a button. This innovation redefined convenience and set the stage for a digital future. Key highlights of RKE systems: Enhanced security with encrypted signals to prevent unauthorized access. Added features such as panic buttons and trunk releases. For many, the ability to control their car remotely became synonymous with modern luxury and convenience. Smart Keys and Digital Transformation As the 21st century arrived, car keys underwent another transformation, becoming “smart.” These keys, often shaped more like fobs than traditional keys, allowed for keyless ignition and entry. Equipped with proximity sensors, smart keys automatically unlock doors and start engines when the fob is nearby. Features of smart keys include: Passive entry and start systems, eliminating the need to physically insert a key. Advanced encryption technologies to combat modern car theft tactics. Automotive giants such as Mercedes-Benz and BMW led the charge in incorporating smart keys into their vehicles, reflecting a growing trend toward connectivity and automation. Biometric and Smartphone Integration: A Glimpse into the Future Today, the car key is on the brink of another revolution. Biometric systems and smartphone integration are becoming increasingly common, offering even greater security and convenience. Emerging trends include: Fingerprint and facial recognition systems : Some luxury vehicles now allow drivers to unlock and start their cars using biometric data. Digital keys : Smartphone apps are replacing physical keys entirely, enabling drivers to control their vehicles remotely. These innovations are part of a broader shift toward connected mobility. With digital ecosystems becoming central to the automotive experience, car keys are evolving into multifunctional tools that integrate seamlessly with a driver’s digital life. Global Perspectives: Trends Across Markets The evolution of car keys has not been uniform across the globe. In developed markets such as North America, Europe, and Japan, digital and smart keys dominate, reflecting advanced technological adoption. In contrast, mechanical keys remain prevalent in emerging economies, where affordability and simplicity often take precedence over cutting-edge innovation. Automotive manufacturers are responding to these differences by tailoring their offerings. For instance: In premium markets, luxury carmakers emphasize smart and biometric key systems as standard. In cost-sensitive regions, manufacturers offer basic mechanical or remote keys as a practical solution. These distinctions highlight the diverse ways in which the car key continues to evolve, shaped by cultural, economic, and technological factors. The Challenges Ahead: Balancing Innovation and Security While modern car keys offer unparalleled convenience, they also come with challenges. Cybersecurity threats, such as hacking and relay attacks, pose significant risks to digital and smart key systems. Industry experts emphasize the need for robust encryption and regular software updates to mitigate these risks. Moreover, the shift toward digital keys raises concerns about dependency on smartphones. What happens if a phone runs out of battery or malfunctions? Manufacturers are exploring hybrid solutions that combine digital and physical access to address such scenarios. Unlocking the Future The evolution of the car key mirrors the broader changes in automotive technology, from mechanical simplicity to digital sophistication. As we move toward an era of autonomous and connected vehicles, the humble car key is poised to become an even more integral part of our mobility experience. For now, car keys remain a fascinating blend of past, present, and future. Whether it’s a vintage metal key or a cutting-edge biometric system, they continue to unlock not just our vehicles but also the stories of innovation and progress. The next time you hold your car key—be it physical, smart, or digital—pause for a moment to appreciate the journey it represents. Who knows? In a few decades, we might be reminiscing about keys altogether as we step into fully autonomous, keyless vehicles.

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

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

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

The Fascinating History of Car Safety Features: How Far We’ve Come to Keep You Safe
02.10.2024

The Fascinating History of Car Safety Features: How Far We’ve Come to Keep You Safe

When you think about cars, what comes to mind? Speed, design, or maybe the feeling of freedom when you hit the open road? But there’s one crucial aspect of driving that you might not think about as much—safety. Cars today are safer than ever, thanks to decades of innovations and advancements. But how did we get here? Let’s dive into the history of car safety features and see just how far we’ve come to protect you and your loved ones on the road. The Early Days: A Lack of Safety Awareness Back in the early 1900s, cars were viewed as luxury items and status symbols. Safety wasn’t really a concern. Cars had no seat belts, no airbags, and certainly no crumple zones. People focused more on making vehicles go faster and look better than on keeping passengers safe. In those days, accidents were far more dangerous, often leading to severe injuries or fatalities. It wasn’t until the rise of car ownership in the 1920s and 1930s that people began to notice just how dangerous cars could be. The growing number of vehicles on the road led to more accidents, and the need for safety features became evident. The Invention of Seat Belts: The First Major Breakthrough Seat belts were one of the first car safety features to be introduced. But they didn’t become standard right away. In fact, the idea of a seat belt first appeared in the late 19th century, designed for use in airplanes, not cars. It wasn’t until the 1950s that the seat belt began to find its way into automobiles, thanks to Swedish engineer Nils Bohlin, who designed the three-point seat belt in 1959. Bohlin’s invention, which you still use today, was a game-changer. It saved countless lives and reduced serious injuries in crashes. Volvo was the first company to introduce the three-point seat belt in their vehicles, and soon after, other manufacturers followed suit. Airbags: A Revolutionary Step Forward As seat belts became more common, automakers started looking for additional ways to protect drivers and passengers. Enter the airbag. The airbag was initially developed in the 1950s, but it took decades of refinement before it became a standard feature in cars. The first production car equipped with an airbag was the 1973 Oldsmobile Toronado, but it wasn’t until the 1990s that airbags became widely available. Today, airbags are a critical component of vehicle safety systems, with front, side, and even curtain airbags designed to protect you from all angles in a crash. Alongside seat belts, airbags are now seen as one of the most effective life-saving technologies in modern vehicles. Crumple Zones: Protecting You in a Collision Crumple zones are another innovation that may not be immediately obvious, but they play a huge role in keeping you safe. In the event of a crash, crumple zones are designed to absorb and dissipate energy, reducing the force transferred to passengers. Introduced in the 1950s by Mercedes-Benz, crumple zones help reduce the impact of a collision by sacrificing the car’s body to protect the occupants. Today, crumple zones are standard in virtually every car, and their design continues to evolve, improving crash safety with each new model year. Anti-lock Brakes: Helping You Keep Control The introduction of anti-lock braking systems (ABS) in the 1970s was another massive leap forward in car safety. ABS prevents the wheels from locking up during braking, which helps maintain steering control during an emergency stop. This system is especially useful on slippery surfaces like rain-soaked or icy roads. Before ABS, sudden braking could lead to skidding, causing drivers to lose control of their vehicles. ABS has significantly reduced the number of accidents caused by loss of control and has become a staple of modern driving safety. Electronic Stability Control: The Technology That Saves Lives Electronic Stability Control (ESC) was a groundbreaking safety feature that hit the market in the 1990s. ESC helps you maintain control of your car during skids or oversteering by automatically applying brakes to individual wheels. Studies have shown that ESC can reduce the risk of a fatal crash by as much as 50%. In fact, the National Highway Traffic Safety Administration (NHTSA) now mandates that all cars sold in the United States come equipped with ESC. This technology has proven to be especially helpful in preventing rollovers, which are among the most dangerous types of accidents. The Future of Car Safety: What’s Next? Car safety features have come a long way, but we’re not done yet. The future of vehicle safety lies in advanced driver-assistance systems (ADAS), which use sensors, cameras, and radar to detect potential hazards and prevent accidents before they happen. Some of the technologies that are becoming increasingly common include lane departure warnings, automatic emergency braking, and adaptive cruise control. And let’s not forget the promise of self-driving cars, which could drastically reduce accidents caused by human error, which accounts for the majority of crashes today. The Importance of Car Safety As we look back on the history of car safety features, it’s incredible to see how far we’ve come. From the early days of no seat belts or airbags to today’s cutting-edge technology, the automotive industry has made safety a top priority. The next time you get behind the wheel, take a moment to appreciate all the safety features designed to protect you. Whether it’s a simple seat belt or a high-tech stability control system, these innovations have made driving safer for everyone. And remember, no matter how advanced your car’s safety systems are, the best protection is still responsible driving. Stay alert, drive safely, and always buckle up!

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