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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.

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The Essential Car Parts Guide: Understanding Your Vehicle's Core Components

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How to Easily Find Your Key Code for a Hassle-Free Replacement

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When it comes to replacing a car key , knowing your key code is essential. This code allows you to obtain a precise duplicate, ensuring that your new key fits seamlessly without any issues. Whether you've lost your key, broken it, or simply need a spare, understanding where to locate this code can make the replacement process faster and more affordable. In this guide, we’ll walk you through what a key code is, where to find it, and tips to ensure a smooth replacement process. Why Is the Key Code Important? A key code is more than just a number; it's a unique identifier that tells a key cutter exactly how to replicate your key. Without it, the process can be longer, more complicated, and potentially costly if the key doesn’t match your vehicle’s lock. Ensures a Perfect Fit : The key code guarantees that your new key will be cut to match your original one precisely. 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The Fascinating History of Car Safety Features: How Far We’ve Come to Keep You Safe

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!

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