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.

The Importance of Regularly Updating Your Car's Key Fob Software
25.02.2025

The Importance of Regularly Updating Your Car's Key Fob Software

In the digital age, vehicle security has evolved beyond traditional locks and keys. Modern cars rely on sophisticated electronic systems, with key fobs playing a crucial role in convenience and safety. However, many car owners overlook the importance of regularly updating their key fob software. Like any other electronic device, key fobs require updates to function optimally and protect against emerging threats. This article explores why keeping your car's key fob software up-to-date is essential for security, functionality, and overall vehicle performance. Enhanced Security Against Keyless Theft One of the primary reasons to update your key fob software is to safeguard your vehicle against hacking and theft. Car thieves have become increasingly tech-savvy, using methods such as relay attacks and key cloning to gain unauthorized access to vehicles. Manufacturers frequently release software updates to counteract these evolving threats, strengthening encryption protocols and implementing new security measures. Regular updates ensure that your vehicle remains protected against the latest hacking techniques, reducing the risk of keyless car theft. Improved Functionality and Performance Software updates do more than just enhance security; they also improve the functionality of your key fob. Updates can optimize the communication between the key fob and the vehicle, ensuring seamless operation of features like remote start, keyless entry, and trunk access. Some updates may also introduce new capabilities, such as extended remote range or better battery efficiency. By keeping your key fob software up to date, you maximize the effectiveness of these features, enhancing your overall driving experience. Fixing Bugs and Resolving Malfunctions Like any software-based system, key fobs can experience glitches or bugs over time. You may notice issues such as delayed responses, intermittent connectivity, or complete failure to unlock or start your car. In many cases, these problems stem from outdated software. Manufacturers release updates to fix such bugs, ensuring that your key fob operates smoothly. If you’ve been experiencing issues with your key fob, checking for software updates is a simple yet effective solution. Compatibility with Newer Vehicle Features Automakers continuously upgrade their vehicle software, adding new safety and convenience features. To ensure compatibility, your key fob software must also stay updated. For example, if your car receives an over-the-air (OTA) update that enhances security protocols, an outdated key fob may no longer function correctly. Keeping both your vehicle and key fob software current ensures seamless integration, preventing functionality issues and maintaining an optimal driving experience. How to Update Your Key Fob Software Updating your key fob software may vary depending on the manufacturer and model of your vehicle. Here are a few common ways to ensure your key fob is up to date: Check the Manufacturer’s Website – Automakers often release software updates for key fobs and other electronic components on their official websites. Look for any available updates specific to your vehicle model. Visit a Dealership or Certified Service Center – Many car manufacturers require key fob updates to be installed at an authorized dealership or service center. Technicians can update your key fob and ensure it is properly synced with your vehicle. Use a Mobile App (If Available) – Some modern car brands offer mobile apps that allow users to update their key fob software remotely. Check if your vehicle’s manufacturer provides such an option. Consult Your Owner’s Manual – Your car’s manual may provide instructions on how to check for key fob software updates and whether they can be performed manually. Regularly updating your car's key fob software is a simple yet crucial step in maintaining vehicle security and functionality. Updates help protect against theft, fix software glitches, and ensure compatibility with new vehicle features. Given the increasing reliance on electronic key systems, staying proactive about updates is essential. Whether through a dealership visit or an online update, keeping your key fob’s software current will help you enjoy a safer and more convenient driving experience. Stay informed, stay updated, and keep your vehicle secure.

Key Fob vs. Transponder vs. Smart Key: What’s the Difference?
23.05.2025

Key Fob vs. Transponder vs. Smart Key: What’s the Difference?

Unlocking the Modern Car Key In the past, a car key was a simple piece of metal. You inserted it into the door, turned it, and the car unlocked. You repeated the process in the ignition to start the engine. Today, however, a car key might be a sleek device that never even leaves your pocket. It may unlock your doors remotely, start the car with a button, or communicate with your vehicle without you even touching it. This evolution in key technology has introduced convenience, security, and — for many drivers — a bit of confusion. What kind of key do you actually have? Is it a transponder key , a key fob , or a smart key ? And why does it matter? In this blog, we break down each type of modern car key, explain how they work, and highlight what makes them different — so you can better understand, maintain, and protect the device that starts your vehicle. What Is a Transponder Key? The transponder key was the first major step toward electronic vehicle security. Introduced in the 1990s, it features a small microchip embedded in the plastic head of a standard metal key. This chip communicates with the car's immobilizer system. When you insert the key into the ignition and turn it, the car sends out a low-frequency signal. If the chip responds with the correct, pre-programmed code, the vehicle starts. If the code is incorrect — or missing — the car won’t start at all. Key characteristics: Looks like a traditional key Contains a passive chip (no battery needed) Requires physical insertion and turning Designed to prevent hotwiring and unauthorized key copies Transponder keys are still widely used, especially in vehicles produced between the late 1990s and early 2010s. They’re simple, reliable, and provide basic but effective protection against theft. What Is a Key Fob? The term key fob typically refers to a small, handheld remote that controls access to your car without inserting a key into a lock. Most modern fobs include buttons for locking and unlocking the doors, opening the trunk, and triggering a panic alarm. Some also support remote engine start. In many vehicles, the fob is attached to — or integrated with — a mechanical key that includes a transponder chip. Others are "flip keys," with a metal blade that folds inside the fob casing. Key fob features: Enables remote locking/unlocking May include a transponder chip Often includes a mechanical backup key Battery-powered (usually coin cell batteries) May include passive entry on some models Key fobs offer a balance between convenience and control. While you still need to press buttons or insert a key in many cases, they streamline the process and add useful features. What Is a Smart Key? The smart key is the most advanced and convenient type of car key available today. It communicates with your vehicle wirelessly using radio frequency or low-energy Bluetooth. As long as the smart key is within range — often in your pocket or bag — the car will unlock automatically when you touch the handle, and start when you press the ignition button. Unlike a key fob, there’s no need to press buttons or insert anything into the ignition. The system detects the key’s presence and grants access and engine start as needed. Smart key features include: Passive keyless entry (PKE) Push-button start Proximity detection Fully hands-free operation Often includes comfort access features like memory seating and climate control However, smart keys also introduce new considerations. They rely entirely on battery power, so a dead battery can temporarily disable key functions. Because smart keys are always transmitting a signal, they are also vulnerable to relay attacks , in which thieves use signal amplifiers to trick the car into unlocking. Key Comparison Table To help clarify the differences between each type of key, here’s a side-by-side comparison: Feature Transponder Key Key Fob Smart Key Physical key required Yes Sometimes (flip blade) No Remote locking/unlocking No Yes (buttons) Yes (proximity-based) Push-button start No No Yes Battery required No Yes Yes Security level Moderate High (with chip) High Common years of use 1995–2012 2000–present 2015–present Risk of relay attack None Low (in some cases) High (without signal shield) Why It Matters: Practical Impacts for Drivers Understanding what kind of car key you have can save you time, money, and stress in several situations: 1. Replacing Lost or Broken Keys Smart keys can cost anywhere from $200–$600+ to replace and usually require dealership programming. Transponder keys are cheaper and often programmable by locksmiths. 2. Diagnosing Key Issues If your car won’t start, it could be due to a dead battery in your fob or smart key. But if you have a transponder key, the issue might be with the chip or immobilizer system. 3. Security Awareness Smart keys are vulnerable to digital theft via relay attacks. If you have one, consider using a Faraday pouch or signal-blocking case to protect your vehicle while parked. Want to protect your key? Browse Mr Key's security accessories here. 4. Choosing Accessories Batteries, protective covers, signal-blocking cases, and replacement parts vary depending on your key type. Buying the wrong product can lead to frustration or compatibility issues. Know Your Key, Protect Your Car Your car key is more than a tool — it’s an entry system, a security feature, and a communication device. Whether you’re carrying a traditional transponder key, a button-operated key fob, or a proximity-based smart key, knowing the difference is the first step toward better security, smarter repairs, and fewer surprises. In a world where cars are smarter than ever, your key plays a more important role than most drivers realize. Take a moment to identify which type you have — and take steps to protect it.

The Impact of Artificial Intelligence on Automotive Innovation: A Glimpse into the Future of Driving
09.01.2025

The Impact of Artificial Intelligence on Automotive Innovation: A Glimpse into the Future of Driving

The automotive industry is experiencing a transformative shift, and at the center of this revolution is artificial intelligence (AI). From the development of fully autonomous vehicles to enhancements in key systems, AI is changing how we drive, maintain our vehicles, and secure them. While these advancements promise increased efficiency and convenience, they also raise new questions, particularly regarding cost, accessibility, and how car owners will interact with their vehicles in the future. Let’s take a closer look at how AI is reshaping the automotive world and why it’s important for car owners to understand these changes. Smarter Cars, Smarter Keys Artificial intelligence isn’t just revolutionizing self-driving cars—it’s also transforming the traditional car key. What once required a physical key is now being replaced by more advanced, secure alternatives. With the rise of smart keys, biometric access, and mobile apps, car keys are becoming increasingly sophisticated. AI-powered keyless entry systems allow you to unlock and start your car without needing to take a physical key out of your pocket or bag. The car senses your presence and communicates wirelessly to grant access. Additionally, biometric keys such as fingerprint or facial recognition are gaining traction, ensuring that only authorized users can access the vehicle. These systems are nearly impossible to duplicate, offering an unparalleled level of security. While these innovations add layers of convenience, they also highlight the growing need for professional key replacement services to ensure your car's security isn’t compromised. Autonomous Vehicles: A Step Toward the Future The idea of self-driving cars has long been a futuristic concept, but AI is making it a reality. Although fully autonomous vehicles are not yet mainstream, the technology is evolving quickly. AI algorithms are able to process data from sensors, cameras, and radars in real-time, allowing the car to navigate without human input. While fully autonomous driving has the potential to reduce accidents caused by human error—responsible for over 90% of crashes today—there are still many challenges to overcome. Self-driving cars must be equipped with robust systems capable of handling emergencies and unpredictable situations, which are crucial for ensuring safety. Even if true autonomy is still a few years away, many modern vehicles already feature semi-autonomous capabilities, such as adaptive cruise control, automatic emergency braking, and automated parking. These features, powered by AI, offer significant improvements in driving safety and convenience. Predictive Maintenance: Preventing Problems Before They Happen Imagine a world where your car could tell you when it’s about to break down. With AI, this is becoming a reality. Predictive maintenance, powered by AI, is revolutionizing how we approach vehicle care. AI-driven systems can analyze your car’s performance in real-time, predicting when parts need servicing before they fail. Examples of Predictive Maintenance : Notifications for upcoming maintenance, such as oil changes or brake pad replacements. Alerts about issues like low tire pressure or a battery nearing its end. Suggestions for repairs based on your driving patterns, reducing the chances of unexpected breakdowns. By identifying potential issues before they become major problems, AI helps save you time and money, providing a smoother, more reliable driving experience. Enhanced Driving Experience AI is not only about improving vehicle performance but also enhancing your overall driving experience. Through smart technologies, driving has become more intuitive and enjoyable. Voice assistants, for example, allow you to control various functions hands-free, from adjusting climate settings to managing calls and navigation. AI also customizes your vehicle experience based on your preferences. Over time, AI learns your favorite seating positions, climate control settings, and even your regular routes, making every drive more comfortable. With AI-powered infotainment systems, you can enjoy real-time traffic updates, personalized music playlists, and even hands-free control over entertainment choices. These innovations make driving safer, more enjoyable, and tailored to your individual needs. Transforming Vehicle Security The introduction of AI in automotive security is setting new standards. As vehicles become increasingly connected, the potential for cyber threats rises. Fortunately, AI is being implemented to protect against these risks, offering peace of mind for car owners. AI-enhanced Security Features: Advanced Theft Protection : AI systems can detect unusual activities, like attempted break-ins, and alert you immediately via your smartphone. Geo-fencing : Some vehicles now allow you to create safe zones. If your car moves outside the designated area, you’ll receive an instant notification. Anti-Hacking Measures : As cars become more integrated with the internet, AI helps protect against cyberattacks, ensuring your vehicle's systems remain secure. These features not only protect your vehicle from theft but also provide you with more control over your car’s safety, no matter where you are. What This Means for Key Replacements As AI continues to evolve in the automotive industry, the process of replacing and programming car keys is becoming more complex. Advanced keys, such as those based on biometric authentication or smartphone applications, are more expensive to replace than traditional metal keys. Furthermore, these modern systems require specialized equipment and expertise to program properly. For car owners, it’s essential to stay informed about your vehicle’s key system. Always keep a spare key on hand and familiarize yourself with emergency unlocking features, so you're prepared if something goes wrong. Challenges of AI in Cars While the benefits of AI in automotive innovation are clear, there are also some challenges to consider. AI can drive up the cost of manufacturing and repairs, and adapting to new features can sometimes be overwhelming for drivers. High Costs : Implementing AI technologies in vehicles can increase both the initial price and the cost of repairs. Learning Curve : Some drivers may find it difficult to adapt to new, AI-driven features, especially if they are not technologically inclined. Dependence on Connectivity : Many AI-powered systems require an internet connection, which can be problematic in remote areas or locations with poor service. Being aware of these challenges will help you navigate the evolving automotive landscape and make informed decisions about your car’s technology. Embracing the Future of Driving Artificial intelligence is rapidly transforming the automotive industry, changing everything from how we drive to how we secure and maintain our vehicles. For car owners, these innovations bring immense convenience and enhanced security. But they also require a deeper understanding of the systems that power your car, from keyless entry to semi-autonomous driving features. As AI continues to develop, staying informed will help you make the best decisions for your lifestyle and budget. Whether you’re exploring new key technologies or considering a fully autonomous vehicle, the future of driving is undeniably shaped by AI—and it’s already here.

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