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What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them

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  • What You Need To Know About BMW  Swirl Flaps and How To Solve The Problem With Them
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25.03.2024

 

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 flapss:

 

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 Benefits of Smart Car Keys: A Leap Into the Future of Automotive Convenience
17.06.2024

The Benefits of Smart Car Keys: A Leap Into the Future of Automotive Convenience

Smarter, Simpler, Safer Imagine walking toward your car, and instead of fumbling through your bag or pockets for keys, your vehicle recognizes your presence and unlocks itself. This convenience is not a futuristic concept—it’s the reality of smart car keys, an innovation that has redefined automotive technology. As vehicles become more advanced, smart keys are becoming indispensable for drivers seeking security, convenience, and style. But what exactly makes smart keys so revolutionary? Let’s explore their features and benefits. What Are Smart Car Keys? Smart car keys, also known as proximity keys or keyless entry systems, use advanced technology to simplify the interaction between you and your vehicle. Unlike traditional keys or even remote fobs, smart keys rely on radio frequency identification (RFID) or Bluetooth to communicate with your car. Once within a specific range, the car recognizes the key, unlocking the doors and enabling push-button ignition. These keys offer far more than just access and starting capabilities. They are designed to enhance security and integrate features like personalized settings, making them a step ahead of conventional systems. From luxury sedans to electric vehicles, smart keys are rapidly becoming a standard feature in modern cars. The Key Benefits of Smart Car Keys One of the most noticeable advantages of smart keys is their unmatched convenience. Imagine walking to your car with hands full of groceries or during a rainstorm. With a smart key in your pocket or bag, the car automatically unlocks as you approach, eliminating the need to dig around for your keys. Similarly, starting the engine is as simple as pressing a button, streamlining the driving experience. Smart keys also prioritize security. Unlike traditional keys that can be duplicated, smart keys use encrypted communication to connect with the vehicle. This encryption ensures that unauthorized users cannot access or start the car. Some smart systems even include anti-theft mechanisms that disable the engine if the key is not detected nearby, adding an extra layer of protection. Moreover, many smart keys are equipped with customizable features. Depending on the car, they can store and recall settings such as seat positions, climate control preferences, and mirror adjustments. Some even allow for remote control of the car via a smartphone app, enabling users to lock, unlock, or preheat their vehicle with a simple tap on their phone. Smart Keys Around the World: Trends and Adoption The use of smart keys is growing globally, with different regions adopting the technology at varying rates. In developed markets like North America, Europe, and Japan, smart keys have become standard in mid-range and luxury vehicles. These regions, driven by technological advancements and consumer demand, are setting the pace for smart key adoption. In emerging markets, traditional keys are still more prevalent due to their affordability. However, the demand for smart keys is on the rise, especially among buyers of premium cars. As automotive manufacturers expand their offerings, smart keys are becoming accessible to a broader audience. The future of smart keys is even more exciting. Many automakers are exploring app-based systems and biometric authentication, such as fingerprint or facial recognition. These innovations aim to further integrate vehicles into the digital ecosystems of their owners, offering seamless connectivity and enhanced personalization. Challenges of Using Smart Keys While smart keys bring significant advantages, they are not without their challenges. One of the primary concerns is the cost of replacement. Losing a smart key can be expensive, with replacements often requiring programming by a dealership or specialized locksmith. This cost is significantly higher than that of traditional keys. Another issue is the potential vulnerability to hacking. Relay attacks, where thieves amplify the signal from a smart key to unlock a vehicle, are a known risk. While manufacturers are continually improving encryption methods, owners should take precautions, such as using signal-blocking pouches, to protect their keys. Battery life is another consideration. Smart keys depend on batteries, and if the battery dies unexpectedly, you may find yourself locked out of your car. Most manufacturers include a physical backup key or emergency override options, but staying mindful of your key’s battery status is essential. Why Smart Keys Are the Future Smart keys represent more than just a technological advancement—they symbolize a shift in how we interact with vehicles. Their ability to enhance convenience, security, and personalization makes them a must-have feature for modern drivers. As cars become increasingly integrated with digital ecosystems, smart keys are expected to evolve, incorporating features like biometric security and deeper smartphone integration. For drivers, this evolution means a more intuitive and tailored experience. From automatically adjusting settings based on the detected key to integrating with smart home systems, smart keys are paving the way for a connected and seamless future. Embrace the Smart Key Revolution Smart car keys are more than a luxury; they are becoming an essential tool in modern driving. Their convenience, advanced security, and customizable features make them a game-changer in automotive technology. However, as with any innovation, understanding their potential challenges and how to address them is crucial. Whether you’re unlocking your car as you approach or starting the engine with a simple button press, smart keys represent a leap forward in convenience and functionality. As automotive technology continues to advance, smart keys are leading the charge, offering a glimpse into a future where cars seamlessly adapt to our needs.

The Secret Life of Car Keys: Unlocking Their Evolution and Hidden Potential
02.04.2024

The Secret Life of Car Keys: Unlocking Their Evolution and Hidden Potential

In the modern age of technology, where smartphones dominate our lives, it’s easy to overlook the small yet significant gadgets we use daily—like car keys. What was once a simple metal tool has now transformed into a sophisticated device, integrating technology, convenience, and security. But how did we get here? And what surprising secrets do car keys hold? This journey into the secret life of car keys will reveal their evolution, innovative features, and potential future. From Metal to Smart: A Brief History of Car Keys The history of car keys is a fascinating reflection of automotive innovation. In the early 20th century, cars relied on simple ignition switches, but by the 1940s, car keys became standard. These were basic metal tools designed to operate mechanical locks and ignitions. The 1980s marked a significant milestone with the introduction of remote keyless entry systems. Suddenly, unlocking a car was as simple as pressing a button, a feature that quickly became a standard in most vehicles. By the early 2000s, car keys had evolved into smart keys, incorporating technology that allowed keyless ignition and enhanced security. These advancements weren’t just about convenience—they were a response to rising concerns about car theft. Today, digital car keys take innovation even further. Some manufacturers now allow drivers to unlock and start their vehicles using smartphone apps, integrating biometric authentication for added security. This evolution highlights how far we’ve come from the humble metal key. Hidden Features: What Your Car Key Can Do Modern car keys are more than just tools for unlocking and starting your car—they’re packed with features that many drivers don’t even realize exist. Panic Button : Most car key fobs have a panic button, which emits a loud alarm to deter potential threats or help locate your car in a crowded area. Remote Start : Certain keys allow you to start your car from a distance, a lifesaver in extreme weather conditions. Window Control : Some key fobs can roll your windows up or down remotely, perfect for venting a hot car before stepping inside. Valet Mode : This feature limits the speed and access to certain compartments when you hand over your keys, enhancing security. These features reflect how car keys have grown beyond their traditional roles, becoming integral to the driving experience. Car Keys Across the Globe: Different Innovations, Same Purpose Car key technology isn’t uniform—it varies across regions, catering to different needs and preferences. Asia : In countries like Japan and South Korea, biometric car keys are becoming the norm. Fingerprint or facial recognition ensures that only authorized users can access the car. Europe : European car manufacturers emphasize eco-friendly designs, often using recycled materials in key fobs. North America : Remote start and smartphone integration are popular features, reflecting the region’s focus on convenience. These regional differences underline how car keys adapt to meet the diverse demands of global markets. Challenges with Modern Car Keys While advanced car keys offer unparalleled convenience, they’re not without drawbacks. High Replacement Costs : Losing a smart key can be expensive, with replacements costing hundreds of dollars due to programming requirements. Security Risks : Keyless entry systems can be vulnerable to relay attacks, where thieves intercept and amplify the key’s signal to gain access to the car. Battery Dependency : Smart keys rely on batteries, and a dead battery can leave drivers stranded. To address these challenges, drivers are encouraged to keep spare keys, invest in signal-blocking pouches, and regularly check key fob batteries. The Future of Car Keys As technology advances, the future of car keys looks exciting. Biometric keys are expected to become mainstream, offering unmatched security through fingerprint or retina scanning. Additionally, digital keys, which allow drivers to control their vehicles entirely through smartphones, are gaining traction. In the coming years, sustainability will likely play a bigger role. Manufacturers are exploring ways to make key fobs more environmentally friendly, such as using biodegradable materials or incorporating solar charging for battery-free operation. These innovations signal a future where car keys become even more sophisticated, secure, and eco-conscious. Why Car Keys Matter More Than You Think Car keys are small devices with big responsibilities. Beyond their practical use, they symbolize how technology can integrate seamlessly into our lives. Understanding their features and potential can help you make informed decisions, whether it’s upgrading to a smart key or taking precautions to protect your investment. Pro Tips for Car Key Maintenance : Keep a Spare Key : Always have a backup in case of loss or damage. Check Battery Life : Replace key fob batteries regularly to ensure consistent performance. Use Protective Covers : These prevent wear and tear, especially in extreme weather conditions. By caring for your car keys, you ensure their longevity and reliability, saving you from unexpected hassles. More Than Just a Key Car keys have evolved from simple metal tools into complex devices that enhance security, convenience, and connectivity. As technology continues to advance, their role in our daily lives will only grow. By understanding their capabilities and challenges, you can fully appreciate the innovation behind these essential tools. The next time you hold your car key, take a moment to think about its journey—from the past to the future, it’s a small device with a story as dynamic as the automotive industry itself.

How to Maintain and Extend the Life of Your Car Keys
10.07.2024

How to Maintain and Extend the Life of Your Car Keys

Your car keys are more than just tools to unlock and start your vehicle—they’re essential components for your car's convenience and security. Taking proper care of them can prevent unexpected failures and ensure they last for years. Here are seven easy and practical tips to help you keep your car keys in the best condition possible. 1. Keep Your Keys Clean and Dry Why It Matters: Moisture and dirt are the biggest enemies of car keys, particularly electronic fobs. Exposure to these elements can cause internal corrosion and failure. How to Do It: Avoid Moisture: Keep your keys away from water, rain, and high humidity. If they accidentally get wet, dry them immediately with a soft, absorbent cloth. Regular Cleaning: Gently wipe your keys with a clean cloth to remove dirt and dust. For crevices around buttons, use a cotton swab to clean hard-to-reach areas. 2. Handle Your Keys with Care Why It Matters: Dropping, tossing, or mishandling your keys can cause physical damage or misalign internal components, rendering them unusable. How to Do It: Avoid Drops: Be mindful when handling your keys. Attach them to a lanyard or key holder for better grip and to reduce accidental drops. Use a Protective Key Cover: A well-fitted key cover adds an extra layer of protection against scratches, drops, and general wear and tear. Plus, they’re available in various styles to match your preferences. 3. Replace Key Fob Batteries on Time Why It Matters: A weak battery can lead to your car key fob failing to work when you need it most, leaving you stranded or locked out. How to Do It: Watch for Warning Signs: If your key fob’s range decreases or requires multiple presses to function, the battery is likely weak and needs replacement. Replace Properly: Follow your car’s manual for step-by-step instructions on changing the battery. Using the correct battery type ensures reliable performance. 4. Protect Your Keys from Extreme Temperatures Why It Matters: Excessive heat or cold can harm the electronic components inside your key fob or damage the metal of traditional keys. How to Do It: Avoid Direct Sunlight and Heat: Don’t leave your keys exposed to the sun on your dashboard or near heaters. Extreme heat can warp materials and damage internal circuits. Keep Away from Freezing Temperatures: In colder months, avoid leaving your keys in your car or outside for prolonged periods, as freezing conditions can impact their functionality. 5. Rotate and Use Spare Keys Why It Matters: Spare keys can deteriorate if left unused for long periods. Regularly using them ensures they remain functional and ready in emergencies. How to Do It: Alternate Keys: Use your spare key occasionally to keep it in good working condition. This prevents any surprises when you actually need it. Safe Storage: Store spare keys in a dry, cool place, away from moisture, heat, or any magnetic devices that could interfere with their programming. 6. Avoid Overloading Your Keychain Why It Matters: A heavy keychain might seem harmless, but the extra weight can wear down your car’s ignition switch or damage your key over time. How to Do It: Limit What You Carry: Stick to the essentials—remove unnecessary keys, charms, or heavy accessories. Use Lightweight Keychains: Choose minimalistic and lightweight keychains to prevent undue stress on the ignition and the key itself. 7. Regularly Inspect for Wear and Tear Why It Matters: Keys, especially those with buttons or electronic components, can show signs of wear over time. Early detection helps avoid complete failure. How to Do It: Look for Physical Damage: Check for cracks, faded buttons, or scratches that might affect functionality. Seek Professional Help: If you notice significant wear or damage, consult a professional locksmith or dealership for repairs or replacement. Ignoring issues could lead to bigger, costlier problems down the line. Why Car Key Maintenance is Worth Your Effort Properly maintaining your car keys ensures they stay reliable, functional, and secure for years to come. Whether it’s a traditional key or a modern electronic fob, these small actions can save you from costly replacements or inconvenient malfunctions. Taking care of your keys isn’t just about preventing problems—it’s also about convenience, peace of mind, and getting the most out of your vehicle’s features. By following these simple tips, you’ll keep your car keys in top shape and avoid the stress of unexpected failures.

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.

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