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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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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.

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Why You Should Consider Aftermarket Car Keys and Parts
16.07.2024

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Why You Should Consider Aftermarket Car Keys and Parts When it comes to replacing car keys or parts, many people assume they need to go straight to the dealership for original equipment manufacturer (OEM) options. However, aftermarket car keys and parts offer a reliable, affordable, and often superior alternative. By choosing aftermarket solutions, you can save money, enjoy wider availability, and even customize parts to better suit your needs. Here’s why you should consider aftermarket car keys and parts. 1. Cost-Effective Without Compromising Quality Let’s face it—car repairs and replacements can get expensive, especially when you go the OEM route. Aftermarket parts are produced by third-party manufacturers and are usually much more affordable. Significant Savings: You can often save up to 50% compared to dealership prices. Comparable Quality: Many reputable aftermarket manufacturers meet or exceed OEM standards, delivering reliable performance at a lower cost. The key is to do your research and purchase parts from trusted suppliers to ensure quality and longevity. 2. Greater Availability and Variety OEM parts are often tied to a specific car manufacturer, which can limit options and availability. Aftermarket parts, on the other hand, are widely accessible and come in a variety of styles, materials, and features. Easier to Find: Whether you drive a newer model or an older car, aftermarket keys and parts are readily available in stores and online. Tailored Choices: Aftermarket solutions allow for customization, such as upgraded key fobs or unique designs that match your personal style. This variety gives you more flexibility to find the part that best fits your budget and needs. 3. High-Quality Alternatives There’s a common misconception that aftermarket parts are of lower quality. In reality, many aftermarket manufacturers use advanced technology and durable materials to produce products that rival, or sometimes exceed, OEM quality. Rigorous Testing: Reputable aftermarket brands follow strict testing protocols to ensure durability and performance. Improved Features: Some aftermarket keys and parts may include enhanced features, such as better security systems or longer-lasting batteries for key fobs. By choosing the right provider, you can enjoy high-quality parts that work just as well as—or better than—OEM versions. 4. Faster and More Convenient Solutions Getting parts or keys from the dealership can be a time-consuming process, often requiring appointments or long waits for shipping. With aftermarket solutions, you can get replacements quickly and hassle-free. Quick Delivery: Many aftermarket suppliers offer fast shipping options, so you get what you need sooner. No Middleman: Skip the dealership markup and go straight to trusted providers. For car owners looking for fast and affordable replacements, aftermarket parts are the perfect solution. 5. Customization and Personalization One of the standout benefits of aftermarket car keys and parts is the ability to personalize your vehicle to suit your needs and preferences. Unique Designs: Choose key fobs with modern, sleek designs or personalized engravings. Performance Upgrades: Many aftermarket parts offer enhanced features, such as stronger key signal ranges or improved materials. Whether you want a stylish upgrade or improved functionality, aftermarket options let you add a personal touch to your vehicle. 6. Environmentally-Friendly Options Many aftermarket manufacturers focus on sustainability, offering eco-friendly solutions that help reduce waste. Recycled Materials: Some aftermarket parts are made using recycled materials, reducing environmental impact. Longer Lifespan: High-quality aftermarket parts can outlast some OEM options, reducing the need for frequent replacements. Choosing aftermarket parts can be a smart decision for both your wallet and the planet. 7. Supporting Small Businesses When you purchase aftermarket car keys or parts, you often support small businesses and independent manufacturers. This helps create a competitive market that benefits consumers. Affordable Pricing: Increased competition keeps prices lower for car owners. Innovation: Smaller manufacturers often push for innovation, delivering unique and improved solutions for vehicle owners. By opting for aftermarket solutions, you contribute to a market that prioritizes affordability, quality, and innovation. Why Aftermarket Is Worth It Aftermarket car keys and parts are a smart, affordable choice for car owners who want quality, reliability, and convenience. With a wide variety of options, high-quality alternatives, and opportunities for personalization, aftermarket solutions offer clear advantages over traditional OEM parts. Next time you need a replacement key or car part, consider exploring aftermarket options. By choosing carefully, you’ll save money, find the perfect fit for your vehicle, and enjoy greater flexibility—all without compromising on quality.

Why Your Car Remote Isn’t Working and How to Fix It
07.01.2025

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Car remotes have become an essential part of modern vehicle ownership, offering convenience and added security. However, when they stop working, it can lead to frustration and delays. If you’ve ever faced a malfunctioning car remote, don’t worry—you’re not alone. Here’s a guide to help you understand the common reasons why your car remote might fail and how you can fix the issue quickly and affordably. 1. Dead Battery: The Usual Suspect One of the most common reasons for a non-functional car remote is a dead battery. Over time, the small coin batteries in your remote lose their charge, making the remote unusable. Signs of a Dead Battery: Reduced range, inconsistent functionality, or complete failure to respond. How to Fix It: Replace the battery with a compatible CR-type coin battery. Check your car manual or the remote’s casing for the correct battery type. Pro Tip: Always keep a spare battery in your glove compartment to avoid getting stranded. 2. Signal Interference: The Invisible Barrier Signal interference can block communication between your remote and your car. This can happen in areas with high electromagnetic activity or if the remote’s signal is weakened. Common Causes: Proximity to cell towers, Wi-Fi routers, or even other key fobs . How to Resolve It: Move closer to your car and try again. Change your location if you’re in a crowded parking area. Keep your remote away from other electronic devices that might cause interference. Prevention Tip: Avoid storing your car remote near electronics when not in use. 3. Remote Needs Reprogramming Sometimes, a car remote loses its programming, which is essential for communicating with your car. This can happen after battery replacement, electrical system resets, or software glitches. Signs Your Remote Needs Reprogramming: The buttons don’t respond, or the remote only works intermittently. What You Can Do: Check your car manual for DIY reprogramming instructions. If DIY methods fail, consult a professional locksmith or your car dealer for assistance. Pro Tip: Always reprogram your remote immediately after replacing its battery to avoid compatibility issues. 4. Physical Damage: More Than Just Wear and Tear Daily use, accidental drops, or exposure to moisture can damage your car remote, leading to malfunction. The internal components, such as the circuit board, are particularly sensitive. Signs of Damage: Cracks on the casing, loose buttons, or water ingress. How to Address It: For minor issues, replace the remote casing or repair loose buttons. If the circuit board is damaged, you’ll need a replacement remote. Preventative Measures: Use a protective key cover to shield your remote from damage. Keep your remote away from water and extreme temperatures. 5. Faulty Car Receiver: The Problem Isn’t Always the Remote In some cases, the issue lies with your car’s receiver rather than the remote. If the receiver is damaged or malfunctioning, it won’t recognize signals from the remote. How to Diagnose: If multiple remotes fail to work with the same car, the receiver might be the issue. Test your remote on a similar vehicle, if possible, to rule out the remote as the problem. How to Fix It: Consult a professional mechanic to inspect and repair the car’s receiver system. General Tips to Keep Your Car Remote Functional Prevention is better than cure, especially when it comes to car remotes. Here are some tips to avoid future issues: Regular Maintenance: Inspect your remote periodically for wear and tear. Store It Safely: Keep your remote in a safe, dry place to avoid accidental damage. Backup Plan: Always have a spare key or remote handy for emergencies. Invest in a Tracker: Attach a Bluetooth tracker to your remote for easy location if it gets misplaced. When to Seek Professional Help While many car remote issues can be resolved with DIY methods, some problems require professional assistance. If your remote still doesn’t work after troubleshooting, consult a locksmith or an automotive specialist. They can help with repairs, replacements, and reprogramming at an affordable cost. Don’t Let a Faulty Remote Slow You Down A malfunctioning car remote can be a hassle, but most issues are fixable with a little know-how. Whether it’s a dead battery, signal interference, or physical damage, understanding the root cause will help you resolve the problem efficiently. With proper care and maintenance, your car remote will continue to offer the convenience and security you rely on every day.

The Environmental Impact of Car Manufacturing: A Deep Dive into Its Global Consequences
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The Environmental Impact of Car Manufacturing: A Deep Dive into Its Global Consequences

The automobile industry has long been a driving force of economic growth and technological advancement. However, beneath its sleek exteriors and high-speed innovations lies a significant environmental footprint. From the extraction of raw materials to the assembly line and eventual disposal, every stage of a car's life cycle carries substantial ecological consequences. As the world grapples with climate change and resource depletion, it is imperative to assess the environmental impact of car manufacturing and explore sustainable alternatives. Resource Extraction: The Hidden Cost of Manufacturing Before a car even reaches the production line, the journey begins with the extraction of raw materials. The automotive industry relies heavily on metals such as steel, aluminum, and lithium, all of which require energy-intensive mining operations. Steel and aluminum production involve large-scale mining activities that contribute to deforestation, soil degradation, and biodiversity loss. The World Steel Association estimates that steel production alone accounts for 7-9% of global CO2 emissions. The demand for lithium and cobalt, key materials in battery production, has led to extensive mining operations in countries like Chile and the Democratic Republic of Congo. These activities have been linked to water shortages, toxic waste, and human rights violations. The environmental impact of resource extraction does not end at the mines. Refining these materials also emits significant greenhouse gases and pollutants that affect both the atmosphere and local ecosystems. Energy Consumption and Carbon Footprint in Production The manufacturing process itself is a major contributor to carbon emissions. Producing a single vehicle requires immense amounts of energy, primarily derived from fossil fuels. Car factories depend on energy-intensive machinery for stamping, welding, painting, and assembling components, with most facilities still relying on non-renewable energy sources, exacerbating their carbon footprint. According to the International Energy Agency (IEA), the automotive industry accounts for roughly 10% of total global CO2 emissions. While traditional internal combustion engine (ICE) vehicles release an average of 4.6 metric tons of CO2 annually, even EV production is not emission-free due to battery manufacturing. Water Usage and Pollution in Car Manufacturing Water is a crucial resource in vehicle production, used for cooling systems, paint shops, and cleaning processes. On average, it takes up to 151 cubic meters of water to manufacture a single car. This excessive water consumption poses a severe strain on local water supplies, especially in arid regions. Furthermore, wastewater from factories often contains hazardous chemicals, heavy metals, and microplastics. If not properly treated, these contaminants can seep into local water bodies, affecting marine ecosystems and public health. Air Pollution and Toxic Emissions Beyond CO2, car manufacturing emits various pollutants that contribute to poor air quality and respiratory illnesses. The painting and coating processes release volatile organic compounds (VOCs), which contribute to smog formation and have been linked to lung diseases. Emissions from factory operations and power plants used to supply energy to car manufacturing facilities contribute to nitrogen oxides (NOx) and particulate matter pollution, leading to acid rain and cardiovascular diseases. Waste Generation and Recycling Challenges The car manufacturing process generates vast amounts of waste, from metal scraps and plastic components to hazardous chemicals and non-recyclable materials. While a large percentage of scrap metal can be recycled, many plastic and composite materials used in modern cars are difficult to process. With the rise of EVs, battery disposal is a growing concern. Many lithium-ion batteries contain toxic elements like lead and cadmium, posing environmental hazards if not properly recycled. Global Efforts Toward Sustainable Car Manufacturing Recognizing the urgency of reducing their ecological impact, car manufacturers are gradually shifting toward greener alternatives. Companies like Tesla and BMW are integrating solar and wind power into their production facilities to reduce reliance on fossil fuels. Some automakers are exploring the use of recycled aluminum, biodegradable plastics, and sustainable textiles to minimize waste. Many factories are implementing closed-loop water recycling systems to reduce water consumption and prevent pollution. Efforts to promote sustainability in the industry include: The use of renewable energy sources such as solar and wind in manufacturing plants. Innovative recycling programs that repurpose old car parts and materials. Improvements in energy efficiency within production lines to reduce emissions. Adoption of cleaner, alternative materials for car interiors and body structures. Electric Vehicles: A Double-Edged Sword? While EVs are often touted as the future of sustainable transportation, their production still presents environmental challenges. The extraction and refining of lithium, nickel, and cobalt require vast amounts of energy and water, sometimes offsetting the carbon savings of driving an EV. An EV’s overall sustainability depends on the energy grid it charges from. In coal-dependent regions, EVs may not offer a significant reduction in emissions compared to efficient hybrid vehicles. The Road Ahead for a Greener Auto Industry The environmental impact of car manufacturing is a multifaceted challenge that requires a collaborative effort from governments, corporations, and consumers. Transitioning toward sustainable production practices, investing in recycling infrastructure, and promoting clean energy solutions are crucial steps in mitigating the industry's ecological footprint. As consumers, we can contribute by supporting manufacturers committed to sustainability, opting for fuel-efficient or electric vehicles, and advocating for stricter environmental policies. The road to a greener automotive industry is long, but with continued innovation and commitment, a more sustainable future is within reach.

The Importance of Having a Spare Car Key: What Every Driver Should Know
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The Importance of Having a Spare Car Key: What Every Driver Should Know

When it comes to car ownership, many of us take pride in maintaining our vehicles. We keep up with oil changes, tire rotations, and insurance renewals. But there’s one crucial aspect that many drivers overlook: having a spare car key. It might seem like a small detail, but nearly 40% of car owners don’t have a backup key for their vehicle. That’s a risk you might not want to take. Let’s explore why having a spare car key is so important and how it can save you time, money, and frustration. The Hidden Risks of Having Only One Key You may think that having just one car key is fine—after all, you always know where it is, right? But life has a funny way of surprising us, and car keys get lost or damaged more often than you might think. Here are some common risks you face when relying on just one key: Lost Keys : Losing your only car key can leave you stranded. Whether you're in a rush for work or on your way to an important event, misplacing your key means you're stuck until you find it—or worse, until you get a replacement. Key Damage : Keys, like anything else, wear out over time. A bent or broken key can cause problems with your car’s ignition, and if it's your only one, you’re in for a headache. Lockouts : It’s easy to accidentally lock your keys inside your car. Without a spare key, you’ll need to figure out how to regain access—both costly and inconvenient. Theft : If someone steals your key, not only are you locked out of your car, but you also face a potential security risk. A spare key can give you quick access and peace of mind while you handle the situation. Why a Spare Key Is a Lifesaver Having a spare key is more than just a backup plan; it’s a practical solution that can save you in many situations. Here’s why having a spare key should be on your to-do list: Saves You Time : If you’ve ever lost a key, you know how time-consuming it can be to get a replacement. With a spare key, you can avoid the wait and get back on the road quickly. Prevents Expensive Lockouts : Getting locked out of your car is stressful and costly. Emergency situations like this can cost you not just time but money, and depending on the circumstances, you might even need additional assistance. Convenience for Multiple Drivers : If you share your car with a spouse, roommate, or family member, having a spare key allows both of you to have access without needing to coordinate every trip. Peace of Mind : With a spare key, you won’t have to worry about the “what if” scenarios. It’s a simple safety net that ensures you’re never completely stranded. Affordable Solutions for Replacing Your Car Key You might be wondering how to go about getting a spare key. Fortunately, the process has never been easier or more affordable. Gone are the days when you had to rely on expensive or complicated processes to secure a replacement key. Here are some practical ways to get a spare key: Online Key Replacement Services : Many services offer easy, affordable options for getting a spare car key. Simply upload a photo of your key, and you’ll receive a replacement. Automotive Dealerships : Dealerships provide spare keys for almost any car make or model. However, this option is often more costly and may require you to bring the car in for verification and programming. How to Choose the Right Key Replacement Option When deciding on how to get a spare key, consider these factors: Cost : Depending on the service or method you choose, prices can vary. Evaluate your budget and the type of key your car requires before proceeding. Convenience : For some, the most convenient option is one that doesn’t require in-person visits. Research which option offers the best balance between time and convenience for your needs. Speed : Depending on your urgency, choose an option that fits your timeframe. Some services offer express options, while others may take longer. Don’t Wait Until It’s Too Late Many car owners don’t think about getting a spare key until they’re faced with an emergency. Don’t let that be you. Having a backup key is a small investment that can save you from significant stress and financial strain down the line. Take action today and make sure you have a spare key for your vehicle. Whether it’s for a just-in-case moment or for daily convenience, having that extra key can make all the difference when you need it most.

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