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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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Simple Tips to Free a Stuck Lock: What You Need to Know
29.10.2024

Simple Tips to Free a Stuck Lock: What You Need to Know

Locks are meant to provide security, but when they seize up, they can leave you feeling frustrated and helpless. Dealing with a stuck lock is more common than you might think, and thankfully, there are affordable and effective solutions to get it working smoothly again. Whether it's a car door, trunk, or your home lock, here are some tried-and-true methods to free up a jammed lock. Why Locks Seize Up Understanding the causes behind a stuck lock can help you prevent it from happening in the future. Locks can seize up for various reasons: Dirt and Debris : Over time, dust, grime, or even small particles can accumulate inside the lock mechanism, making it harder for the internal parts to move smoothly. Rust and Corrosion : Exposure to moisture, humidity, or salty air can lead to rust buildup on metal parts within the lock, which can prevent movement. Lack of Lubrication : Locks need to be lubricated occasionally to ensure smooth operation. Without lubrication, friction increases, and the lock may eventually jam. Now, let’s look at some simple steps to tackle a seized lock. Step 1: Use Graphite Powder or Dry Lubricant The first thing to try is applying a lubricant, but be careful about what type you use. Wet or oil-based lubricants can attract dust, which eventually clogs the lock. Graphite Powder : This is one of the best options for freeing up a stuck lock. Sprinkle a small amount of graphite powder into the keyhole, insert the key, and gently move it back and forth. This spreads the graphite, reducing friction and allowing the lock components to move more freely. Dry Lubricants : These are specifically designed for locks and are ideal for situations where you want to avoid residue buildup. Spray a small amount into the lock, then insert the key and gently turn it. Pro Tip : Avoid using regular WD-40 or other oil-based products, as they may lead to a buildup over time, making the problem worse. Step 2: Try the Key with Gentle Force If lubrication alone doesn’t do the trick, the next step is to use a little gentle force with your key. Be cautious here; applying too much force could break the key inside the lock. Insert the Key : Once the lubricant has been applied, insert the key fully into the lock. Wiggle Carefully : Gently wiggle and turn the key without applying too much force. This movement may help distribute the lubricant further and gradually loosen up any stuck components. Caution : If you feel excessive resistance, don’t force the key. Forcing it can cause damage or even snap the key, which would require additional assistance to remove. Step 3: Warm Up the Lock (Especially Useful for Cold Weather) Cold temperatures can cause locks to seize due to ice or metal contraction. If you suspect the cold is the issue, warming up the lock can be effective. Use a Hair Dryer : Direct warm air onto the lock for several minutes to allow the metal to expand and the ice (if any) to melt. Heat the Key : You can also try warming the key slightly with a lighter, but exercise caution and make sure it isn’t too hot before inserting it into the lock. Safety Note : Avoid open flames directly on the lock itself, as this can damage surrounding surfaces or even warp the lock mechanism. Step 4: Use a Vinegar Solution for Corroded Locks If rust is the culprit, vinegar is a great household solution for loosening rust and corrosion in a lock. Apply Vinegar : Put a few drops of vinegar on the key, insert it into the lock, and let it sit for a minute or two. Vinegar can help dissolve light rust, making it easier to turn the key. Follow with Lubricant : After using vinegar, apply a small amount of graphite powder or dry lubricant to ensure the lock remains smooth and functional. Step 5: Work with Compressed Air to Remove Debris If dirt or debris has accumulated inside the lock, compressed air is a quick and efficient way to clear it out. Blow Out Dust : Use a can of compressed air and direct the nozzle into the keyhole. Short bursts of air can blow out dust and small debris that may be obstructing the mechanism. Follow Up : After using compressed air, it’s a good idea to add a dry lubricant to prevent any remaining dust from causing future jams. How to Prevent Lock Seizure in the Future Once you’ve successfully freed a seized lock, it’s helpful to take steps to prevent it from happening again. Here are some preventive tips: Regularly Lubricate : Use a dry lubricant or graphite powder once or twice a year, especially if you live in a humid or dusty area. Keep Locks Clean : Wipe off any visible dirt or dust around the lock mechanism. If the lock is exposed to elements (like outdoor or car locks), covering it can help keep debris and moisture out. Avoid Overusing Keys : If your key shows signs of wear, consider getting a replacement. Worn-out keys can cause more friction inside the lock, leading to jams. When to Seek Professional Help Sometimes, despite your best efforts, a lock just won’t budge. In cases where the lock is significantly damaged, heavily corroded, or if the key breaks inside, it’s best to reach out for professional assistance. A professional has specialized tools and expertise to address these issues without causing further damage. Taking Care of Your Locks A stuck lock can be an inconvenience, but by following these simple steps and using a little patience, you can often resolve the issue without professional help. Keeping locks in good condition with regular care is the key to ensuring they function smoothly for years to come.

KEY COVERS: WHAT DO YOU NEED TO KNOW?
05.02.2025

KEY COVERS: WHAT DO YOU NEED TO KNOW?

What is a Key Cover? A key cover , often referred to as a key shell or key case, is the outer part of your key. It houses the electronic board, chip, and battery but excludes the internal electronics themselves. If your key casing is damaged, there’s no need to replace the entire key – just changing the key cover can restore its durability and usability while saving you money. When Do You Need a New Key Cover? You might need a key cover replacement when: The buttons on your key become worn out or stop responding. The outer case cracks, exposing the internal electronics. The key mechanism no longer functions smoothly. You want to refresh the appearance of your key with a new, sturdy shell. Instead of struggling with a faulty key, simply replace the cover and extend the lifespan of your original key! How to Choose the Right Key Cover? When selecting a replacement key cover, consider the following factors: Button Layout: Ensure that the number of buttons and their symbols match your existing key. Blade Shape: If your key includes an integrated blade, make sure the new shell accommodates it correctly. Quality: A good-quality key cover ensures a snug fit, smooth functionality, and long-lasting durability. At MR-KEY , we offer a variety of key covers designed to match your specific car model perfectly, providing both aesthetics and functionality. How to Change Your Key Cover? Replacing your key cover is simple and doesn’t require professional assistance. Here’s how: Purchase a compatible key cover from our website. Open your old key case carefully. Transfer the electronic board and chip from your original key to the new key cover . Reassemble the key, ensuring all components fit securely. Test the buttons and functions to confirm everything is working properly. For step-by-step guidance, we provide video tutorials on our website, showing you exactly how to change your key shell and even replace the battery if needed. What Else Can You Change When Replacing the Key Cover? While changing your key cover, it's the perfect time to: Replace non-functional click buttons on your key’s electronic board. Change the battery since you're already disassembling the key, ensuring it lasts longer. At MR-KEY , we strive to make key replacements easy, affordable, and accessible to everyone. Explore our website to find the perfect key cover, key cutting services, and useful video guides to help you maintain your car key like a pro!

Are Key Fobs Waterproof? A Comprehensive Guide to Keeping Your Key Fob Safe
21.01.2025

Are Key Fobs Waterproof? A Comprehensive Guide to Keeping Your Key Fob Safe

In an era of advanced automotive technology, key fobs have become an essential part of modern driving. From unlocking doors to starting engines remotely, these small yet powerful devices are a marvel of convenience. However, one question often looms in the minds of car owners: are key fobs waterproof? With water being a common hazard in everyday life, understanding the limitations and care requirements of your key fob is crucial. Understanding Key Fob Technology Key fobs are more than just electronic keys; they are compact computers that communicate with your car. Using radio frequency (RF) technology, they transmit encrypted signals to your vehicle, enabling features like remote locking, engine start, and even personalized settings. This intricate technology is housed in a small casing that protects the internal components. While key fobs are designed to endure daily wear and tear, their resilience to water varies. Some models offer water resistance, but this is not synonymous with being fully waterproof. The degree of water resistance depends on the design and build quality of the key fob, which can differ significantly between manufacturers and models. Are Key Fobs Waterproof or Water-Resistant? The terms “waterproof” and “water-resistant” are often used interchangeably, but they have distinct meanings. Waterproof indicates that a device can be submerged in water without damage, while water-resistant means it can withstand splashes or brief exposure to water but not submersion. Most key fobs fall into the latter category. For example, some car manufacturers claim their key fobs can handle minor splashes or light rain. However, prolonged exposure to water or immersion—such as dropping your fob into a pool—can damage the electronic components and render the device unusable. Global Standards and Variability Globally, there is no universal standard governing the water resistance of key fobs. Manufacturers often follow internal guidelines or industry best practices. In some regions, automakers have started offering key fobs with improved water resistance as a response to customer demands for greater durability. For instance, luxury brands like BMW and Mercedes-Benz have introduced models with enhanced protection, but even these devices are not guaranteed to survive complete immersion. Comparatively, in markets where cost efficiency is prioritized, such as in certain developing countries, key fobs may lack advanced water-resistant features. This variability underscores the importance of checking the specifications of your specific key fob model. What to Do If Your Key Fob Gets Wet Accidents happen, and it’s not uncommon for key fobs to encounter water. If your key fob gets wet, quick action can often prevent permanent damage. First, remove the key fob from water immediately and dry it thoroughly with a soft cloth. If possible, open the casing to allow air circulation and dry the internal components. Avoid using heat sources such as hair dryers, as excessive heat can warp the plastic casing or damage the sensitive electronics. In cases of significant water exposure, placing the key fob in a container of uncooked rice or silica gel packets can help absorb moisture. However, this is not guaranteed to save a severely water-damaged key fob. If the device does not work after drying, contacting a professional locksmith or dealership for repair or replacement is the best course of action. Tips for Protecting Your Key Fob To minimize the risk of water damage, there are several precautions you can take: Use a protective case or cover designed specifically for key fobs. These accessories provide an added layer of protection against moisture and physical impacts. Avoid placing your key fob in pockets or bags where it may come into contact with liquids, such as water bottles or spilled drinks. Store your key fob in a designated dry area when not in use, particularly in environments where water exposure is likely, such as beaches or pools. The Future of Waterproof Key Fobs As technology advances, so does the potential for more robust key fobs. Automotive manufacturers are exploring the use of advanced materials and sealing techniques to create truly waterproof devices. Additionally, the rise of smartphone-based digital keys may eventually render physical key fobs obsolete, eliminating concerns about water damage altogether. Internationally, innovations in waterproofing technology are being driven by consumer demand and environmental considerations. For example, in regions with high humidity or frequent rainfall, automakers are under pressure to offer more durable solutions. As a result, future key fobs may combine water resistance with other features, such as solar charging or biometric security. Navigating the Realities of Key Fob Care Key fobs are indispensable in modern driving, but they are not invincible. While some offer limited water resistance, the majority are vulnerable to prolonged exposure or immersion. Understanding these limitations and taking proactive measures to protect your key fob can save you time, money, and frustration. As technology evolves, the prospect of waterproof or entirely digital keys becomes more realistic. For now, car owners should familiarize themselves with the specifications of their key fobs and follow best practices for care. Whether you’re navigating a sudden downpour or an accidental spill, a little knowledge and preparation can go a long way in safeguarding your key fob and ensuring uninterrupted access to your vehicle.

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

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

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.

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