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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 Complete Guide to Car Key Cutting: Everything You Need to Know
19.06.2024

The Complete Guide to Car Key Cutting: Everything You Need to Know

Unlocking the Mysteries of Car Key Cutting Have you ever been in a situation where you needed a spare car key or had to replace a lost one? Car key cutting is an essential process for creating duplicate keys or replacements, but it’s often misunderstood. From traditional keys to modern transponder and smart keys, the art of key cutting has evolved dramatically with advancements in technology. This guide will walk you through the key cutting process, its types, and when professional help is required, helping you navigate the complexities of car key duplication with confidence. What Is Car Key Cutting? Car key cutting is the process of creating a new key that matches the physical shape and specifications of your vehicle’s locks and ignition. This process involves cutting the metal key blade to fit the car’s lock mechanism precisely. For modern cars, this may also include programming the electronic components of the key, such as transponder chips or remote controls. The method used for cutting a car key depends on the type of key and the car model. Traditional keys are simpler to cut, while transponder and smart keys require specialized tools and expertise. Types of Car Keys and Cutting Methods Traditional Keys These are the classic mechanical keys used in older vehicles. Cutting these keys involves duplicating the grooves and ridges of the original key using a key-cutting machine. Transponder Keys Found in most modern cars, transponder keys contain a microchip that communicates with the car’s computer. After cutting the blade, these keys must also be programmed to function. Smart Keys These advanced keys use wireless communication to interact with the car. They don’t require physical cutting but involve programming to sync with the vehicle. Each type of key requires a different approach and level of expertise, making it essential to know what kind of key you have before proceeding with duplication. The Key Cutting Process: Step by Step Identify the Key Type Determine whether you have a traditional, transponder, or smart key. This will dictate the tools and process needed for cutting and programming. Gather Required Information Provide the key cutter with details about your car, such as the make, model, and year. For some keys, a Vehicle Identification Number (VIN) may be required. Cutting the Key Blade For traditional and transponder keys, the blade is cut using a key duplicator or a laser key-cutting machine. Precision is crucial to ensure the key fits perfectly in the lock. Programming (if required) For transponder and smart keys, the key must be programmed to the car’s computer system. This step may require specialized equipment or professional expertise. When to Seek Professional Help While traditional keys can often be duplicated at local hardware stores, transponder and smart keys typically require specialized tools and knowledge. Professional locksmiths and dealerships are equipped to handle these advanced key types, ensuring proper cutting and programming. Reasons to choose a professional: Complexity: Smart and transponder keys require technical expertise. Accuracy: Professionals use precise equipment to ensure the key functions flawlessly. Programming Needs: Only trained specialists can program keys to sync with your vehicle. Cost of Car Key Cutting The cost of cutting a car key varies depending on the type of key and the service provider. Traditional keys are the most affordable, typically costing between $10 and $50. Transponder and smart keys, however, can range from $50 to $300 or more due to the additional programming required. Tips to save money: Have a spare key: This simplifies the duplication process and reduces costs. Compare prices: Contact multiple locksmiths or dealerships to find the best deal. Be Prepared for Every Key Emergency Car key cutting is a vital service for any car owner, whether you’re duplicating a spare key or replacing a lost one. Understanding the process and knowing when to seek professional help can save you time, money, and frustration. By staying informed and proactive, you can ensure that your vehicle remains accessible and secure, no matter what challenges arise.

The Environmental Impact of Car Manufacturing: A Deep Dive into Its Global Consequences
24.02.2025

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 Evolution of the Car Key: Unlocking the Future of Mobility
16.04.2024

The Evolution of the Car Key: Unlocking the Future of Mobility

A Journey Through Time Imagine holding a car key from 1920 and trying to start a modern electric vehicle. The mere concept of what a “car key” represents has undergone a profound transformation, reflecting changes in automotive technology, security, and convenience. From simple mechanical tools to sophisticated digital devices, car keys have evolved alongside the vehicles they unlock. But how did we get here, and what does the future hold for this essential accessory? The Humble Beginnings: Mechanical Keys The car key’s story begins in the early 20th century, a time when cars were a luxury rather than a necessity. Early automobiles didn’t require keys as we know them today. Drivers used manual cranks to start the engine, a labor-intensive and often hazardous process. By the 1920s, the first generation of mechanical car keys emerged. These keys were simple, utilitarian devices used to lock the vehicle’s ignition or steering mechanisms. They marked the beginning of an era where security and convenience started to merge. Key features of early car keys included: A straightforward design, often a single-sided cut metal key. Limited security, as locks were rudimentary and easily picked. Despite their simplicity, these keys represented a revolutionary leap in vehicle security and usability. Entering the Electric Era: Ignition and Beyond The 1940s and 1950s saw a significant evolution in car keys with the introduction of ignition locks. These new systems required a key to start the vehicle, making cars both safer and easier to use. Manufacturers like Chrysler pioneered these innovations, creating a standard that would dominate for decades. The electric ignition systems introduced: A dual-purpose functionality: keys could unlock doors and start engines. Enhanced security, discouraging theft by eliminating manual starts. However, as automotive theft techniques became more sophisticated, so did the need for better security measures. The Advent of Remote Keyless Entry The 1980s and 1990s marked a pivotal period in the evolution of car keys with the introduction of remote keyless entry (RKE) systems. These keys included a built-in transmitter, allowing drivers to lock and unlock their cars with the push of a button. This innovation redefined convenience and set the stage for a digital future. Key highlights of RKE systems: Enhanced security with encrypted signals to prevent unauthorized access. Added features such as panic buttons and trunk releases. For many, the ability to control their car remotely became synonymous with modern luxury and convenience. Smart Keys and Digital Transformation As the 21st century arrived, car keys underwent another transformation, becoming “smart.” These keys, often shaped more like fobs than traditional keys, allowed for keyless ignition and entry. Equipped with proximity sensors, smart keys automatically unlock doors and start engines when the fob is nearby. Features of smart keys include: Passive entry and start systems, eliminating the need to physically insert a key. Advanced encryption technologies to combat modern car theft tactics. Automotive giants such as Mercedes-Benz and BMW led the charge in incorporating smart keys into their vehicles, reflecting a growing trend toward connectivity and automation. Biometric and Smartphone Integration: A Glimpse into the Future Today, the car key is on the brink of another revolution. Biometric systems and smartphone integration are becoming increasingly common, offering even greater security and convenience. Emerging trends include: Fingerprint and facial recognition systems : Some luxury vehicles now allow drivers to unlock and start their cars using biometric data. Digital keys : Smartphone apps are replacing physical keys entirely, enabling drivers to control their vehicles remotely. These innovations are part of a broader shift toward connected mobility. With digital ecosystems becoming central to the automotive experience, car keys are evolving into multifunctional tools that integrate seamlessly with a driver’s digital life. Global Perspectives: Trends Across Markets The evolution of car keys has not been uniform across the globe. In developed markets such as North America, Europe, and Japan, digital and smart keys dominate, reflecting advanced technological adoption. In contrast, mechanical keys remain prevalent in emerging economies, where affordability and simplicity often take precedence over cutting-edge innovation. Automotive manufacturers are responding to these differences by tailoring their offerings. For instance: In premium markets, luxury carmakers emphasize smart and biometric key systems as standard. In cost-sensitive regions, manufacturers offer basic mechanical or remote keys as a practical solution. These distinctions highlight the diverse ways in which the car key continues to evolve, shaped by cultural, economic, and technological factors. The Challenges Ahead: Balancing Innovation and Security While modern car keys offer unparalleled convenience, they also come with challenges. Cybersecurity threats, such as hacking and relay attacks, pose significant risks to digital and smart key systems. Industry experts emphasize the need for robust encryption and regular software updates to mitigate these risks. Moreover, the shift toward digital keys raises concerns about dependency on smartphones. What happens if a phone runs out of battery or malfunctions? Manufacturers are exploring hybrid solutions that combine digital and physical access to address such scenarios. Unlocking the Future The evolution of the car key mirrors the broader changes in automotive technology, from mechanical simplicity to digital sophistication. As we move toward an era of autonomous and connected vehicles, the humble car key is poised to become an even more integral part of our mobility experience. For now, car keys remain a fascinating blend of past, present, and future. Whether it’s a vintage metal key or a cutting-edge biometric system, they continue to unlock not just our vehicles but also the stories of innovation and progress. The next time you hold your car key—be it physical, smart, or digital—pause for a moment to appreciate the journey it represents. Who knows? In a few decades, we might be reminiscing about keys altogether as we step into fully autonomous, keyless vehicles.

How to Program a Car Key: A Step-by-Step Guide
19.06.2024

How to Program a Car Key: A Step-by-Step Guide

Lost Your Car Key Programming? Here's What to Do Have you ever lost your car keys or found yourself with a spare key that doesn’t start your vehicle? While the process of programming a car key might seem intimidating, it’s often simpler than you’d expect. In many cases, car owners can program keys themselves without needing a visit to a dealership. This guide walks you through the essentials of car key programming, helping you save time, effort, and potentially a significant amount of money. Understanding Car Key Programming: The Basics Car key programming is the process of syncing a key with a car's internal computer so it can communicate securely. Modern vehicles use transponder keys or smart keys equipped with chips that emit a unique signal. Without proper programming, these keys won’t function, even if they fit perfectly into the ignition. While older mechanical keys didn’t require programming, today’s advanced systems add a layer of security, reducing the risk of car theft. However, this added sophistication means that replacing or reprogramming a key is no longer as simple as cutting a piece of metal. Quick Tip: Check your vehicle’s owner manual to see if programming your car key is a DIY-friendly process, as some models allow self-programming, while others require professional tools. Step-by-Step Guide to Programming a Car Key Before starting, ensure you have all necessary tools and information: The vehicle’s owner manual. All keys that need programming, including the functional ones. Step 1: Access Programming Mode Start by sitting in the driver’s seat with all the doors closed. Insert the already functional key into the ignition and turn it to the “on” position (do not start the engine). Some vehicles require you to cycle the key between “on” and “off” positions a specific number of times to enter programming mode. Step 2: Add the New Key Once in programming mode, remove the functional key and quickly insert the new key into the ignition. Turn it to the “on” position. The vehicle’s security light may flash to indicate the key has been successfully programmed. Step 3: Test the Key After programming, remove the new key and test it to ensure it can start the car and unlock the doors. Note: Each car manufacturer has unique programming steps. Be sure to consult your owner’s manual or the manufacturer’s website for specific instructions. When Professional Help Is Needed While many vehicles allow for DIY key programming, others require specialized equipment or software that only dealerships or locksmiths can access. This is particularly true for luxury or high-end cars with advanced encryption and security features. If your DIY efforts fail, it’s best to seek help from a certified professional. Visiting a dealership is a reliable, albeit more expensive, option. Alternatively, professional locksmiths often provide programming services at a lower cost, making them a practical choice for many drivers. Costs and Considerations The cost of programming a car key varies significantly based on the vehicle’s make and model. For basic models, self-programming might cost nothing if you already have a functional key. However, professional programming can range from $50 to $300 or more, especially for smart keys or proximity fobs. To minimize costs: Have a spare key : Always keep a functional spare to simplify programming if a replacement is needed. Research costs : Call local locksmiths or dealerships to compare pricing. Empower Yourself with Knowledge Programming a car key doesn’t have to be a daunting task. With the right tools and information, many car owners can handle the process themselves, saving time and money. However, it’s essential to recognize when professional assistance is necessary, particularly for complex key systems. By understanding the basics of car key programming and following a step-by-step approach, you can ensure your vehicle remains secure and functional. So, whether it’s a spare key or a replacement, you now have the confidence to tackle the task or know where to turn for help.

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