Apr 27, Effective Tuning. The reason is that swirl flaps are some of the most problematic vehicle components and they cause serious damages. Swirl flaps are also known as tumble flaps or intake manifold runner flaps. They are small butterfly valves situated within the inlet manifold intake manifold just before the cylinder head intake ports.
This device can be found in most of the modern diesel and petrol automotive engines. The swirl flap is made from stainless steel and is smaller than the intake runner. The main role of the swirl flaps is to control and regulate the fuel to air ratio and to improve torque and emissions. As we said above, swirl flaps are intended to help the engine for better fuel-air mixing into the cylinder. They also help for more power, better torque at lower speed and reducing certain toxic emissions.
Swirl Motor Resistor Mod OM642
The swirl flap position is regulated by an electrical or vacuum-actuated servo mechanism. This mechanism is controlled by the ECU engine control unit. Typically, the swirl flaps are closed at idle or low speed. That way, they create a swirl additional turbulence in the intake manifold.
That swirling effect improves combustion when engine RPM is low, improves emissions and helps for better torque. As engine speed increases, for example after rpm, the swirl flaps become at a fully opened position. That way, they are parallel to the airflow and present no resistance. In other words, at higher speed, the swirl flaps have only a little effect on engine performance, so they allow the engine to function on its maximum power.
The swirl flaps are some of the most problematic components of almost every engine from every manufacturer. Here are some of the biggest problems that swirl flaps are causing:. In other words, those swirl flaps were prone to failure.
Intake Manifold Swirl Flaps Removal / Delete
In addition, the small metal screws holding each swirl flap to the spindle were not stable enough. They could become loose and break away. As you know, the swirl flaps and their screws are situated within the intake manifold.
Their location is a prerequisite for any broken part of the flap or the screw to enter the combustion chamber. This mechanical failure often leads to catastrophic engine damage such as damaged cylinder head, valves, injectors, pistons, turbo, etc. Another serious problem is that the intake swirl flaps often fowl due to the intake manifold tarry carbon deposits.They fit like a glove, nice and snug.
I liked how the oring made a a nice see as well as it seemed to be mad of a nice material that would last a while. It feels like removing the flaps with the carbon has let it breath a little more.
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You can hear a faint bit of turbo whistle or blowoff but otherwise it was really just peace of mind. The product quality is great and removing the bar and motor means that future trips into the motor will not require removal of the swirl flap plug which sucks to get off. Very easy to install and perfect fit. Engine woke up and has way more power since.
Nice side effect. Product fitment was simple and easy. No problems whatsoever. Very good quality, fitment was perfect, all in all very good product. Awesome job on these. They have a tight fit and work flawlessly. Created with Sketch. Toggle menu Gift Certificate Login or Sign Up 0. Super car territory AARodriguez Corp. Call AARodriguez Corp. RSS Syndication. MK4 Brakes 1. Replacement Parts Wheel Accessories. Bearings Bushings, bumpers and mounts Steering Struts and Shocks. Turbo Accessories VW Turbos.
You save. Yes, I understand this and am aware my car will not pass emissions testing.Mercedes Diesel GL, ML, R, E 320/350 OM642 Oil sucking eliminated/broken Y-intake fix
Current Stock:. Quantity: Decrease Quantity: Increase Quantity:. Share This Article.Swirl flaps are small butterfly valves located within the inlet manifold on modern diesel and petrol engines, they are designed to help regulate the fuel to air ratio, improve emissions and help generate better torque at low engine speeds. At light engine loads the flaps close, causing the air to swirl into the combustion chamber, the swirling affect aids combustion and helps to improve emissions and generate more torque.
After rpm the flaps are generally activated to a fully open position and have very little effect on engine performance and emissions. Leaking Manifolds Overtime the seals surrounding the flap spindle brakes down and causes pressurized air from the inlet manifold to leak to atmosphere. Carbon build up: Carbon from the EGR system along with oil from the breather system causes carbon to build up on the flaps, this reduces the intake manifold size and can hinder performance. Electronic actuators: Modern manifold designs incorporate an electronic actuator which opens and closes the flaps.
These actuators can fail, along with the position sensors, this can result in the flaps staying in the closed position and thus hindering performance, along with an engine management light and in some cases limp mode.
The process for removing the flaps depends on the design, in some cases the manifold is unbolted and the flaps physically removed, in other cases where the mechanical status of the flaps are good and the fault is due to an electronic actuator, the actuator function can be disabled and the flaps left in place. In our opinion very little, the reduction in emissions and performance at low engine speeds is almost unnoticeable and would only be relevant if no carbon build up had occurred, due to the fact that carbon build up begins as soon as the vehicle leaves the factory, the removal of the flaps is likely to result in increased performance and efficiency.
Full set of replacement seals to complete an oil cooler seal replacement. Includes all gaskets and seals for the items that must be removed in order to access the oil cooler. Consider purchasing new clips for the swirl flap motor, available below.
These are typically soaked in oil and will break when you try to remove them. There are 4 in total. Please select your vehicle in the filter above to show the version that your vehicle requires in the Add-Ons section below.
Please be sure to enter your vehicle above and check the fitment status below. You will need to remove the thermostat as part of removing the intake manifolds in order to reach the oil cooler. We strongly recommend using this oppurtunity to replace the thermostat, but if you plan on re-using your existing thermostat please add the thermostat gasket to your cart, available below.
Removing the intake manifolds requires removing the injector lines. The lines at the injector take a 17mm wrench, but there is not enough clearance to get a wrench around the line.
Therefore, we stock and recommend getting the special 17mm injector line socket below to take off the lines without damaging the lines or injectors. I spent nearly 2 hours trying to locate all these seals I need by myself and then I found this kit.
Great kit. Best price I've found anywhere. You don't need all the extra crap that Mercedes makes you buy, just the seals. Definitely get the little arm clips as those are a bear and always break. Sign In. By creating an account at IDParts. Reset Password. Is it: Actually In Stock? Many online stores do not stock parts and advertise products that they do not actually have.
Can my Ecdi run as well without swirl flaps? Hello all, This is my first time posting on the forum, but I have been pulling bits and bobs from it for some and have found some seriously useful threads from other members regarding the typical problems caused by the EGR system on the cdi's.
I've had a wee poke around and have noticed that the connecting rod from the actuating motor to the swirl flap pivots has come off, and there is no movement possible in the swirl flap mechanisms.
I am working under the assumption that the EGR has nicely gummed up the flaps along with everything else in the inlet manifold, and I'm planning to remove it and clean it up along with the EGR pipework. I'm also going to install the shunt posted by Dieselman to stop the EGR doing the same again. My question is this- Has anyone tried simply removing the swirl flaps? What would be the result? Would taking them out cause an engine management fault code or reduced fuel economy?
I'm assuming there must be a reason as people have posted about getting new manifolds when they snap one off trying to clean it.
Any advice would be most welcome before i tackle the wee buggers! I'd be interested to know too, would be a lot cheaper than replacing the whole manifold. Couldn't you just try and jam the flaps open since they've disconnected now anyway? That will tell you before hand what is likely to happen if they are permanently removed.
The flaps are typically closed at lower engine speeds where airflows are lower anyway, so that the throttling losses are minimized. The reason for all this complexity is to reduce smoke - particularly at lower rpms and high loads. The BMW owners you report are probably seeing marginally better fuel economy and performance through less pumping work.Mercedes OM V6 vehicles suffer issues with the intake manifold, the swirl flaps within this manifold are controlled by an external operating rod.
This is made of a poor-quality plastic which wears prematurely. Swirl flaps are designed to aid with low down torque and fuel economy. Over time the plastic wears at the connection points with the manifold, creating an oval shape which eventually lifts up the rod leading to breakages causing the faults noted above.
A physical inspection of the intake manifold will quite often show that the rod has snapped in half. The wear is caused by the plastic being the wrong specification for this task, it cannot deal with the heat and constant mechanical motion involved.
These intake manifolds can also get severely clogged up with carbon deposits which can lead to the swirl flaps becoming harder to move which in turn leads to more stress on the motor and rod.
You can ordinarily identify this issue by removing the engine cover and inspecting the intake manifold, often the rod is snapped or you can test the excess play in the rod linkage. Our repair kit is the best solution to this fault. The new manifold would come with the same plastic rod attached which will lead to the same problem further down the line. In the case of this engine, there are two intake manifolds, each with a rod, so to replace both will cost a small fortune, especially as its generally just the rod that needs replacing.
Our kit comprises of an aluminium rod machined from billet aluminium and anodised. It will not snap like the plastic versions and is designed to cope with the sustained heat and movement experienced during operation. Our rod comes complete with anti-friction adaptors, these interact with the plastic bushes of the rod and the plastic of the manifold connections, this means there is plastic on plastic operation, our anti friction adaptors allow easy slip and protect from wear. Not a metal on plastic operation which would ultimately fail.
A far superior improved design and material part. Our part features sensor pick-ups. Some manifolds have a position sensor on the plastic rod, failure to replicate this in a replacement rod will throw up errors. Our rod has this feature built in so can be a straight swap. Our rod will work with manifolds both with and without sensors. This list is for guidance only, and may not be a complete list of vehicles with this engine.
We have taken measures to ensure that all the below cars have compatible manifolds but you are best to check before purchasing. Find your model, click Engine, click Intake and Exhaust Manifolds. You can then check the part number corresponds to the ones in this listing. You can also visually inspect the manifold by removing the engine covers to confirm compatibility. Please check your intake manifold rod to make sure that it has a sensor pickup point at either end of the rod facing opposite ways.
If it has sensors back to back at one end of the rod, this option is not compatible with our kit. Position a thin flat head screwdriver under the head of the clip and lever it upwards and out of its position.
Install the anti-friction adapters. These have one side which is stepped in design and this goes downwards into the recess on the rotating arm.Swirl flaps are small butterfly valves fitted to the intake manifold just before the cylinder head intake ports of many modern automotive engines, including those from Mazda, AudiBMWVauxhall and Alfa Romeo. The flaps are smaller than the intake runners and therefore allow air to pass around them even when "closed".
The flap itself is made from stainless steel and secured to a spindle by two small Torx screws. The sealing O-ring and external actuating lever can be seen below the flap itself. Swirl flap position is adjusted by an electrical or vacuum-actuated servo mechanism which is under the control of the engine management system.
In a typical implementation the flaps will be closed at idle speed, creating additional turbulence in the intake. As engine speed increases, the flaps are gradually opened until, at around 2, rpm, they are parallel to the airflow and present virtually no resistance. Their purpose is to ensure that the air entering the cylinder is sufficiently turbulent for good fuel-air mixing even at low engine speeds.
This aids in reducing certain toxic emissions and may also improve low-end power and torque. The disadvantages of swirl flaps are mainly associated with fouling by exhaust gas recirculationwhich leaves tarry deposits on the flaps and the inside of the intake manifold.
Over time the flaps can begin to stick in one position and the engine management system may report an error code if the correct flap position cannot be achieved within a few percent of the design specification. More seriously, the flaps or their mountings can fracture under the strain and parts can enter the cylinder. The BMW M47TU 2-litre engine manufactured between andand the similar 3-litre engine,  is mentioned for swirl flap failure, as the small screws used to secure the flaps to their spindle will fall into the intake ports if the spindle fractures; in the intake manifold was redesigned to eliminate these.
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