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Vectra C 1.9 Cdti 16V Swirl Flap Removal

  • 07-04-2014 3:16pm
    #1
    Registered Users, Registered Users 2 Posts: 2,122 ✭✭✭


    The swirl flaps on my newly purchased vectra are on the way out. The flaps are stuck in the open position (thankfully!!). The is no Engine management light coming on as the rotor arm on the swirl flap control motor is free to move. This is due to the fact that there is so much wear in the linkage. It seems that the carbon in the intake manifold has seized the flaps and the linkage has become worn as a result of trying to move but being prevented from doing so by the seized swirl flaps. Also I've noticed that when I blip the throttle the black plastic bushings in the manifold are trying to pop out of the manifold are are only being prevented from doing so by the linkage! There is also an oily sooty residue present on the manifold around the swirl flaps where deposits from the EGR have built up.

    I'm thinking of removing the swirl flaps from the manifold completely and buying a blanking kit to seal up the holes left in the manifold. This is the same setup as at present where the flaps are stuck open. The car drives really well with great pickup and oodles of power so I'm guessing having the flaps open aids performance as airflow is unrestricted?

    My plan of action involves cleaning the manifold thoroughly and blanking the swirl flap holes off. Has anyone experience of doing this and have any tips? I read somewhere that this will not trigger an EML as long as the control motor for the linkage is left attached and plugged into the ECU, is this true?

    I'm also toying with the idea of blanking off the EGR and bypassing it to prevent further carbon entering the engine. Has anyone experience of doing this also and have any tips?


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