Vectra C 1.9 Cdti 16V Swirl Flap Removal

almostover

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?

paulells

hi there i found a cheap alternative to the rod popping off as this happened to my signum same engine.DSCF0067.JPG buy these for a quid and cut the cap off and just glue the bit with the hole over the rods cups (should fit snuggly) and pop back on presto job done

almostover

Unfortunately my swirl valves are stuck and wont move at all. The rods/linkage bushings are also very worn so I have decided to buy a blanking kit and remove the flaps altogether. Has anyone tried this kit or similar? http://www.ebay.co.uk/itm/VAUXHALL-VECTRA-1-9-CDTI-INLET-MANIFOLD-SWIRL-FLAP-BLANKING-CAPS-Z19DTH-NEW-/360896619271

paulells

Hi there you will have to remove the manifold completely which isnt easy without removing a few things first but there is a video on you tube if you search cambelt and manifold change but it is worth trying.
If you do remove the manifold spray mr muscle oven cleaner into it and leave it overnight then rinse off and let dry.
this might unstick your valves but if not then you could try that kit its pretty easy to do.
Also use the oven cleaner on the egr valve and throttle body as these will also be gummed up.

Good luck and hope you get it sorted

andy t

could you just take out the swirl flaps completely & save a headache in the future