Vauxhall Fiat Alfa Saab 1.9 Pierburg Intake Manifold Swirl Flap Blank Blanking Removal Repair Kit
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- เผยแพร่เมื่อ 30 มี.ค. 2016
- Link to purchase product: x8r.co.uk/vauxhall/vauxhall-m...
The Problem
The ball joints on the swirl flaps can wear to excess rendering the swirl flaps un-functional also the seal on the swirl flaps can fail causing inlet manifold air leaks.
It is a very common fault for the swirl flap operating rod bushes to wear down and for the operating rod to pop off causing these symptoms, this can easily be rectified with our replacement improved design operating rod which can be purchased in our eBay store.
Unfortunately on occasions the ball joints on the swirl flaps which this rod connects to can be too worn to repair with a new rod, alternatively the seals on the swirl flaps on occasions fail and cause air leaks. Previously this necessitated the replacement of the whole intake manifold at vast expense. However using our blanking kit the swirl flaps can be removed and blanked off allowing you to repair the manifold you have; saving the cost of a new manifold and preventing any future swirl flap issues.
Symptoms of the fault
Engine management light (EML) lit, high fuel consumption, rough idling, rough running, poor power and torque, smoking from exhaust, error P2279-11 Intake system air leak,P2075 fault code.
Vehicles affected and compatibility
Some of the vehicles affected and associated part numbers:
Alfa Romeo - 939A200 ( 1.9 MultiJet JTDM 16V 110 kW / 150 PS)
147 - 1.9 JTDM 8v 2005+ [HP 120]
147 - 1.9 JTDM 16v 2005+ [HP 150]
147 - 1.9 JTD 16v 2004+ [HP 136]
156 - 1.9 JTD 2003-2005 [HP 126]
156 - 1.9 JTD 2004-2005 [HP 150]
156 Sportwagon - 1.9 JTD 16v Q4 2004-2006 [HP 150]
156 Sportwagon - 1.9 JTD 2005-2006 [HP 150]
156 Sportwagon - 1.9 JTD 2003-2006 [HP 126]
159 Saloon - 1.9 JTDM 8v 2005+ [HP 120]
159 Saloon - 1.9 JTDM 8v 2005+ [HP 115]
159 Saloon - 1.9 JTDM 16v 2005+ [HP 136]
159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 120]
159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 115]
GT - 1.9 JTD 2003+ [HP 150]
Fiat - Enigines M91 & M92
Croma - 1.9 D Multijet 2005+ [HP 150]
Stilo - 1.9 D Multijet 2005+ [HP 150]
Stilo Multi Wagon - 1.9 D Multijet 2005+ [HP 150]
Vauxhall - Engines Z19DTH & Z19DTJ
Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 150]
Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 120]
Astra Mk V (H) Estate - 1.9 CDTi 2004-2009 [HP 150]
Astra Mk V (H) Sports Hatch - 1.9 CDTi 2004-2010 [HP 150]
Astra TwinTop Mk V (H) - 1.9 CDTi 2006+ [HP 150]
Astravan (H) - 1.9 CDTi 2005+ [HP 150]
Signum - 1.9 CDTi 16v 2004-2008 [HP 150]
Vectra MK II (C) - 1.9 CDTi 16v 2004-2005 [HP 150]
Vectra MK II (C) GTS - 1.9 CDTi 16v 2004-2005 [HP 150]
Vectra MK II (C) Estate - 1.9 CDTi 16v 2004-2005 [HP 150]
Zafira MK II (B) - 1.9 CDTi 2005-2011 [HP 150]
Saab - Engines Z19DTH & Z19DTJ
9-3 Saloon - 1.9 TiD 2004+ [HP 150]
9-3 Convertible - 1.9 TiD 2006+ [HP 150]
9-5 Saloon - 1.9 TiD 2006+ [HP 150]
9-5 Estate - 1.9 TiD 2006+ [HP 150]
Associated part numbers:
Older design 55206459, 55190238, 55194739, 55206460, 2.03462.01, 2.03462.00
Newer design 55210202, 55210201, 2.03462.03, 2.03462.02
Our solution
Remove the swirl flaps from the inlet manifold and blank off using our kit; eliminate swirl flap faults without having to buy a complete new intake manifold.
Our unique design kit allows you to blank off the swirl flaps on your original intake manifold resolving swirl flap faults permanently. Our blanks are precision engineered from billet aluminium and are fitted with a Viton O ring to ensure a good seal, a far better alternative to pressed parts which can fail to seal.
A cost effective alternative to a whole new manifold which would likely fail again. Save the cost of a new manifold and prevent any further swirl flap issues. Some of our customers have installed our blanks as a preventative measure to avoid swirl flap issues further down the line and some customers have experienced performance gains from removing the swirl flaps.
You will receive
4X Large cnc machined billet aluminium blanks (fitted with high quality Viton O-ring)
1X Small cnc machined billet aluminium blank (fitted with high quality Viton O-ring)
1X Adhesive to secure the blanks
X8R Ltd www.x8r.co.uk - ยานยนต์และพาหนะ
Das Teil mit der Dichtungseite, ohne Zwischenlage in Schraubstock eingeklemmt ! Gute Meister !
Is there a kit for the 1.9 TTiD manifold?
What's the difference between the first kit and the second one? And which ones better?
These turbines do not drop and cp? Or is it better to say that it does not decrease the engine power in acceleration?
Or cut threads and just put a small bolt in?
@X8R Ltd
Whats liable to happen if you get the supplied JB weld on the O Ring?
Also it seems odd to use grease on the Oring then JB weld on the plug considering the o ring is at the front and will shed grease onto the wall and stop the JB weld fully adhering......
Shame the plugs couldn't be inserted from the inside facing outwards, therefore the pressure would push them more firmly into place instead of trying to blow them out under boost....something to consider
How can I repair this problem in my 2002 Nissan pathfinder v6 3500 it's not firing it's showing Swirl control valve control solenoid valve on computer what can I do help me with a video
im in the process of swirl flap deleting my z19dth... Was thinking about these bungs, But seeing how easy they are to insert, Doesnt give me peace of mind that they will permanently remain in place under heavy turbo boost...
Think i will just get them TIG welded up instead..
Hello would I need to get remap for this ?
Hello, I have reviewed your video which explains a lot about how it works. Unfortunately, I can't find a video of this kind anywhere for the opel astra h z17dtr. I have big problems with it, I changed everything, and even put in a new turbocharger, but it still smokes black smoke, sometimes bluish, and when it starts twitching at two thousand rpm it throws out a P0299 error. smoke very well and lose traction. Please help and explain about replacing the intake manifold. THANK YOU
jesi rijesio iznogude
I'm wondering what is the point of applying the grease before applying a glue????
grease first and then adhesive ? no cleaning at all ?
It's always a good idea to clean up the manifold as well as you can these are normally very full of carbon build up.
Do i have to make software corrections after fitting them?
No, providing the actuator motor is left connected electronically the vehicle won't detect a fault.
Someone might watch this video and word for word fail to clean the grease from the blank and orifice! The go and apply the loctite - what a mess!
Do you have model for opel astra 1.9cdti 150CV 2006 ??
Are the flaps on the second type which are secured with screws made from plastic or are they from metal? Great video.
Hi there,
The screws that retain the original flaps are metal.
Hope this helps!
I have a Fiat bravo II year 2007 1.9 diesel 150ps, the same as opel and Saab. I needed to open and clean that intake minifold. What should I buy before I open it?
A new one and fit egr black and map it out
Blank
Do you put the actuator back in with Manifold?
Yes
What do you get them fixed? Is this some glue or something else?
they have some gum, how you see, to fix them :D
I've done this on my saab 93 - but now has no boost at all? I just left the actuator plugged in to the sensor but not in it's origional place - does this matter ? Any help would be great
Did you use a new intake gasket? theres no reason why this would effect boost other than an air leak from the manifold itself.
I had same issue was ok revved fine drove fine for 5 mins til engine warmed up then went into limp mode any advice???
Just get a used intake manifold from a CF3 Fiat Stilo, Alfa 147 or 156?
same manifold, same problems.
It will just develop, if it hasn't already, the same issue with the swirl flaps over time.
CF3 doesn't have swirl flaps
Does the manifold have to be removed or could the swirl flaps be removed from the top (the type that doesn't have screwed on flaps)
Did u ever get an answer to this question I was wondering if they can just be lifted out without removing manifold also
Did u do that
Does the car run better starting ect with blanks installed
@@paulMason-zm4kr did you ever get an answer to this question? I'm going to attempt to just lift out tomorrow 😄
@Ricky Halpin oh this was from years ago but I ended up removing manifold and tbh it wasn't that hard to do.
Once it was removed i split the manifold and completely cleaned out the manifold insides and all other parts going to it and blanked off the ports with plates I bought of ebay.also connect the power back onto the rod so no alarms cone up just so it thinks it's doing what it's there for
After fitting back on car it has so much more power it seemed to much for the front to handle.
Well worth doing only 1 issue I had was when you lock of the fuel pump pulley there is a woodlock key which was an absolute pain to refit without it falling out as its upside down
Took me about 10 attempts
@paul cheers for the reply, I've planned to remove 3 and leave the one that's attached to the arm for now, cambelt is due in a few months anyway will get a mechanic to do the rest then 👍
Yes the manifold needs to be removed. Once you've removed it, its well worth splitting the manifold in half. I think there are like 14 bolts holding it together and a couple of metal dowels. You can then completely clean it of all the carbon build up and trust me, it will be full of carbon. I just did mine.
Have you had any reports of these plugs coming out afterwards.
Hi, no we have not had anyone say the plugs falling out if that is what you mean. - Georgina, X8R Ltd
How does this affect emissions and overall function? After all, the swirl flaps have been designed into the manifold for a reason.
This will have little affect on the emissions of the vehicle
It is designed for optimal fuel and air concetracation makeing, if you remove it your engine will work in low rpm with too much air and you lose power....
Nothing like you said. Swirl flaps only regulate exhaust gases, that are recirculated by egr valve. Original air intake is not effected by those.
@@jaroslawchmiel3410 No, they do change the way the car accelerates. It improves acceleration on low and high RPMs by opening or closing the flaps.
Are good also for Fiat grande punto 1.9 multijet 8v?
Hi there, potentially. Please email us on sales@x8r.co.uk with the part number from your intake manifold and we can look into this for you. - Georgina, X8R Ltd
Merhaba benim aracım opel vectra 1.9 cdti z19dth motor. Benim aracımın sorunu geç çalışıyor. İki veya üç kere marş tekrarı yapıyorum. Araç 2. Marşta başlatmada çalışıyor. Enjektör sağlam , kızdırma bujileri sağlam sizce sorun nedir ? Hava sıcaklığı 20 derece olsa bile çalışmakta zorlanıyor. Marş motoruda sağlam akü , pilde sağlam
Merhaba aynı sorundan muzdaripim 9 ay olmuş paylasim yapalı herhangi bir çözüme ulaşabildiniz mi?
will I get any problems blanking it ?
Not likely, the blanking of these manifolds improves mpg/ overall fuel consumption in some instances.
I'd rather say, that it restores fuel consumption from before swirl flap failure. After blanking mpg went back to what originally I had.
This model is 16valve
why remove flaps
Faulty swirl flaps can cause the engine management light (EML) to be lit, high fuel consumption, rough idling, rough running, poor power and torque, smoking from exhaust and error P2279-11 Intake system air leak,P2075 fault code. Deleting the swirl flaps removes these issues. - Georgina, X8R Ltd
I know most people care less, because it is hard to notice for the inexperienced eye. But as a manufacturer of this blanking kit you may want to mention that cars lose their homologation when this is installed. The swirl flaps are not there for nothing.
Sure i agree. But can you ensure me that my next air inlet will work for more than 20 to 30 thousand kilometers? I changed 3 of them and not giving a cent for a new one again. It costs a fortune because of poor engineering and solutions so i can change them every year and half.
Since when? At MOT tests blanking is not even picked up, as emissions test is within parameters. If it cannot fail MOT, then how it could lose homologation?
@@jaroslawchmiel3410 If swirl flaps were not necessary to pass homologation tests and to get better fuel economy at part load, why would car manufacturers spend the extra money?
Most tests are done by just looking at the car's sensor data. And I agree the car's sensors don't notice blanking. But if emissions were measured at the exhaust, there would indeed be a deviation at part load. So if you have MOT done and the person checking the car knows about blanking plates and sees them, you're in trouble. Because it is not just a worn part or so, but you have installed components that violate the car's homologation. Legally it's the same as removing a catalytic converter or particulate filter, for example, and I think everyone understands that this is something one shouldn't do.
@@phswirl1167 So if you have a broken (disconnected) swirl flap bar you lose homologation too, as the whole mechanism is not doing it's job. I don't think so buddy
@@alejandroperez5368 Officially, if this is noticed during MOT, one would be asked to fix it. And there is a difference between this happening accidentally, or by using these blanking plugs purposely. As I wrote before, most likely nobody will notice, but if someone sees and understands that swirl flaps have been replaced by blanking plugs, you're in trouble.
big shit ... i waited one week to receive the plugs BAD
Do not book with X8R
I am very angry
Our sincere apologies for the delay.
bonjour je les ai supprimé et j'ai perdu beaucoup en puissance a bas régime.