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Thread: Vectra c 1.9 CDTI 150 Swirl flaps refurbishment?.

  1. #1
    Regular Member felixx's Avatar
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    Exclamation Vectra c 1.9 CDTI 150 Swirl flaps refurbishment?.

    Because of the inherent problems that have been found with the inlet manifold of the 16 valve diesel 150 engine,and the failure of the swirl flaps,sometimes at a very early stage in the engine's life,does anyone know of,or heard of,any company that can carry out or sells a kit needed to refurbish the manifold flaps and swirl bar?,and does anyone else think there is a need for a DIY kit,or something similar,to address this issue?. FELIXX.

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    Regular Member LADmachining's Avatar
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    Someone already has addressed the issue - Pierburg - the manufacturer of the manifold! ;-)

    By the time you have taken the old one off to refurbish it, I know I would rather fit a whole new manifold and have done with it...

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    Regular Member felixx's Avatar
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    Quote Originally Posted by LADmachining View Post
    Someone already has addressed the issue - Pierburg - the manufacturer of the manifold! ;-)

    By the time you have taken the old one off to refurbish it, I know I would rather fit a whole new manifold and have done with it...
    Fair enough!!!.
    Can't argue with that,lol,I was thinking more of recouping some of the replacement costs by selling a refurbished item......if it was viable,etc. FELIXX.

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    Regular Member mozzer99's Avatar
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    It would be quite possible for someone to make a rebuild kit by designing brass bushes/inserts and replacement butterfly's etc.
    On a BMW diesel which suffers from failed butterfly's dropping into the engine, a set of blanking plates used to cost £100. Now down to £8 each. You may note the manufacturer of the failed swirl flaps is Pierburg!(same as the 150bhp 1.9) http://www.pmwltd.co.uk/?page_id=155
    Trouble is now that the manifold is down to £134 it probably would not be cost effective. Also it appears* that the later modified manifold design does not suffer the seized butterfly's like the old one.


    An option would be to DIY blank off the spindle holes (drill and tap for BSP taper plugs?)and leave the ports permanently open - this would leave the full performance at WOT (wide open throttle) but would be very flat until the turbo cut in (just like with a failed manifold!).

    It is such a pain to remove the manifold to experiment most decide to spend the cash on a new one.......
    If the manifold was £500 it would be a different story


    *fingers crossed it is still relatively early days....

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    Regular Member sloper's Avatar
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    Quote Originally Posted by mozzer99 View Post
    It would be quite possible for someone to make a rebuild kit by designing brass bushes/inserts and replacement butterfly's etc.
    On a BMW diesel which suffers from failed butterfly's dropping into the engine, a set of blanking plates used to cost £100. Now down to £8 each. You may note the manufacturer of the failed swirl flaps is Pierburg!(same as the 150bhp 1.9) http://www.pmwltd.co.uk/?page_id=155
    Trouble is now that the manifold is down to £134 it probably would not be cost effective. Also it appears* that the later modified manifold design does not suffer the seized butterfly's like the old one.


    An option would be to DIY blank off the spindle holes (drill and tap for BSP taper plugs?)and leave the ports permanently open - this would leave the full performance at WOT (wide open throttle) but would be very flat until the turbo cut in (just like with a failed manifold!).

    It is such a pain to remove the manifold to experiment most decide to spend the cash on a new one.......
    If the manifold was £500 it would be a different story


    *fingers crossed it is still relatively early days....
    Id guess the swirl butterfly will retract from the inlet manifold when the bush is removed? If so, surely it would still be cheaper to replace the swirl butterfly and bush considering labour costs for changing the inlet manifold?

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    Regular Member mozzer99's Avatar
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    Unfortunately what you can't see is that the butterfly itself is sideways on in my image above, so it wouldn't lift out - otherwise I quite see your point! The later manifold butterflys seems to be solid plastic and probably would lift out when worn? This pic is of the early manifold where you can see the butterfly's held in place by grub screws, this stops the whole arrangement being blown up out by the turbo pressure when worn.

    There is no bush as I remember, part of the problem, the alloy wears as does the plastic, so there is no bush to remove.

    Last edited by mozzer99; 5th December 2010 at 21:04.

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    Vehicle : Golf 7

    Trim : GTD

    Engine : 2.0 TDI 184PS

    Year : 2014

    Mileage : 40000

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    I think on the old manifold the only refurbishment would be to remove the flaps altogether and seal up the holes where the bearing would be. Then you would have no swirl flaps to worry about. Obviously though you would need to keep the drive module plugged up to the car but not connected to the mechanism.

    Gazza4

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    Regular Member sloper's Avatar
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    Quote Originally Posted by mozzer99 View Post
    There is no bush as I remember, part of the problem, the alloy wears as does the plastic, so there is no bush to remove.
    My god an engineer designed this without considering the consequences of ware?

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    Regular Member sloper's Avatar
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    Quote Originally Posted by Gazza4 View Post
    I think on the old manifold the only refurbishment would be to remove the flaps altogether and seal up the holes where the bearing would be. Then you would have no swirl flaps to worry about. Obviously though you would need to keep the drive module plugged up to the car but not connected to the mechanism.

    Gazza4
    Yes that would be worth considering but i understand you'll loose lowdown power. Could a re-map sort that one?

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    Vehicle : Golf 7

    Trim : GTD

    Engine : 2.0 TDI 184PS

    Year : 2014

    Mileage : 40000

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    Quote Originally Posted by sloper View Post
    Yes that would be worth considering but i understand you'll loose lowdown power. Could a re-map sort that one?
    That's what the 'know it all' will say.

    Quote Originally Posted by sloper View Post
    Could a re-map sort that one?
    A remap would be the way to go. But the 'know it all' will say otherwise. then again he has had experience with a tuning box so any sane person would be lost with his opinions on that one.

    Gazza4

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