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Thread: Swirl Flap Linkage Rod 'Cheap' Fix

  1. #1
    Regular Member AntSSSS's Avatar
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    Vehicle : Vectra Estate

    Trim : SRI

    Engine : CDTI 150 (Z19 DTH)

    Year : 2008

    Mileage : 100k

    Default Swirl Flap Linkage Rod 'Cheap' Fix

    All,

    not sure if this has been done in a post before - but here was my attempt on the Swirl Flap Linkage Rod £1 fix for Chrisvectra's 1.9 CDTI (150)

    So - I sourced some tap washers from Focus DIY for £0.99

    I have my old inlet from when mine was changed - so i used my old bar and Inlet to measure the washer holes and fit.

    First I looked at the size of the holes on the tap washers - they were about 3mm ID so were too small and VERY hard to get over the Swirl nob!.
    - So I drilled out the hole 1 mm at a time and checked how it felt on the inlet, 4.5mm was still too tight to allow the swirls to turn, 5mm seemed spot on..



    You will see that I also counter sunk the top of the hole. reason being is that the washer was thick and this meant that the top half of the washer was griping the nobbly bit of the swirl flap post. by counter sinking the hole, the washer 'snapped' over the nobble and then was gripping the section below the nobble.
    This is shown well here:



    ..and here:



    Next was to tackle the rod itself. Due to the thickness of the washer - I wanted to grind the rod joints so that the bar was the same height as origional when the washers are glued on - so I did - out with the bench grinder



    ....final result after grinding the rod links:



    Here are the washers and rod - all ready to be glued. I litterally touched the face of the washers on the grinder so that he surface of the washer was flat from where I drilled - but also slightly rough so the glue would hold:



    So - out with the Araldite Rapid set..

    Mixed some up - put a little on the rod faces where the washers will sit - and also some on the face of the washer faces, and put them together.

    Let it set for an hr or so, so that the washers dont fall off when I put it on and off the inlet and hay presto!:




    I actually forgot to take a pic of it on the inlet - ooops and Chris has the bar now... but I think you can all see that it looks the part

    Lets just see how Chris gets on..

    Hope this all helps..

    A
    Last edited by AntSSSS; 29th March 2009 at 21:06.

  2. #2
    Regular Member Gr4eme's Avatar
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    top job and great pics

  3. #3
    Regular Member Tadpole's Avatar
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    Looks a top job let's hope after all your effort it works ok .....................

  4. #4
    Regular Member Hideous's Avatar
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    Vehicle : Insignia

    Trim : SRi Nav

    Engine : CDTI158

    Year : 2012

    Default

    Good fix there, by the look of it.
    Flippin part is an absolute disgrace. Mine's stuffed now too, or at least I think that's part of the problem I'm having http://www.vectra-c.com/forum/showthread.php?t=76180
    I was under the impression from another thread that it is "possible" to fix this rod cheaply without taking the inlet manifold off, but I can't do it.
    Taking the manifold off is beyond my scope - looks like a nightmare of a job.

  5. #5
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    Hideous, where in the uk are you, I have done the tap washer thing to mine and has worked ok, if you are local, either you can wheel it round, or i'll pop over and have a look, also got a code reader, reset tool, so can have a go at getting it out of limp mode, PM me with your location.
    Cheers
    Mark

  6. #6
    Full Member chrisvectra's Avatar
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    Vehicle : VXR8 6.0 muscle SRI ESTATE XP1

    Trim : VXR/ SRI ESTATE CDTI XP1

    Engine : 6.0 V8 Thunder

    Year : 2008

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    top man ant
    when i get a spare half hour i will try and fit your modified arm and let you know how i get on
    VXR IS FOR LIFE NOT JUST FOR THRILLS !



  7. #7
    Regular Member Hideous's Avatar
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    Vehicle : Insignia

    Trim : SRi Nav

    Engine : CDTI158

    Year : 2012

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    I had a great result with my engine problem.
    If anyone's interested, you can read an update here http://www.vectra-c.com/forum/showth...121#post898121

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