1. This site uses cookies. By continuing to use this site, you are agreeing to our use of cookies. Learn More.
  2. It's been bought to our attention that certain users are spamming new and existing users with links to their own websites. This is not permitted on VxON.
    Should you receive such a message, please report this using the 'Report' link you will find at the bottom of the message.
    Those users will then be dealt with accordingly.
    Dismiss Notice
  3. Use The Search Function That's what It is There For!
    The chances are that the post you are about to make has already been asked so USE the search function first! You can either search JUST this forum by clicking on the search button on the top right (under the page numbers) or click on the main search button that is on the top tool bar.
    This will save you time and stop the same duplicate posts from appearing.
    Dismiss Notice

HOW TO - Repairing / Fixing / Modifying 1.9 DTH CDTI Swirl Flaps Bar

Discussion in 'All Model Vauxhall / Opel / GM / Holden How2' started by Jimmy-James, Feb 4, 2013.

  1. Jimmy-James

    Jimmy-James Member

    Messages:
    63
    Likes Received:
    22
    Drives:
    Volkswagen T4 and Zafira TDCI 150 SRI
    Guide to fitting Vauxhall Opel / Saab 1.9 16 150 TID swirl bar repair kit

    Before you start, check out the new guide on page 5 which provides slightly easier instructions and a link to a much cheaper swirl flap bar repair kit (y)

    Both @Jimmy-James instructions and the one posted by myself on page 5 are well worth reading and cross referencing
    ;)



    Here it is then for those that are interested, it took about 30 minutes from start to finish and they really do pop on snugly like the seller promised, well worth doing! Their site is HERE and you can buy a set of 4 (for just over £37) from the German eBay HERE

    Here you can see how much more substantial the kit is than the plastic connections Pierberg supply.

    As supplied in the kit, does not allow the control arm to fall over due to better support.
    [​IMG]
    Stock showing the control rod falling over causing premature wear. If you have never looked at this part of your engine i strongly suggest you do so. We have a Zafira 1.9cdti 150 Sri and it wasn't connected at all, it was just rattling around loose!
    [​IMG]
    Step one is to make sure the flaps are free and if not gently try to free them with a little WD40, Plus Gas or similar. When this is done you can get cracking. DO NOT force the flap 3rd in from the right (or second from the left) this is the control flap which is connected to an actuator on the bottom of the manifold.

    I had to make a couple of hooks to remove the rod and to aid in the positioning of the modified rod when finished, i dont think you will manage very well without them, bent coathanger wire is adequate.
    [​IMG]

    I followed the instructions and removed the glow plug connectios and pulled the wires out of the way as best i could without forcing them which left me access to remove the rod and left me with this, time to break out the carb cleaner and cloths to clean. When removing the rod remembr the orientation for re-assembly by marking the rod, i used a piece of masking tape. There isn't a lot of space to work here so a paintbrush, microfibre and a screwdriver wouldn't go amiss. Once clean i sprayed with teflon grease to lubricate the mechanism.
    [​IMG]

    Now the rod is out it was time to remove the old, worn plastic connections. I removed them by placing the rod in a vice taking care not to bend it and removed the plastic sockets with a hammer and a small chissel. BEWARE, using this method causes plastic parts to fly off at quite a rate, please make sure to use the correct protective equipment!
    [​IMG]

    I was then left with this.
    [​IMG]

    I had to run a 3mm drill bit through the rod because the fitment was slightly too tight. Once this was done i installed the swirl repair kit which, when finished looks like this.
    [​IMG]
    [​IMG]
    [​IMG]

    Check the nuts are done up tight, but not silly tight, they need enough pressure to squash the spring washer and a little bit more for luck! Using the hooks mentioned earlier and observing the orientation of the rod, simply line it all up on top of the swirl's and pop the conections on with a long screwdriver. They make a nice positive contact and it will be very obvious when they are located correctly. You will notice when its installed that the rod now sits as it should (upright) with only minimum movement. You are almost finished, all that is left is to re-connect the glow plug connectors, reconnect the battery and test it before putting the engine cover on. You will need a second person for this to slowly apply the accellerator while you check the movement of the swirls
    [​IMG]

    If everything is well, pop the engine cover on and feel proud of your achievment, go out and enjoy your car knowing that your swirls are operating as they should!
     
    Last edited by a moderator: Aug 4, 2015
  2. cavwebmaster

    cavwebmaster CavWeb/VxON Forums Admin & Founder Staff / Administrator VxON Club Member VxON Approved Trader

    Messages:
    28,551
    Likes Received:
    1,168
    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    You seem to be on a roll Jimmy (y)

    I've moved this as the 1.9dth is fitted into so many vehicles that it limits it's exposure by just having it in one technical forum.

    Make sure you take some pictures along the way ;)
     
  3. Jimmy-James

    Jimmy-James Member

    Messages:
    63
    Likes Received:
    22
    Drives:
    Volkswagen T4 and Zafira TDCI 150 SRI
    No problems, makes sense. It would be nice to see a more positive approach to the brand and maybe a few useful modification write up's might help things along a bit.

    Its always a minority of people that give certain makes/models/engines etc a bad name just because they have had bad luck, forums never publicise the good points! Not all cars are lemons just because a handfull of people say they have had problems. Some things can be prevented such as the EGR failure and swirl flaps with a little bit of re-engineering, Google is your friend! There was loads of bad press about the Vectra B Dti which almost made me walk away. I'm glad i didn't because appart from the flimsy interior with numerous broken door handles it was the most dependable car i have ever owned! I will get lots of pictures up, hopefully tomorrow :)

    My motto, if it doesn't work - Modify it!
     
    Ribcracker likes this.
  4. Jimmy-James

    Jimmy-James Member

    Messages:
    63
    Likes Received:
    22
    Drives:
    Volkswagen T4 and Zafira TDCI 150 SRI
    First post updated with all the details of the guide, happy spannering! If someone could change the title to "HOW TO - Repair/Modify Swirl Flaps" it would be appreciated. I should just mention that i'm in no way connected with the supplier, he's just a helpfull guy supplying a good fix!

    Cheers
    Jimmy.
     
    cavwebmaster likes this.
  5. Mark

    Mark Because...Race Car! VxON Club Staff

    Messages:
    19,240
    Likes Received:
    355
    Location:
    Bristol, United Kingdom
    Done.
     
    cavwebmaster and Jimmy-James like this.
  6. Jimmy-James

    Jimmy-James Member

    Messages:
    63
    Likes Received:
    22
    Drives:
    Volkswagen T4 and Zafira TDCI 150 SRI
    Cheers bud!
     
  7. cavwebmaster

    cavwebmaster CavWeb/VxON Forums Admin & Founder Staff / Administrator VxON Club Member VxON Approved Trader

    Messages:
    28,551
    Likes Received:
    1,168
    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    Great write up and pictures Jimmy (y)
     
  8. Jimmy-James

    Jimmy-James Member

    Messages:
    63
    Likes Received:
    22
    Drives:
    Volkswagen T4 and Zafira TDCI 150 SRI
    Glad to be of service, i'm really pleased with how it all turned out and how easy it was to do. Its well worth doing for piece of mind. We (VXOn) have a mention and a link on his site now too so its a bit of publicity for the site.
     
  9. cavwebmaster

    cavwebmaster CavWeb/VxON Forums Admin & Founder Staff / Administrator VxON Club Member VxON Approved Trader

    Messages:
    28,551
    Likes Received:
    1,168
    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    Considering the manifold with a new swirl bar attached costs around £170 (+ a day to fit it) a touch over £37 (including postage and converted from Euros to Pounds) is quite a bargain :)

    Oh and as the link on their site to buy this modification is a German Ebay listing, I've added that link along side your site link (y)
     
  10. Alex

    Alex I do the jokes. Staff / Moderator VxON Club Member VxON Approved Trader VxON Club Staff

    Messages:
    10,588
    Likes Received:
    3,178
    Location:
    Horsham, West Sussex
    Drives:
    Skoda Superb, Rascal Van
    Excellent stuff

    Can you believe it took Vauxhall 6 weeks to diagnose and repair this on my dad's old Vectra SRI Diesel?
     

Share This Page