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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. playamonte

    playamonte Well-Known Member

    Messages:
    200
    Likes Received:
    66
    Location:
    Valencia Spain
    Drives:
    Zafira B 1.9 CDti
    Yes with the engine running you will see it turn if someone blips the throttle, so take a good look as it needs to be turning smoothly.
    Pull the dipstick out and smear onto your fingers, feel the oil, smell the oil & do the same with what is near the S/Flaps.
    Feel / smell the same ?, then chaces are its oil.
    Feel wetter-thinner / smell of diesel, then its fuel.
    Clean the area with kitchen roll (S/flap area) and see if it returns ?
     
  2. Mike 91

    Mike 91 New Member

    Messages:
    29
    Likes Received:
    1
    Location:
    Morden, Merton, United Kingdom
    Drives:
    astra 1.9cdti 150
    I just fitted this kit I checked that everything moved freely first so I put it back together and it just goes in limp mode ?
     
  3. djandyh

    djandyh Active Member

    Messages:
    187
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    16
    Drives:
    zafira cdti
    which is a good kit on ebay to buy, thank you
     
  4. playamonte

    playamonte Well-Known Member

    Messages:
    200
    Likes Received:
    66
    Location:
    Valencia Spain
    Drives:
    Zafira B 1.9 CDti
    I bought my kit that is linked on the first post of this thread marked "here" in the first few lines, it came from a German seller and I bought the complete ready to fit arm.
     
  5. djandyh

    djandyh Active Member

    Messages:
    187
    Likes Received:
    16
    Drives:
    zafira cdti
    how long have you had it on for mate and have you had the eml came on, my car is off the road due to be sold someone elses problems, only found out a couple of weeks later that it needs a gearbox rebuild and a new dual mass, so am doing a lot of googling on these little problems so i can get them sorted before they happen,
     
  6. playamonte

    playamonte Well-Known Member

    Messages:
    200
    Likes Received:
    66
    Location:
    Valencia Spain
    Drives:
    Zafira B 1.9 CDti
    Since I posted about it (july)
    Yes EML was on & off but this was for the DPF issue I had that was fixed when I replaced the sensor and no light since (Touch Wood)
     
  7. djandyh

    djandyh Active Member

    Messages:
    187
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    16
    Drives:
    zafira cdti
    Hopimg to get my dpf removed and remapped at a later date. We dont have mot on the isle of man and due to the roads being so short, its not doing any good to the car
     
  8. playamonte

    playamonte Well-Known Member

    Messages:
    200
    Likes Received:
    66
    Location:
    Valencia Spain
    Drives:
    Zafira B 1.9 CDti
    Yes Andy that is the route I would take and will do at some stage when I find out if this is (or not) a MOT issue here in Spain.
    Cannot believe that there is no indication (obvious that is) if and when it needs a re-gen or in fact is one going on apart from looking atop-comm which I have just bought, having said that the bus is pulling/driving well since I replaced that DPF temp sensor. The biggest issue for me since buying the car is trying to get an accuratedipstickk reading & I now leave the stick out overnight to allow (hopefully) any oil to drain away from the dipsick holder but it still manages to wet the stick at different places above the full level (spent 40 years dipping oil on everything from an A35 to Scania 140's)

    Hope you have a nice view at TT time mate & I will be able to hear the cheer in Spain if Guy gets a win next year.
     
  9. djandyh

    djandyh Active Member

    Messages:
    187
    Likes Received:
    16
    Drives:
    zafira cdti
    Lol island is only well known for the TT lol. My reading are everywhere atm, not driving due to waiting for parts. Had it for a month. Done less then 150 miles and found all these problems out. Was to late then so not very happy
     
  10. cavwebmaster

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

    Messages:
    28,483
    Likes Received:
    1,192
    Location:
    Nottingham
    Drives:
    Modified Astra H Sporthatch 150 CDTI
    Fitting Vauxhall / Saab 1.9 swirl bar repair kit / bushes

    Over the last few days I have 'repaired' two 1.9 DTH CDTIs engine swirl flap bars using this £7.25 kit (Now £9.99)

    http://www.ebay.co.uk/itm/151087231742?_trksid=p2060778.m2763.l2649

    The first repair was on my own car but after an hour of jigging around I could not get the swirl bar back on with the tools I had available. In the end I took off the fuel rail (which made positioning it a lot easier) but I still had to fit the actuator bush on number 3s cup pin before I fitted the bar / rod.

    After I had fitted the bush to number 3 (left to right) I realised that you can actually refit this bar without removing the fuel rail, and you don't need any specially made up tools (you do however need a way of holding the screw for number 3 which requires some extra long nose pliers or a blob of glue/silicon on the end of a screw driver)

    So how did I do it it?

    READ EVERYTHING BELOW HERE FROM TOP TO BOTTOM BEFORE YOU START!

    First I removed the engine cover.
    I then I pulled off all the glow plug leads and put them out of the way.
    Then I removed the swirl bar noting that the longest straight end goes on the left.
    Then I used a lot of rags and a screw driver to remove as much of the oil and crap as I could around the swirl bar linkage cups (I didn't use carb cleaner as I didn't want to dry out the linkages)
    Then I cleaned the bar, broke off the plastic clips with some wire cutters (after cutting them cross ways on both sides with a junior hacksaw) fitted 3 out of the 4 alloy bushes with thread locking fluid to the bar (I did not fit number 3 bush - with the screw - to the bar) and then fitted the O rings into all 4 of them (they have a recess a 2mm in)

    Then I used a 8mm HSS drill bit to countersink number 3s swirl bar hole so the screw sits flush to the bar (this is very important as the screw isn't very long!)

    Back to the car I pressed number 3 bush onto the swirl flap cup pin until it clicked, rotated the top to the right position (they have grooves so when screwed to the bar they cannot twist) and then made sure that the other 3 cup pins were all set to the same position as number 3.

    I hope you are still with me :D

    I put the bar back in popping number 4 on first (until it clicks) and then one and two (if one and two don't line up just move the cups so the pins line up and push down till they click)
    Now you should have the bar back on, BUT the bar is just laying on top of number 3, so move the bar left or right until number 3s hole in the bar lines up with number 3s bushes thread.

    This is the tricky bit as you need to be able to insert the screw into number 3s bar hole without dropping it (before you do this make sure you put a blob of thread lock on the screw thread!) I tried to hold it with a magnetized screwdriver but the bond with the screw was too weak, so I bought an 8 inch pair of long nose pliers (you could put a blob of glue/silicon on the end of the screw so it sticks to a screwdriver and then it can be broken off)

    Lastly screw the screw into the bush through the countersunk bar hole.

    Hopefully this will help someone out there as I couldn't for the life of my get the bar back on with all 4 bushes on it.

    Oh and don't try and turn number 3 as this is controlled by an electronic actuator, which moves the other 3 flaps using the bar ;)
     
    Last edited: Aug 4, 2015
    chris wray, oberlisc and andyl like this.

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