Swirl flap danger

[Solo Man]

Guys, just a warning!. Removed the swirl flaps on my "new" 2006 E60 530d yesterday and found one of the flaps was hanging on my the small part that is on the end of the flap. It was actually stuck in the opening thanks to the fact that the end part kept it from going any further. I am convinced that had i driven the car maybe another 1k kms or maybe gunned it, i may have had a flap in the engine! My warning is for owners to get the swirl flaps out as soon as possible!

 

[Waseem 333i]

Luckily you caught your one in time. When I did my car the flaps and screws were still solid but you never know with these things

Sent from my VKY-L09 using Tapatalk

 

[ChefDJ]

You were so so lucky :thumbs:

 

[Dre]

Glad you caught this in time.
Is this also a concern on the F30 320d ?

 

[GoCart]

I believe the 07+ models have revised intake manifolds with improved flaps. I drive a 09 530d, which I assume was manufactured in 08, and therefore suffers from the illusion of not having to remove the flaps.

However, I see on your for sale add, you have removed the flaps from your 09. Why and what was the condition upon removal?

PS' the label on my intake states TE, if that means anything.

 

[ChefDJ]

I believe the 07+ models have revised intake manifolds with improved flaps. I drive a 09 530d, which I assume was manufactured in 08, and therefore suffers from the illusion of not having to remove the flaps.

However, I see on your for sale add, you have removed the flaps from your 09. Why and what was the condition upon removal?

PS' the label on my intake states TE, if that means anything.

They redesigned the intake manifolds and swirl flaps back in 2004 already and still it's a problem. I would remove them regardless of the manufacture year.

 

[Schalk94]

Where can I get the blanking plates locally?

 

[ChefDJ]

These plates are not easily available locally. I had to import them from eBay. Ensure you know what size you need, otherwise just get both sizes. You don't want to go through the effort of removing that manifold and realise you don't have the correct parts.

 

[Schalk94]

These plates are not easily available locally. I had to import them from eBay. Ensure you know what size you need, otherwise just get both sizes. You don't want to go through the effort of removing that manifold and realise you don't have the correct parts.

I see that the post 2004 motors need the 32mm blanking plates. So I will definitely make it a priority to order them.

 

[sash]

They redesigned the intake manifolds and swirl flaps back in 2004 already and still it's a problem. I would remove them regardless of the manufacture year.

In the e60, there was a revision between the pre-lci and lci. Whether or not the issue has been completely eliminated..., hard to say since one would have to look at each individual engine to see whether the flap were the cause or a consequence.

 

[Isamu22]

This link is quite helpful on whether you want to check if your car has swirl flaps (posted in 2012 but should cover most cars)

http://www.bmwforums.info/general-g...diesel-engine-swirl-flaps-to-swirl-flaps.html

 

[ChefDJ]

These plates are not easily available locally. I had to import them from eBay. Ensure you know what size you need, otherwise just get both sizes. You don't want to go through the effort of removing that manifold and realise you don't have the correct parts.

I see that the post 2004 motors need the 32mm blanking plates. So I will definitely make it a priority to order them.

Not sure. In the E39/E46 it was either 22mm or 33mm.

 

[GoCart]

I've been looking at the below DIY for some time, I rather enjoy the resolve this fella has come up with.

https://5series.net/forums/diy-do-yourself-14/removing-swirl-flaps-diesel-engine-70452/

 

[ChefDJ]

There are a number of ways it can be modified. Some people simply leave the spaces open. My mind was more at ease knowing I fitted the blanks designed for the job.

I would link you my DIY but photobucket screwed that up for me.

 

[Waseem 333i]

I've been looking at the below DIY for some time, I rather enjoy the resolve this fella has come up with.

https://5series.net/forums/diy-do-yourself-14/removing-swirl-flaps-diesel-engine-70452/

Ive done this. It works and costs next to nothing.

 

[Solo Man]

The flaps on my 2009 (build date Feb 2008) E60 530d was still in good condition. The newer (newer than 2005/6) design is slightly different from the older cars as they have a plastic "shroud" for lack of a better word around them but i am convinced that if they break off they could get by the schroud and get into the engine. Furthermore, the screws come loose and also get into the engine. In my case the whole flap broke right where it goes throught the side with the swivel on, so the other end was still in its hole and it had jammed in that position, not 100% open but slightly (about 10%) closed. Was just a matter of time (or revs) for it to let go!!

 

[shailesh]

https://5series.net/forums/diy-do-yourself-14/removing-swirl-flaps-diesel-engine-70452/


I have done exactly as the above but luckily before fitment, i got a set of plastic swirl flaps from one of the guys on the forum.
When checking my flaps the screws seem to be well seated.

 

[ChefDJ]

There are a number of ways it can be modified. Some people simply leave the spaces open. My mind was more at ease knowing I fitted the blanks designed for the job.

I would link you my DIY but photobucket screwed that up for me.

Seeing as the photos are restored, here's the link within my thread to the DIY for the swirl flaps:

https://www.bmwfanatics.co.za/showthread.php?tid=40650&pid=798231#pid798231