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SwirlFlapFailure
Thesevaluesaredesignedtocreateaswirl(hencethename)inthein
letmanifold,thisaidstowardsbettercombustionunderlightload.The
flapsarefullyopenduringhigherloadconditionstomaximisevolumetric
efficiencyandpoweroutput.Inrealitythissystemlooksbetteronpaper
thanitdoesintherealworld.
(http://www.ogs
mechanics.com/wordpress/wpcontent/uploads/2014/10/M47Ndieselengineswirlflap.jpg)
TheabovepictureisofastandardBMWswirlflapremovedforainletmanifold.
Sadlyswirlflapsarepoorindesignandarepronetofailure.Thebelowpictureisofausedswirlflapremovedfromavehicle
with80,000milesontheclock,asyoucanseetheshaftisfractured(wheretheclosestboltmeetsthebase).
(http://www.ogsmechanics.com/wordpress/wp
content/uploads/2014/10/removed.jpg)
Whenaswirlflapfails,thedebrisdropsdownintotheengine,eitherstickinginthevalveportandjammingitopen,causingthe
pistontocollidewiththevalve,orfallsintothecylinderitselfcausingthepiston,valvesandheadtobecomedamaged.
Theotherissueweregularlyseewiththeseswirlflapunitsiswhenthesmallscrewsholdingtheflaptotheshaftworklooseand
findtheirwayintothecombustionchambercausingconsiderabledamage.Theycausefurtherdamageontheirwayoutofthe
enginewhenpassingthroughtheturboandCAT.
Belowisapictureofanewpistonandswirlflap(ontheleft)withadamagedpistonandswirlflap(ontheright).Whenacom
ponentcollideswithapistonat3000rpmyoucanseethedamageisquiteextensive.
(http://www.ogsmechanics.com/wordpress/wp
content/uploads/2014/10/engine.jpg)
BMWintroducedamodifiedinletmanifold(withswirlflapsstillfitted)tryingtoaddressthisproblem,thespindleofthevalveis
thickerandstronger,sadlythisdesignisalsopronetofailure.BMWfinallygaveuponswirlflapsinlate2008.
IfyouareunluckyenoughforyourvehicletosufferfromswirlflapfailureBMWonlyofferoneoption.Anewengine(circa8,500
to13.500fitted).
AtO.G.S.Mechanics,wecanrepairswirlflapdamagedenginesforaroundthe2,750mark(dependingontheextentofthe
damage).
ButThereisasolution!Astheysay,preventionisbetterthancure.
Wealwayslooktosolveaproblemandpreventitfromeverhappeningratherthanpickingupthepiecesaftertheinevitable
happens.
Wehavehadswirlflapblankscustomengineeredanddevelopedforusfromaircraftgradealuminumwithvitonseals(modifica
tionplatepicturedbelow).Werecommendthismodificationonanyengineover60,000milesor4yearstoavoidyouasacus
tomer,becomingoneoftheunluckynumbers.
(http://www.ogsmechanics.com/wordpress/wpcontent/uploads/2014/10/bmwswirl
flap3.jpg)
HowwedoitinO.G.S.Mechanics.
Weremoveyourinletmanifoldwhichisthensteamcleaned.
TheEGRvalveisthencleaned.
Thebadlydesignedswirlflapsareremovedandreplacedwithourbilletmodifiedblanks.
Thevacuumrail(thatdrivestheswirlflaps)isthenremovedandblankedoff.
Werefitthemanifoldusingbrandnewinletmanifoldgaskets(theseareoftenoverlookedelsewhere).
Removeandreplaceengineblockbreather.
Thecarwillfunctionthesamewithouttheflaps,theflapsarethereforemissionspurposes,howeverthecarwillremain
withinguidelinesandyouwillnotnoticeaperformancechange!EGRvalveremoved,readytobecleanedPicturedbelow.
(http://www.ogsmechanics.com/wordpress/wp
content/uploads/2014/10/ynepuqe9.jpg)
Whentheinletmanifoldisremoved,thisiswhatwearequiteoftenleftwith.Thecarbonbuildupreallyrestrictsairflowthrough
theinletmanifold.
(http://www.ogsmechanics.com/wordpress/wp
content/uploads/2014/10/22mminstall528x528.jpg)
Thetopbreatherwasremovedfromacarwith60,000mileswithanewunitpicturedbelow.Thissumsuphowimportantitisto
changethisunitastheoldbreatherhasquiteliterallyswelledupduetobeingsocontaminatedwithoil.
(http://www.ogsmechanics.com/wordpress/wp
content/uploads/2014/10/crankcase21.jpg)
Finally,InletmanifoldgasketsasreplacedduringreassemblyPicturedbelow.
(http://www.ogsmechanics.com/wordpress/wpcontent/uploads/2014/10/Un
titled3.jpg)
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BestgarageIeverbeento,foundtheproblemthat3othergaragescouldnotfind!,startedwork
onmycarstraightawayandneverfinisheduntilitwasfixed,wellrecommended.Andthanks
againGerogeandteam.
ReeceVidler,04/04/16
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