(http://www.ogsmechanics.

com/)
advancedvehiclerepaircentre

T:02083466755(tel:02083466755)M:07908640578(tel:07908640578)

SwirlFlapFailure

WHAT ARE SWIRL FLAPS?

HOME (HTTP://WWW.OGSMECHANICS.COM) / WHAT ARE SWIRL FLAPS?

Swirl flaps are one of BMWs greatest design

mistakes, causing 1000s of owners through
out the world either very expensive repairs
or even vehicles being written off.
TheflapsliveintheinletmanifoldofBMWdieselM47TU&M57TUen
gines(either4or6flapsdependingontheamountofcylinders).

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)


Tweet Like 0

Written by Joe (http://www.ogsmechanics.com/author/joeh/)

Viewallpostsby:Joe(http://www.ogsmechanics.com/author/joeh/)

Commentsareclosed.

SEARCH OUR WEBSITE

search

MOTOR CODES FEEDBACK

BestgarageIeverbeento,foundtheproblemthat3othergaragescouldnotfind!,startedwork
onmycarstraightawayandneverfinisheduntilitwasfixed,wellrecommended.Andthanks
againGerogeandteam.
ReeceVidler,04/04/16
CHECKATRADE

CheckatradeinformationforO.G.SMechanicsLtd(http://www.checkatrade.com/OGSMechanics)

LIKE US ON FACEBOOK!

OGS Mechanics LTD

Like Page 11K likes
stolen, lost, or because your vehic ...
CARKEYSSOLUTIONS.CO.UK

GOOGLE+

RECENT POSTS
NOVEMBER2,2015

NEW DEVELOPMENTS
(HTTP://WWW.OGSMECHANICS.COM/INFORMATION/DEVELOPMENTS/)

(HTTP://WWW.OGSMECHANICS.COM/INFORMATION/DEVELOPMENTS/)
PROUDTOANNOUNCENEWDEVELOPMENTSONOURWORKSHOPANDON...
readmore(http://www.ogsmechanics.com/information/developments/)

(HTTP://WWW.OGSMECHANICS.COM/ANNOUNCEMENTS/2014CHRISTMASNEWYEAROPENINGHOURS/)

DECEMBER12,2014

CHRISTMAS & NEW YEAR OPENING HOURS

(HTTP://WWW.OGSMECHANICS.COM/ANNOUNCEMENTS/2014CHRISTMASNEWYEAROPENING
HOURS/)
ITSTHATTIMEOFTHEYEARAGAIN!THISYEARWE...
readmore(http://www.ogsmechanics.com/announcements/2014christmasnewyearopeninghours/)

FEBRUARY24,2014

CHEAP CAR SERVICING IN FINCHLEY CENTRAL. SAVE BY DRIVING TO OUR CAR GARAGES
(HTTP://WWW.OGSMECHANICS.COM/INFORMATION/CHEAPCARSERVICINGCHEAPCARGARAGES/)