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Swirl flaps
The number one
design problem
is a failure in the construction of an inlet partwhich can lead to serious
damage to the engine and when it occurs will causehigh costs to
repair.The BMW diesel engines produced between 2000 and 2008 all
have a particular
design problem
with inlet manifold butterfly flaps (commonly known as swirlflaps).
Swirl flaps are used inside the inlet manifold of the BMW M47TU
&M57TU diesel engines to vary the length of inlet manifold tract
subject to load

and anticipated demand.

5
BMW/Pierburg made a decision to manufacture those diesel engine
swirl flapsfrom steel. BMW swirl flaps will commonly fail in such a way
that they either:drop an affixing screw and or the upper section of
spindle. If this does not stopthe engine the remaining swirl flap falling
completely in will! The outcome of such failure is not pretty in the
slightest. Diesel engine’s piston cycles at leastat 60 revs per minute, so
an ingested metal piece fallen off the butterfly flapwill be slammed by
the moving internal components. Most often one or morepiston ends up
being severely damaged along with several valves, an injector and the
cylinder head,with possible collateral damage spreading to the turbo as
well!Later; around 2004, BMW addressed this fault; the swirl flap
supporting spindle was increased in sizealong with the affixing screw
diameter. Despite the increased spindle diameter, we have seen and
hadnumerous reports from customers all over the country of modified
type swirl flap failure! bmw