To err is human,but
feel is divine...
Join Date: Feb 2008
Location: Novi Sad
Today, in local workshop, I removed swirl flaps from plastic (1.9 JTDm 16v, Euro4) intake manifold (Magnetti Marelli, No. 55202680 according to ePer). Procedure differs for variants with older full aluminium manifold and plastic+aluminium manifold...
a) All operation before removal of manifold are same for both variants (job of approx. two hours).
b) After removal of bottom aluminium part of manifold (connected with engine head) it is necessary to unmount electric-motor which drives swirls.
c) Next step is removing of plastic cover which protects mechanism for rotation of swirls (rack bar and little spring) and detach of rack.
d) The most important step is braking of metal swirls and extraction of swirl axles (see picture).
e) Four holes in manifold (Ø7mm top and and Ø5mm bottom) you can blank with proper bolt (conical head, previously treated by adhesive) or by welding - I prefer welding.
Final results are very well - smooth driving performance in low RPM range, better acceleration and obviously high performance in top RPM end...
Last edited by dusanGT; 08-08-14 at 21:30.