The ball joints on the swirl flaps can wear to excess rendering the swirl flaps un-functional, also the seal on the swirl flaps can fail causing inlet manifold air leaks.

It is a very common fault for the swirl flap operating rod bushes to wear down and for the operating rod to pop off causing these symptoms, this can easily be rectified with our replacement improved design operating rod.

Unfortunately, on occasions the ball joints on the swirl flaps which this rod connects to can be too worn to repair with a new rod, alternatively the seals on the swirl flaps on occasions fail and cause air leaks. Previously, this necessitated the replacement of the whole intake manifold at vast expense. However, using our blanking kit the swirl flaps can be removed and blanked off allowing you to repair the manifold you have; saving the cost of a new manifold and preventing any future swirl flap issues.

Remove the swirl flaps from the inlet manifold and blank off using our kit; eliminate swirl flap faults without having to buy a complete new intake manifold.

Our unique design kit allows you to blank off the swirl flaps on your original intake manifold resolving swirl flap faults permanently. Our blanks are precision engineered from billet aluminium and are fitted with a O ring to ensure a good seal, a far better alternative to pressed parts which can fail to seal.

A cost effective alternative to a whole new manifold which would likely fail again. Save the cost of a new manifold and prevent any further swirl flap issues. Some of our customers have installed our blanks as a preventative measure to avoid swirl flap issues further down the line and some customers have experienced performance gains from removing the swirl flaps.

YOU WILL NEED TO CHECK THE PART NUMBER ON YOUR INTAKE MANIFOLD BEFORE ORDERING AS THERE ARE TWO TYPES OF MANIFOLD. THIS LISTING IS FOR MANIFOLDS WITH THE PART NUMBERS LISTED BELOW:

55210202, 55210201, 2.03462.03, 2.03462.02

The common symptoms

Engine management light (EML) lit, high fuel consumption, rough idling, rough running, poor power and torque, smoking from exhaust, error P2279-11 Intake system air leak,P2075 fault code.

Some of the vehicles affected:

Alfa Romeo - 939A200 ( 1.9 MultiJet JTDM 16V 110 kW / 150 PS)
147 - 1.9 JTDM 8v 2005+ [HP 120]
147 - 1.9 JTDM 16v 2005+ [HP 150]
147 - 1.9 JTD 16v 2004+ [HP 136]
156 - 1.9 JTD 2003-2005 [HP 126]
156 - 1.9 JTD 2004-2005 [HP 150]
156 Sportwagon - 1.9 JTD 16v Q4 2004-2006 [HP 150]
156 Sportwagon - 1.9 JTD 2005-2006 [HP 150]
156 Sportwagon - 1.9 JTD 2003-2006 [HP 126]
159 Saloon - 1.9 JTDM 8v 2005+ [HP 120]
159 Saloon - 1.9 JTDM 8v 2005+ [HP 115]
159 Saloon - 1.9 JTDM 16v 2005+ [HP 136]
159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 120]
159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 115]
GT - 1.9 JTD 2003+ [HP 150]

Fiat - Enigines M91 & M92 C
Roma - 1.9 D Multijet 2005+ [HP 150]
Stilo - 1.9 D Multijet 2005+ [HP 150]
Stilo Multi Wagon - 1.9 D Multijet 2005+ [HP 150]

Vauxhall - Engines Z19DTH & Z19DTJ
Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 150]
Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 120]
Astra Mk V (H) Estate - 1.9 CDTi 2004-2009 [HP 150]
Astra Mk V (H) Sports Hatch - 1.9 CDTi 2004-2010 [HP 150]
Astra TwinTop Mk V (H) - 1.9 CDTi 2006+ [HP 150]
Astravan (H) - 1.9 CDTi 2005+ [HP 150]
Signum - 1.9 CDTi 16v 2004-2008 [HP 150]
Vectra MK II (C) - 1.9 CDTi 16v 2004-2005 [HP 150]
Vectra MK II (C) GTS - 1.9 CDTi 16v 2004-2005 [HP 150]
Vectra MK II (C) Estate - 1.9 CDTi 16v 2004-2005 [HP 150]
Zafira MK II (B) - 1.9 CDTi 2005-2011 [HP 150]

Saab - Engines Z19DTH & Z19DTJ
9-3 Saloon - 1.9 TiD 2004+ [HP 150]
9-3 Convertible - 1.9 TiD 2006+ [HP 150]
9-5 Saloon - 1.9 TiD 2006+ [HP 150] 9-5 Estate - 1.9 TiD 2006+ [HP 150]

Content
4X Large cnc machined billet aluminium blanks (fitted with high quality Viton O-ring)
1X Small cnc machined billet aluminium blank (fitted with high quality Viton O-ring)

Please check out our Install Guide page for further help when carrying out the installation