Swirl flap repair

[Gazdkw]

Taking into account my recent issues and the fact I know my swirl flaps have stopped working, I am going to replace the swirl flaps.

Could any of you knowledgable ones help me with what needs to actually be replaced outside of the swirl flap assembly, intake gasket and injector seals.

Does the swirl flap assembly differ between engine variations of D5?

I plan to take the EGR out and cooler and clean that up as much as I can. I noticed an oil leak around that area. Are there any common gaskets that fail around that area?

[Kev0607]

There isn't really anything else. Buy a kit, it comes with all you need (swirl flaps, swirl flap link rod (the plastic arm), intake manifold gasket and injector seals).

I don't thnk there's variations, as its only the euro 4 engines that use swirl flaps. Euro 5's onwards have no swirl flaps (as far as I know).

Here's an example of a kit. You can see it fits various models, all of which had swirl flaps.

https://www.partsforvolvosonline.com...ducts_id=10307

As for the oil leak you've noticed, that's likely a build up of carbon that has just turned to sludge with the heat of the engine over time. Its not unusual to see cars that have worn swirl flaps caked in oily sludge.

Note, the EGR valve gasket can be reused once. If you've had the valve off the clean it in the past, you'd have to put a new gasket on it this time. The EGR valve gasket isn't included in the swirl flap kit.

This is a messy job. So make sure you have gloves, plenty of old cloths or towels, plenty of EGR cleaning spray, brushes to help with cleaning... Its not a five minute job. Don't be surprised if the intake manifold is very dirty. Cover any injector ports with pieces of tissue and the cylinder holes. You don't want oily crud or carbon chunks falling down there.

[Gazdkw]

That's brilliant, thanks kev.