Vauxhall Vectra 1.9 Cdti Inlet Manifold Swirl Flap Blanking Caps Z19Dth New ***Suitable for manifold part number 55210201***

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Seller: vauxhallpartsuk ✉️ (25,067) 0%, Location: Market Harborough, GB, Ships to: WORLDWIDE, Item: 361063565189 VAUXHALL VECTRA 1.9 CDTI INLET MANIFOLD SWIRL FLAP BLANKING CAPS Z19DTH NEW.
  
 
INDUCTION/INLET MANIFOLD SWIRL FLAP REMOVAL KIT (DE-FLAP KIT)
 

This kit allows you to re-use the original inlet/induction manifold (part number 2.03462.03 55210201), with the swirl flaps REMOVED, meaning there are no further issues with the manifold.

 

This kit is designed specifically to work with the latest design of Pierburg inlet manifold, which is part number 2.03462.03 55210201 (See pic) .

 

This Pierburg inlet manifold is fitted to many Vauxhall (CDTI), Saab (TiD), Fiat (D Multijet) and Alfa Romeo (JTD) 1.9 diesel 150bhp engines. Please check yours is compatible.

 

Please note, if you have an earlier version of the manifold, this kit can still be used, however the swirl flap holes in earlier versions are smaller in diameter, so they would need to be machined out in order to accept the blanking plugs included in this kit.

 

 

This kit consists of:

5 x Taper machined aluminium bushes

1 x BondLoc B603 locking compound (developed for oily environments)

Each aluminium bush is machined to a taper, so it will drop into the hole easily to locate, with around half of its length inserted. The second half of the bush is machined to a tight fit that will require the use of a G clamp*, or similar, to press it into place. This creates an incredibly strong seal. BondLoc is also used, giving even more strength than necessary.

Once 'De-flapped' the square runner of the manifold will now be free flowing with no swirl flaps.

The flap actuation motor should be left on the vehicle, and connected electrically, but with the lever arm disconnected. This allows the ECU to recognise that the motor is present, and working, and should not cause the EML to illuminate.

 

From testing and daily use of CDTI (150bhp) engine Astra Van, the manufacturer of this kit reports great results from fitting the De-flap kit. No Engine management light, no rough running and no extra smoke. The engine idles just as before, through the revs  it feels keener and responds to throttle inputs more quickly, and also feels more eager to rev to the redline. From testing, on a rolling road (see picture above**), before and after fitting the De-flap kit, the manufacturer witnessed a 3bhp gain in maximum power and a 3.5lb/ft torque gain after fitting the De-flap kit. These are not big gains but a welcome side effect from fitting the kit.

 

 

Fitting Instructions.

With the inlet manifold removed;

 

1) Remove swirl flaps and all plastic associated components.

2) Clean inlet manifold of soot/oil making sure the 5 holes are degreased and clean.

3) Apply BondLoc generously to 1 bush at a time (be careful, it's very runny) (see eBay image)

4) Press, by hand, the bush into place as far as it will go, this will be around half way into the manifold, the 4 large bushes in the top. The smaller bush goes into the underside, using the same method.

5) Use a G clamp*, or similar tool, to press the bush in the rest of the way, until the top hat is seated squarely on the manifold and the bush can move in no further (see eBay image )

6) Wipe away any excess BondLoc with a lint free cloth.

7) Repeat process until all bushes are pressed in. Leave overnight for the BondLoc to cure. A little warmth will speed up cure time.

8) Refit the manifold according to manufactures instructions, leaving the swirl flap motor and bracket in place but the lever arm disconnected.

 

Please note;

 

*G Clamp - Not included (Available at most DIY outlets)

**Information graph supplied by product manufacturer.

*** LMF Vauxhall does not take any responsibility for loss or damage caused by incorrect use/fitting of this item.

 

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