worn operating rod for flaps inside plastic inlet manifold 2.0 TDI 140 bkp 2006

[jedro750]

When I took the top engine cover off my passat Inoticed oily black carbon pellets next to the top lhs of inlet manifold, this blows out of worn seal around the internal flap operating rod, also causing lots of black smoke from exhaust under hard acceleration, VW say that new plastic manifold has a bush fitted to prevent wear, but this costs £438+vat+ lab,.Can the ali manifold off same bkp engine be fitted bearing in mind that it doesn't have the internal flap in the manifold and is there any difference in power etc or engine management issues, PS I've bought an ali manifold : 03G 129 713--waiting for delivery.
your knowledge would be greatly appreciated, Jedro.

[Crasher]

I am seeing this a lot on cars which we service and some cars have them when according to the parts system they should not. However, we only fit the new manifold which does seem to have been improved.

[martin1810]

I wonder what will happen if you wedge the flaps open to disable the system or even fit a plain manifold. All they seem to do is restrict air flow at low rpm.

[a8 tech]

you will increase carbon monoxide (CO) and hydrocarbon (HC) by wedging and affect fuel consumption

Function
The increased flow rate within the swirl port when
the swirl flap is closed as well as the design and
layout of the swirl port increase intake swirl within
the cylinder at low intake air flow rates.
This (desirable) effect causes the intake air to rotate
faster. This rotation and a higher flow rate are
necessary to ensure better carburetion, particularly
at low engine speeds and torque. Better fuel
economy and lower pollutant emissions are
achieved.
The swirl flaps are kept closed in the engine speed
range of 950 rpm to 2200 rpm depending on the
engine torque. The swirl flaps are always open when
starting the engine and when coasting.

[martin1810]

Cheers A8. I know what they do but they are most effective on petrol engines. That's why I wondered if anyone has tried junking them on a tdi. I know people are looking into junking them on the v6 tdi's. Don't know if anyone has managed to yet.

[jedro750]

I am seeing this a lot on cars which we service and some cars have them when according to the parts system they should not. However, we only fit the new manifold which does seem to have been improved.

Thanks Crasher, It seems a extortionate amount of money for a plastic moulding
Regards, Jedro.

[jedro750]

car now dead !!, was running smooth, pulled away from junction then engine spluttered and lost power. Pulled off the road then tried to restart, firing up on 2-3 cylinders, rocking side to side with blue smoke from exhaust and blue smoke where flap operating rod enters inlet manifold. Cattle trucked I think!!!, Showing no faults on diagnostics, We assume the flaps have dropped into engine, but until we take the inlet manifold off, wer'e just guessing. I'll keep you's posted, Jedro

[Crasher]

I have heard of flap ingestion causing valve damage, I have one in for service next week that I noted was suffering from flap hinge wear a year ago, I think I will warn her again. Apparently this is also a fault on some BMW engines.

[Bazaar]

When I took the top engine cover off my passat Inoticed oily black carbon pellets next to the top lhs of inlet manifold, this blows out of worn seal around the internal flap operating rod, also causing lots of black smoke from exhaust under hard acceleration, VW say that new plastic manifold has a bush fitted to prevent wear, but this costs £438+vat+ lab,.Can the ali manifold off same bkp engine be fitted bearing in mind that it doesn't have the internal flap in the manifold and is there any difference in power etc or engine management issues, PS I've bought an ali manifold : 03G 129 713--waiting for delivery.
your knowledge would be greatly appreciated, Jedro.

Did this part work in the end? The 03G 129 713? Thanks

[jedro750]

Did this part work in the end? The 03G 129 713? Thanks

engine was buggered, fitted 2.0 tdi bkd engine out of golf with alloy manifold, no smoke, very quick, more mpg, now just been for new injectors and download( recall ) and much smoother, quicker and 50 mpg, now done 19,000 miles on new engine , cheers jedro.

[Bazaar]

Ok thanks