Vauxhall Opel Swirl Flaps Strip Down Part 1 -1 9 CDTI 150 BHP

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Vauxhall Opel Swirl Flaps Strip Down 1 9 CDTI 150 BHP.
0:00 Fault explanation
0:44 Intro Music
1:00 Difference between 150bhp and 120bhp engine
1:19 Strip down to get to manifold
4:58 Locking diesel pump sprocket
8:51 EGR valve removal
11:43 Removing sundry items from engine
15:20 Throttle body inspection
16:14 Continue strip down
20:42 Diesel pump removal
25:08 Removing rear bracket and swirl pot
27:38 Manifold removal
In this video I need to remove the inlet manifold so I can fix the swirl flap problem on this Vauxhall Signum 1.9 CDTI and I show how I managed to do this. I will be removing the swirl flaps and deleting them as they are a common problem on this model of engine. Keep an eye out for part 2 where I clean the manifold, the EGR valve and the throttle body as they are all coked up. No need to remove the timing belt for this job, you just need to lock the diesel pump pully as shown in this video.
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Комментарии : 160

@retrorestore 2 года назад

Check out my Amazon Wishlist to help support the channel at www.amazon.co.uk/hz/wishlist/ls/I4S3IK6JV38H

@spencerhawkins8092 2 года назад

"No I don't know what I'm doing" sounds like me 😂

@here_for_the_popcorn4474 2 года назад

Just the ticket.. same engine in mine. Already had the swirl flap issue, fixed it with an upgraded swirl flap bar and a lot of patience; done without any strip down. But if I want to weld them up, now I have a guide for strip down... many thanks... I'll be saving pt 2 also !

@vijayantgovender2045 2 года назад

Thank you Martin I love watching your car repair videos can’t wait to see part two I am from South Africa

@optical70xultrazoom 2 года назад

So glad I found this video. Thanks for giving me the confidence to tackle the job!

@puffyjet 2 года назад

Great video Martin very informative and interesting I love the way you filmed it ,its like being there when your working on the car. I can see why people would gain the confidence to do such a job watching the way you work with such determination on what looks like a very hard bit of work. I cant wait for the next one thanks very much. Kevbo&Jackie

@retrorestore 2 года назад

Thanks Kev.👍

@blankgenerator923 Год назад

Thanks very much for posting this. Helped me in the most part change my inlet manifold for a flap deleted one on my alfa 1.9 gt jtdm. One difference was having to grind away part of the cog bulkhead in order to remove the manifold. I couldn't get my grinder in far enough so resorted to smashing one corner away to be able to get in! Anyway, running much better now. Thanks again.

@davidvickers9029 2 года назад

Good job Martin, looking forward to clean up and reassembly

@user-re3kz3di8c Год назад

Thank you for taking the time to do this video. It helped me get over the line to do this on my Saab 9-3 1.9tid. Keep up the good work!

@ryanrepairs6944 2 года назад

Great as always have a good weekend martin

@matthewharmer1656 2 года назад

Great video martin, you have the patience of a Saint to do the job,.. I just couldn't face it....keep up the good work.

@grippingyarnsuk 2 года назад

Very well made, explained and filmed . Thanks

@STTC 2 года назад

As soon as you described the necessary strip I said, “forget that” to myself🤣🤣. You really are an inspiration Martin, massive technical job and with engine bolts something always breaks for me. I have officially retired from car repairs but love watching your skill and enthusiasm 👍🏻

@retrorestore 2 года назад

Haha Steve, It would cost a fortune in a garage, Cars of this age normally get scrapped for jobs like this because of the garage costs so that's why I do these vids.

@STTC 2 года назад

@@retrorestore Mine would be coming to your house lol

@winsoxuk 2 года назад

Great tip on locking the fuel pump sprocket... Just in middle of doing this on a Saab cabriolet 1.9tid and it takes a pain out of having to remove the strengthening bars underneath to get to support the engine having to take the timing belt off. Much appreciated!

@retrorestore 2 года назад

Good luck with it David.

@andytownsend9163 2 года назад

Great job Mart, very informative as always

@retrorestore 2 года назад

Thanks for watching

@johnhealy9231 2 года назад

Well done Martin, lots of small bits to get out of way to get the inlet manifold off but you did it thanks for showing it 👍

@retrorestore 2 года назад

Thanks John👍

@craigjarvis9489 2 года назад

Some job that mate. What a poxy design. Fair play to you.👍

@peteringram476 Год назад

i had a problem with my saab 93 tid chuckin out smoke ,it turned out to be the swirl flaps and managed to find your video which was great for doing the job .I just blanked them off ,now shes a good un ...........great video

@retrorestore Год назад

Thank you so much 😁

@68xperfectx 2 года назад

Great video Martin, I had the same problem with my saab 93 which shares the same engine, turned out to be the turbo boost control valve once I replaced that all the horses were back in the stable.

@RedEyedJedi Год назад

Great video, very informative 👏 Tip for not losing the gasket when removing the egr valve. Stick a cloth down in the gap to catch it just in case it falls. I've used this tip for lots of things when fixing cars and it has saved me a lot of hassle. It's also handy to have a telescopic magnet 🧲

@Phil-1969 2 года назад

Tutorial videos are the best videos you do Mart , 👍 up

@retrorestore 2 года назад

Thanks Phil👍

@andynorris3537 2 года назад

Great job Martin lot of work involved in getting the manifold off

@georgestewart1325 2 года назад

Wow that was mind blowing. A lot of work thanks for sharing.

@retrorestore 2 года назад

Glad you liked it!

@jameshazell2377 2 года назад

Smashed it. Don’t even own this car but like watching Martin !

@retrorestore 2 года назад

Thanks James

@aerosolu Год назад

thank you, vlog was amazing, i was doing the same thing with this video on tv, worked perfectly, tx

@alandykes2519 2 года назад

Fantastic job Martin on a very tricky job thumbs up 👍👍👍👍

@retrorestore 2 года назад

Yes it was Alan.

@andy_v4443 2 года назад

Great job Martin 👍👍

@danielbevan2192 Год назад

Doin mine now I'm mechanic btt thank for video as I had trouble removing swirlpot braket btt noticed the pot had bolt running through it btt I never thought it b behind the pot so well explained as iv found the nut through ur video so well done for explaining so well mate nearly there just got remove the fuel pump n the bottom bolt off pump il b ready take out the manifold then

@retrorestore Год назад

Glad it helped

@zonda7771 11 месяцев назад

Great video. Thank you.👍

@petefroud5308 2 года назад

Good job Martin . A lot of work .

@retrorestore 2 года назад

Yes it was Pete.

@gerbutt 2 года назад

Good work dude! Saving a small fortune doing it yourself hey 👍

@retrorestore 2 года назад

Thanks 👍

@lewisjenkins1114 Год назад

I've done this job many times and it never gets any easier, that bracket at the back and the charcoal canister is such a pain! I take them off scrap cars and tig weld the swirl flap holes, people are often happy to hear they can be blanked off 🤣

@vdubs6068 2 года назад

Good Job Martin 👍

@alanrollo2942 2 года назад

Same engine that was in my saab 9-3. Had the swirl flap issue but ended up having to replace the the manifold,the swirlflaps and the dpf

@sdone7672 2 года назад

Nice work Martin, like the flesh colored gloves. 😉👍

@retrorestore 2 года назад

Glad you like them lol

@zeez3139 Год назад

Great work my friend ! Feel your struggle very familiar with DIY wrenching 🍀👍🏻🇬🇧

@retrorestore Год назад

Thanks 👍

@markmawson1 2 года назад

I did a mates Corsa B Combo with the 1.7d Isuzu engine in it and he was saying it had no power to what it used to have when he first bought it anyway as it had the old vacuum powered EGR valve on it I thought it would be stuck open so removed it and there was no hole behind it into the manifold so was blocked with an oily sooty residue so decided to remove the inlet manifold and was I in for a nasty surprise the holes down to the valves in the head and inlet manifold what used to be the size of an egg were infact the size of 10p piece so the engine was being strangled, I spend a whole day cleaning out the inlet manifold and inlets in the head with a blow torch for the inlet manifold and vacuum cleaner for the build up in the head, once that was done he said it felt better than it ever did on the road. Every vehicle I work on and is fitted with an EGR valve I blank them off and never had any fail an MOT over a blanked EGR, I just replace the original stainless steel gasket with a piece of tin plate cut to the same shape so tester probably thinks it's just the gasket, a lot of blinking plates are ¼" thick plate so then they will know it's been blanked off that's when they fail them.

@karlfeast 4 месяца назад

Good video mate helped me 👍

@karlfeast 4 месяца назад

What’s the orange connector for under the egr area?

@garyclifton2180 2 года назад

Nice job Martin looks a rite faf but very informative

@retrorestore 2 года назад

It is lol

@astrujurginas861 Год назад

Hey very thanks for this video, realy help

@jimwright5492 2 года назад

Dpf and egr cause that carbon build up,mine mysteriously vanished lol,brilliant vlog as usual Martin, cheers

@retrorestore 2 года назад

Thanks Jim👍

@philipnewton7524 2 года назад

Martin Gloves mate what a job glad I am not doing it very interesting to watch think what a garage would charge for this job the carbon build up inside so thick this car should run better after this them flaps willnot stick closed one removed cant wait for next video Phil in stoke

@fifth-scaleproductions8878 2 года назад

They now sell a heavy duty swirl flap design inlet on ebay. Fitted one to a saab 93 the other week. New timing kit aswell , owner now says its very fast compared to before.

@projectclark123 2 года назад

Really good video thank you

@robstahl2531 2 года назад

Good persistence Martin..and great instruction....what a nuisance some of these engines are to work on now,eh !......(those RD350/LC,ect 'lumps' seem so easy to work on now,eh !)....happy days.....

@retrorestore 2 года назад

Too right Rob, A garage would charge a fortune for this job and the car would probably get scrapped.

@erdemir5641 Год назад

I did this on my astra. Worst bit was the oil bowl thing at the back. Replaced manifold with a welded manifold

@shanebrookes1878 2 года назад

Do cars myself but that looks a pig of a job!! Loving ya videos Martin

@retrorestore 2 года назад

Thanks Shane👍

@01arron 2 года назад

I swapped my swirl flap rod with the fully metal with brass fittings. Haven’t had a problem since

@Jared-qy1jh 2 года назад

I did the exact same job in my Alfa with the same engine. On some of these engines they fitted a plastic manifold with metal flaps that destroy engines when they fail, and the removal is even worse. The fuel pump bracket required some Dremel work to get my manifold off. I had a similar low power issue which was improved by the swirl flap repair, but the biggest fix was from the MAF sensor going faulty. Worth a check by driving with it unplugged if the issue persists, but fixing those flaps is always worthwhile. Good luck with the rest of the job, and great video!

@retrorestore 2 года назад

Yes, I had the MAF issue on our Astra and it transformed the car fitting a new one too.

@barbarawiddowson635 2 года назад

Haven't seen that much carbon since I burnt the toast,wow!! It's a dirty job but well done for taking it on and helping others to try it.Just make sure you put all the pieces back!! LOL.Stay safe.

@retrorestore 2 года назад

Thanks Barbara👍

@patrick103b 2 года назад

I have the 5 cylinder version 250hp in my fiat croma had the swirl flaps tired open egr delete and and dpf delete and it doesn’t half shift and passes mot every year

@tinkeringtaylor3053 2 года назад

Good one there Martin

@WestYorkshireGuy1 2 года назад

Martin, fit a welded inlet manifold. Its the mod most owners with issues do. The EGR delete is an MOT pass if you map it out. It only fails for an EML on the dash. You can also get a blanking plate with a smaller hole to stop the EML coming on. I would advise if not blanking the manifold you fit a new swirl flap actuator.

@retrorestore 2 года назад

Jimmy's mate is welding the manifold up.

@WestYorkshireGuy1 2 года назад

@@retrorestore tbh. I would have mine done as a prevention but it can actually cause some issues. Luckily it was only my bar that came off and I fixed it. Looking at the amount of oil in the throttle body the turbo seals might be on the way out. They are good strong engines apart from the crap to reduce emissions.

@steptoeandson3554 2 года назад

@@WestYorkshireGuy1 all that carbon is exhaust gasses via EGR, the reason there is more than usual is due to the boost/air leak. The ECM sees a high air flow and ups the fuel to suit but as its leaking air/boost it causes rich mixture resulting in incomplete burn and excess soot, on an older diesel without DPF this would be noticeable with black soot clouds out of exhaust. The DPF catches soot so driver is usually unaware of problem or might feel a slight power loss. The slightest of air leaks in the boost circuit causes rapid build up of soot everywhere upstream of the DPF.

@ghislainsambi5285 Год назад

I like it. I like Opel Zafira cdti

@jouniinvelez7469 2 года назад

What a pig of a job! Very instructive video, thanks! (Sticking to petrol engines).

@retrorestore 2 года назад

You're welcome!

@derbyjohn1258 2 года назад

Yes Martin amazing job again so therapeutic. Keep going bud 😍

@retrorestore 2 года назад

Thanks John👍

@josephcarino5829 2 года назад

Ingenious

@RedEyedJedi Год назад

I have all studs on mine and the manifold is getting caught at the side nearest the drivers side. Any idea how to get this out?

@ktheed123 2 года назад

Be careful of the injector return pipes, easy to put your elbow on them and snap them. Coolant flows through the inlet so its drained to prevent it from entering piston 1 and 2 when you pull the inlet away from the engine.

@grippingyarnsuk Год назад

Very good video . Thanks. I’m doing a 159 Alfa . Changed inlet manifold and am getting p2013 fault code so contemplating removing swirl flaps . Will that help get rid of code i your opinion? Cheers !

@retrorestore Год назад

Not sure bud, sorry.

@ghislainsambi5285 Год назад

Thanks

@alejandroperez5368 Год назад

Too many parts need to be stripped down. Way too scary. I once removed the EGR and the Throttle body, but this is on another level.

@philblay4330 11 месяцев назад

I had problems on my Zafira SRi 1.9 CDTi 150bhp, with no power at all. Turned out to be a coked up MAP sensor. (Don't buy cheap ones, stick with Bosch) Once changed there was an obvious power increase. Then found swirl flap bar off. This causes a kind of mis-fire feeling above 2000 rpm, which varies depending on which flaps are stuck open or closed. Put the bar on, problem goes away until it falls off again. My Swirl flaps are badly worn and leaking diesel which seems to cause a P2279 (air leak) error. Now going to blank them off.

@johnharris6091 2 года назад

I bunged the holes where the swirl flaps were .no problems since, just make sure the electrical connection is still on the actuator.

@gingernuts9894 2 года назад

Hello there @retrorestore thank you for putting this video up its been great, got a question for you about the diesel pump removal, iv got the 3 nuts off and the main nut on the pulley, but I can't get the pump out, iv got movement of the bar with the woodruff but it just won't go quite all the way, even with a few taps for persuasion, any advice? Cheers!

@retrorestore 2 года назад

Mine needed a good wack but make sure you don't hit the bare end of the shaft or you'll damage the threads. You can wind the nut on and hit that..

@gingernuts9894 2 года назад

@@retrorestore yeah I think you said about putting the nut on to protect it, so I gave it a go and it'll go flush but then when I take the nut off and try pull through it just won't go 😅 will have at it again tomorrow and see if its just got itself caught on something

@gingernuts9894 2 года назад

Needed a bit more persuasion than I expected, but the manifold is now off!

@Paul-wz1fl Год назад

Hi love all your videos. Your so lucky to be so skillful . Ive a astra H 1.9 CDTI 150 looks like same engine as this one your working on. After watching this video I had to check my own and the metal bar that goes between the 4 swirl flaps and broke off completely. Thinking of tackling taking the inlet manifold off myself as your video is brilliant to follow. Can I ask the threaded bar that the fuel pump is attached the one that has to be removed to allow the inlet to be removed. You had to put two nuts on that bar to then remove it. Can you tell me what size nuts would be needed for that threaded bar. Thank you so much. Wish I lived close by as I'd just leave the car with u to sort 🎉

@retrorestore Год назад

Sorry Paul, I can't remember bud.

@Paul-wz1fl Год назад

Tha k you so much for your time in replying. Is the fuel pump itself held onto the three threaded bars by nuts would just using two of them do of they are held on by nuts?

@geoffgreenhalgh3553 2 года назад

Christ martin, where do you get your patience from? What a ball-ache of a job. Don't we love modern cars. Good work.

@minisareus 2 года назад

Had the same problem with my 120hp version you need to fit the later upgraded inlet manifold and actuator?

@johnharris6091 2 года назад

I didn't think the 120 version had swirl flaps

@Paul-wz1fl Год назад

Hi please help. While taking the inlet manifold off to remove swirl flaps 2007 astra 1.9cdti 150 I forgot to drain coolant. Soon as I started to remove manifold could hear a gargle noise so immediately drain coolant. While draining the coolant from tap on front left underneath water was also leaking down the back of engine. Do I have problems big problems now? I could see in through the 4 holes in the engine when got the manifold off and one had liquid in it just small amount. What do I do please help. Cleaned the liquid out as much as I could see by pushing a cloth in and soaking it up. I've the manifold refitted swirl flaps blanked will it be ok or have I bigger issues now . Would draining the engine oil fix my mistake.

@retrorestore Год назад

I would change the oil just to be safe.

@karlblake2809 Год назад

Hi mate , what are the torque settings for the inlet manifold? Pump pully?

@retrorestore Год назад

I can't remember, sorry.

@Paul-wz1fl Год назад

Hi please reply. When you were putting everything back together after the inlet manifold in place etc. The fuel pump was the nut that was holding onto where the timing belt is.. was it 15nm or 50 nm torque did you say. Cheers

@retrorestore Год назад

I can't remember, sorry.

@Paul-wz1fl Год назад

@@retrorestore how would I find out

@tonypenny848 8 месяцев назад

What would cause these to keep blowing out I've had a second unit fitted and the same one has blown put, is this normal

@retrorestore 8 месяцев назад

Its just a poor design.

@ASH.......................1976 2 года назад

Getting pretty rare those cars Marin ,I've had a look and there Is only 377 left that are still on the road 👍👍

@retrorestore 2 года назад

Yes they are Ash

@ASH.......................1976 2 года назад

@@retrorestore 👍

@jaggass 2 года назад

I cleaned the EGR Valve ,throttle body and inlet on my A3 TDI every year and it was such a dirty job. It wasn't sluggish before i cleaned it up but afterwards my mpg would go up a bit. It didn't have a DPF either which helped. For cleaning EGR valves, throttle bodies and inlet's i recommend Mr Muscle but don't leave it on for too long or it oxidizes the aluminium.

@felbringer5541 Год назад

Need video like this but 1.7cdti

@flange7103 2 года назад

Hi Martin, can I ask how long it took you from starting to getting the airbox out? About to do the job myself although I've a new airbox and EGR so I wont have to clean the ones I take off

@retrorestore 2 года назад

Its hard to say as i'm filming at the same time bud.

@flange7103 2 года назад

Thanks for the reply. Think I’ll have it all done in a day as I have a new air box, EGR valve and map sensor. I’ll let you know how I get on. :)

@kevindavies5429 2 года назад

Hi mate what error code was it reading my vectra has a similar problem thanks

@retrorestore 2 года назад

I can't remember sorry.

@berndb.5097 2 года назад

Again, thank you very much for your effort!👍 Hopefully you can get your hands clean again. 🤷

@retrorestore 2 года назад

I hope so too lol

@user-fh3cv4li4v 11 месяцев назад

What is the symptoms of bad swirl flap? Can be hard start caused by bad swirl valve?

@retrorestore 11 месяцев назад

yes and poor performance

@rekordi 2 года назад

Gloves highly recommended when diesel intake manifolds are involved.

@bigh236 2 года назад

Is that the fiat engine 🤔. It was a nightmare on my 1.9 vectra Estate Sri nav ...

@toafy1014 2 года назад

Intake system air leak fault code is the egr valve, done loads of them, clean it will only last so long to be honest best just to blank or replace

@RedEyedJedi Год назад

If the sensor is on the inlet manifold then it's a MAP(Manifold Absolute Pressure) sensor. If the sensor is near the airbox then it's a MAF(Mass Air Flow) sensor.

@retrorestore Год назад

That is correct.

@AGN-dt2dj 2 года назад

Quick question, I think I have the same issue on my car and I’m wondering should I bother to fix it or is it fine to drive without having to worry about anything blowing up.

@retrorestore 2 года назад

You will probably have a lack of power due to air leaks and it may fail the emmisions due to the ecu trying to compensate for the air leak.

@AGN-dt2dj 2 года назад

@@retrorestore hi thanks for the reply, yeah I have a bunch of issues with it, lack of power, black smoke upon acceleration and boost doesn’t even come on until about 2300 rpm and when I does it’s not good, as well as engine light with air leak fault code, idle also sounds rough makes a few weird noises.

@steven907 2 года назад

Hope Jimmy watches this to see the shift you put in martin

@waynio67 2 года назад

Best cure for these is egr delete and map out plus welded inlet manifold,

@chriscroucher98 2 года назад

Hi Martin …. I have a blanking kit for one of them you are welcome to have …

@WestYorkshireGuy1 2 года назад

The blanking kits are OK but tend to leak again. Better off fitting a welded inlet as its off anyway.

@retrorestore 2 года назад

Thanks Chris. Jimmy's mate is welding the manifold up.

@chriscroucher98 2 года назад

@@retrorestore the other thing we used to do was tap the holes and wind in a blanking plug

@Cal1395 Год назад

I've done a few of these that one 12mm below the fuel pump pain in the ass

@alanpatterson2759 2 года назад

Carbon build up wouldn't be helping as well. thoroughly enjoyed the video.

@janaveien123 2 года назад

👍😊

@alanlewis2867 2 года назад

tip put some petrol in when u fill up with diesel

@baytraders 2 года назад

Martin, if they were handing out medals for tenacity....! - drop the bonnet, stick all the bits in the boot and scrap it. Get yourself a mk3 Cortina or something similar and bask in the glory days of simple mechanicals with room to work on simple engines without all the egr and electronic crap. Funny how that simplicity now commands more money than all the complicated technical, designed to be unservicable tripe we have to live with now - Rant over and good luck with the rebuild..!!!

@retrorestore 2 года назад

It would cost a fortune in a garage, Cars of this age normally get scrapped for jobs like this because of the garage costs so that's why I do these vids.

@baytraders 2 года назад

@@retrorestore Absolutely, and they go on at us all the time about waste and saving the Planet yet they design these cars to be easily assembled and impossible to work on after. Saw an American video recently where Tesla wanted to replace an entire battery pack for $22,000.00 on a car worth $25,000.00. Independent garage swapped 2 cells and it cost $5,000.00..!! - Now I'm a Yorkshireman, so you can imagine my pain..!!!

@ktheed123 2 года назад

Remove the flaps and have the inlet welded and blank egr, there is a polish website you can order an egr simulator from and have it delivered to the UK....problem wont happen again. I did it to mine. msg me if you need more info.

@FixedByDuncan 2 года назад

Nicely done. Why do these muppets think it's a good idea to make these parts out of plastic?, it's almost as if they design them to just last for the warranty period......

@stevebaxter6083 2 года назад

Explained all said the tools you need but you forgot the most important one a swear box ( should sack the catering help no cups of coffee or tea) ha ha

@AdamForeman 2 года назад

This video is a great example of just how bad people treat their cars. It also shows that the only thing to do with this car is fix it and sell it. That engine design, loom etc is probably one of the worst designs for anyone to work on. It's not a car for people to learn car maintenance from. Maybe that's why it's in such disrepair? Still can't get over that it passed its last MOT. That's simply frightening scary. Obviously took the money but didn't go over the car at all in my opinion.

@brownaleguy4837 2 года назад

147bhp

@ASH.......................1976 2 года назад

In fact,if you're is a signum design cdti auto there is only 4 licenced and 4 SORN ,sorry this is nothing to do with your video ,I just thought I'd look 😄👍