Removing Swirl Valves: Experience and Tips

Hello diesel mechanics,

I couldn't find anything using the search function, so here's my question:

"Who has extensive experience in removing swirl flaps?"

I'm referring to some vehicles from the Mercedes-Benz (MB) and BMW portfolios that repeatedly experience problems with these parts.

The risk of major engine damage due to wear and tear is not particularly reassuring.

I have already removed the flaps from several 530d models without any negative consequences.

Replacing the intake manifold every time isn't necessarily a cost-effective alternative.

Can anyone share any direct experiences regarding problems or disadvantages encountered after the expansion?

Best regards, efistho.

Hello,

"I have a 330 Xd from 2001, and it didn't originally have these flaps. They were probably added later due to emissions regulations. I heard that all automatic vehicles are equipped with these flaps, regardless of the year of manufacture. A colleague had an engine failure on his 330 Xd from 2005 because of these damn flaps (a flap came loose and caused a sudden drop in power). I don't think there are any disadvantages to removing these flaps. I've done it myself on two vehicles, and they run without problems. (However, the mechanical system, specifically the vacuum control, must still function, otherwise an error code will be triggered.) So, just like you, I only removed the flaps themselves, so everything regulates as usual, but without the internal components. Best regards."

I know that some early BMW models had switches without flaps.

I think all the flaps are open at Daimler.

Thank you for your statement.

Unfortunately, I cannot translate that word because it does not appear to be a recognized word in the German language. It may be a misspelling or a made-up word. If you can provide more context or clarify the spelling, I would be happy to try again.

What's the point? A little less swirl in the lower speed and load range, which means a bit more soot, hydrocarbons, and carbon monoxide. Maybe even a little idling smoke (and smell) when the engine is cold...

Theoretically, it might also slightly reduce energy consumption due to lower inlet resistance, but the marginal effect is offset by the poorer mixing that results.

I also didn't understand those "Drall" things .

I switched from an Alfa 156 1.9 MJet 16V with 140 hp to a Fiat Bravo 1.9 MultiJet 16V with 150 hp. The differences are: different software, DPF (Diesel Particulate Filter), Euro 4 emissions standard, and swirl flaps. Above 3000 rpm, it has a slightly more noticeable "knocking" sound. The reason given is that the swirl flaps help to reduce exhaust emissions.

"Swirl flaps" isn't actually the correct term for those things.

At Daimler, they refer to a system that shuts off the intake manifold as "EKAS," which stands for "Einlasskanalabschaltung."

Using these flaps, a vacuum is artificially created in the intake manifold in certain operating areas, thereby enabling or improving the function of the EGR (Exhaust Gas Recirculation) system.

With that, we have built the bridge to emission.

For vehicles that don't require AGR (Abgasrückführung) based on their software configuration, the flaps are unnecessary. Even after multiple dynamometer runs (intended for performance measurement after the software modification), I was unable to detect any torque changes with and without the EKAS (elektronische Klappensteuerung) system in a specific E320 CDI model.

Absolutely no effect resembling that of a swirl intake manifold or Thumble valves in the intake could be detected or measured.

Best regards, Tom.

Tom.

I think you're confusing the swirl flaps (I have four of them) with the intake manifold flap (I only have one of those).

The throttle valve is slightly closed to allow the EGR system to function "better." This is precisely the function of what you described as "artificial vacuum."

The swirl flaps cannot change anything about this, because the EGR valve is connected much further upstream.

You're right, they should really be called something else: filler flaps.
Because the swirl channel is always open, while the fill channels are activated or switched on.

Okay, please provide the German text you would like me to translate into English. I will only provide the translation.

Just so we're on the same page, I mean these flaps!

Best regards, Tom.

Are these all inlet channels?

If so, they are similar to the fill and swirl channels I have.

Your top six filling channels can either be fully open or fully closed – at least, that's what the rudimentary vacuum sensor suggests.

Just like with me:
The BMR engine has eight intake ports, four swirl ports, and four filling ports. The four filling ports can be closed.

Okay, please provide the German text you would like me to translate into English. I will only provide the translation.