manifold flaps off

Swirl flaps are small butterfly valves fitted to the intake manifold just before the cylinder head intake ports of many modern automotive diesel engines, including those from Audi, BMW, Vauxhall and Alfa Romeo.
The flaps are smaller than the intake runners and therefore allow air to pass around them even when "closed". The photo shows a cleaned swirl flap removed from the intake manifold of a BMW M47TU 2-litre diesel engine.
The flap itself is made from stainless steel and secured to a spindle by two small Torx screws. The sealing O-ring and external actuating lever can be seen below the flap itself.

The disadvantages of swirl flaps are mainly associated with fouling by exhaust gas recirculation, which leaves tarry deposits on the flaps and the inside of the intake manifold. Over time the flaps can begin to stick in one position and the engine management system may report an error code if the correct flap position cannot be achieved within a few percent of the design specification. More seriously, the flaps or their mountings can fracture under the strain and parts can enter the cylinder. This almost always causes major engine damage due to the very small clearances inside a diesel engine

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