Om642 swirl flap open position. Leaky piezo fuel injectors causing oil dilution.

May 3, 2022 · 2010 W204 C350cdi Blue efficiency sport. Okay swirl flaps. Kajtek1. Best thing to do is remove the fuel filter and see if you can see any snappage in the arms or wear on the pivots to the swirl flaps. Note listing is for emulator only, not a new Pierburg swirl motor. This is made of a poor-quality plastic which wears prematurely. Sep 19, 2022 · previous video shows removing the swirl flaps and shaft. Right: full load, swirl flap open, high filling level. Timing chain issues and turbo issues go hand in hand with extended oil change intervals. They are small butterfly valves situated within the inlet manifold (intake manifold) just before the cylinder head intake ports. Like above, resistor will do the trick, if flaps are still on their place, and actuator is keeping them open position. Driving in limp mode is safe for as long The Mercedes-Benz OM642 engine is a 3. Not for 2007-2009 Sprinters or Mercedes model years with the 'CDI' badging. The swirling effect aids combustion and helps to improve emissions and generate more torque. We offer stage 1, 2 and 3 remaps for the overwhelming majority of cars and light commercial vehicles. I am glad that I found this site, thank you. 0 CRD) commonly found on various vehicles (Jeep/Mer Buy. Mercedes OM642 V6 vehicles suffer issues with the intake manifold, the swirl flaps within this manifold are controlled by an external operating rod. When failed the vehile will be put into "limp home mode". The swirl flaps are left in the open position. PASSENGER side swirl flaps -> The handle that moves the connecting rod should point away from the driver. Mercedes Benz, OM642, V6, 3. The swirl flaps are then pinned automatically into the open position . Does not require removal of Swirl Motor (left in situ unplugged). 7kOhm resistor, plugging the cable into the Swirl motor actuator plug, I have got a CODE: P2015 Intake Manifold Runner Position Sensor/Switch Circuit Range/Performance Bank 1 (that code wasn`t there before the Jun 4, 2011 · Under heavy load the swirl flaps would be in the 'wide open' position and would be causing no turbulence in the intake to allow the highest velocity airflow for maximum power due to the higher volumetric efficiency. Swirl Intake manifold flap position sensor for the Mercedes OM642 engine used in the 2010+ Sprinter and 2010+ Mercedes BlueTEC models. 95. The compression ratio of the 642 is 18 to 1. Over time the plastic wears at the connection Jan 5, 2022 · Swirl flap positions. The swirl flap motor was faulty, which is why I had the bypass (resistor) connected. $30. OM642 Engine intake swirl flaps on Mercedes-Benz ML W164 Sep 11, 2022 · Most likely used the wrong oil and the interval between changes was longer, instead of shorter. Deleted faults and did a small test drive. Download Link Sent to your PayPal email address Jul 19, 2020 · As an added bonus to this video here is a link on How too Video for making the intake Installation brackets that will make installing these intakes so so so Oct 26, 2023 · Unsurprisingly, there is a small cottage industry refurbishing these actuators, and it should have an OM642 back on the road for a few hundred dollars. Nov 22, 2010 · Reaction score. #3 · Mar 25, 2013. 0 V6. ez-office-supplies. 5mpg on the hwy, mixed driving in the last 2k miles has returned about 28. I have found the linkage from the M72 to the left intake lever or swirl flap guide, Dec 17, 2021 · Did my 2006 om642 when I first got it even though It was working ok at 82k. Jan 4, 2024 · I was about to replace the turbo actuator when I found out about the resistor mod for the swirl motor. The issue is, these swirl flaps are plastic, and this plastic gets Oct 26, 2011 · Location. Middlesbrough,North East,UK. 0 This video I’m going to show Find the items that are used on the Dave Sterl channel in the Amazon shop. Als Jan 2, 2024 · Mercedes S350 W222 OM642 engine inlet manifold swirl flaps actuator fixed. This is part of the job to fix leaking oil cooler seal. MADE IN CANADA. I’ve seen great success with these rebuilt actuators, but there’s still plenty that can keep an OM642 down. the swirl motor controls the position of the (air intake) swirl flaps. when the engine is OFF should both of the flaps be on the closed position? ie both control levers down. Intake flap servo motor for the 2007-2008 Jeep Grand Cherokee CRD with the OM642 engine. Sep 6, 2018 · Cleaned the intakes, swirl flaps are just disabled but in the open position. 1. Some really good and useful tricks and tips. May 14, 2017 · If you are interested in pruchase this product please write an email to jcanal82@hotmail. Thats why it was intermittent as it got hot. Contact seller. As the engine speed increases, the flaps gradually opens until, at around 2,000 rpm, they are fully open and present virtually no resistance. This motor is located between the two Jul 5, 2011 · Chirpz Discussion starter. 00. Buy. Aug 18, 2020 · That might sound like a contradiction, it isn’t. 0 V6 Swirl Flap Bypass Plug And Play Motor P2015 P2513. Apr 8, 2024 · Mercedes Om642 Diesel 3. This creates a swirling of the fresh air and better mixing reduces fuel consumption and pollutant emission. Jeep Mercedes OM642 Swirl Motor Simulator Plug. 3 x Anti-friction adapters. I've had this resistor for a couple of months and haven't noticed any issues with mpg or performance . Jun 14, 2017 · 20. 7 mb, 168 pages Format: . 9 cdti swirl flap holding open, how to fix swirl flaps open position, saab vauxhall swirl plates what is open position, 1. Normally, that would produce an EKAS code whenever the ECU tried to close the valves. Feb 16, 2021 · Inlet flaps are made for improving air swirl at certain conditions. com Jan 12, 2012 · They were also selling an electrical circuit similar to the egr shunt we all know about that can apparently replace the swirl flap motor. Leaky piezo fuel injectors causing oil dilution. Jan 29, 2023 · Hi, I had a 4. 0 litres (2,987 cc), 24-valve, aluminium/aluminium block and heads diesel 72° V6 engine manufactured by the Mercedes-Benz division of Daimler AG as a replacement for the Mercedes straight-5 and straight-6 cylinder engines. Crankcase position sensor. Now I want to turn them off in the software. May 20, 2022 · Can you remove the swirl flaps? In a sprinter, Mercedes Om642 Crd common rail Nv3 …… yes on any we can bypass the flaps !! 3. It is also common for the swir Oct 14, 2023 · Common Mercedes OM642 engine problems include: Oil cooler o-ring leaks. 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 BMW, Vauxhall and Alfa Romeo. Applications: Mercedes E-Class W211 - OM642. They're used in just about every new diesel. Seller's other items. 9 cdti swirl flap open, vectra c swirl flaps open position, swirl flaps position 1. Pre-Glow System Problems. This motor is located between the two Nov 9, 2006 · 944 Posts. Also fits the 2007-2008 Jeep Grand Cherokee CRD. That had a tendency to leak oil all over (and in) the swirl flap motor causing it to fail. (compatible with all models with and without sensors) Will fit left and right-hand manifolds. We repair swirl flaps and carry out a swirl flap delete swirl flap remap for you. Now you are ready to blank the flap holes. Dec 19, 2011 · The resistor fix fools the inlet port motor into thinking it’s still connected , it works if there is no swirl flap fault at the time it is fitted . from Wikipedia: "Their purpose is to ensure that the air entering the cylinder is sufficiently turbulent for good fuel-air mixing even at low engine speeds. drill a hole in them and just start smashing them. 9 cdti, swirl valves 1. 7k ohm resistor on the plug to trick it into think the stepper motor is still there. Apr 27, 2020 · Swirl flaps are also known as tumble flaps or intake manifold runner flaps. Over time the plastic wears at the connection points with the manifold, creating an oval shape which eventually lifts up the rod leading to breakages causing the faults noted above. May 14, 2016 · May 27, 2016. To obtain a quotation please call the team on 02380 268351 or visit us at AIB Insurance. But as Cole said, its a bitty job, everything must be cleaned and seals replaced properly. My right bank lever is down and my left one is up. Thanks to this forum, I was able to gain an understanding of the problem. Can someone please show me the map address of the swirl flaps or make the edits to turn them off etc. High mileage OM648 engine problems. All of the egr nonsense has been blocked-off and subsequently, the parts recycled. Hiya. Inspect swirl fl Download: Mercedes OM642 Multi Engine Service Manual. malcolm210 said: As this problem has been bugging me for a while I bought a new set of batwing turbo inlet seals but as this isn’t a total solution I also purchased a stainless steel shield that locates just below the turbo inlet seal and above the inlet swirl flap motor to catch any Buy. Readout too large. After the instant gasket has dried you should mix up the epoxy resin. Avon Tuning remaps are also fine-tuned to improve throttle response, and eliminate any unwanted flat spots in your power curve. . Dynamic Swirl Flaps contribute about 5% to the extreme edges of the emissions performance envelope and make the design engineers’ jobs easier to do, and are not enshrined in emissions standards. Buy an om642 core engine from mb and send your engine back for core value. Ive had one in place for a couple of years now Nothing to do with the egr. Your Mercedes. Ive just had the swirl flaps removed on my Mercedes E320 CDI W211 OM642 3. #4. Mercedes M642 V6 280/320 Inlet Swirl Flap Motor Kit A6421500494 by mail order or collection from SPR Autos, Mercedes Benz & Smart Car Servicing in Stockport, Manchester & Cheshire. Left: part load, swirl flap closed, strong swirling. When I had my 2007 Jeep with the 642 in it, the intake tube had an orange seal where the crankcase breather attached to the tube right before the turbo. 0L Mercedes V6 diesel engine. pdf document, Applications: See Image > USD $19. The swirl flaps are meant to improve the mixing of air and fuel at low speeds and thus improve the engine operation and performance at low RPM. Jun 20, 2019 · Forum Supporter. ( pipe was noticeably worn as it had been replaced with a pipe that was straight and forced into the "bend" position. Fuel injector washer problems and “Black Death”. vectra-c. Turbo actuator problems (due to oil contamination) Swirl flap motor problems. 9cdti site:www. 21. Car. EGR technology was introduced in Eur5 and is enshrined in emissions standards. Following Alex Crows suggestion about a resistor to simulate the swirl motor I decided to give it a try yesterday. Well, back on the road temporarily, at least. 7k ohm resistor tricks the inlet port/swirl flap motor into thinking it’s connected. PCV valve problems. Jun 21, 2010 · B90/2 (Left EKAS end position measurement sensor) The valve is closed. At higher engine speeds and torques, the swirl flap (also known as an ‘inlet May 16, 2014 · The ideal is to remove the manifold, remove all flaps and put bolts through the holes so it is airtight again. #1 · Jul 5, 2011. There are two of these on the engine, one on each bank. 2117 posts · Joined 2009. Repeat this for the three clips and the rod will lift away. refitted the EGR (looks standard). I got a 4. Feb 21, 2023 · It is a common problem on OM642 engine (this one is from a 2009 Mercedes E320) for the swirl flap mechanism to fail over time. Usually if the EGR valve is working (no reason to suspect not) then it will be closed when not being actuated, and a simple ECU 'delete' from a decent tuner will disabled the EGR and prevent any EML codes and therefore resultant MOT fail for EML dash light. Results were compared with the engine’s operation when using two offset cams providing two different levels of retard on the swirl port-30 and 60 crank angle degrees (CAD) respectively. Also referred to as the M55 servo motor. The simulator is for use when the swirl motor is deleted but if it is still in place and faulty it is likely the flaps connected to it are closed and blocking entry to inlet manifold causing limp mode, this simulator will not help your problem until motor is removed and flaps are open. The position of the flaps is determined according to the performance map stored in the CDI control module. Intake manifold for the 2010+ Mercedes, including Sprinter with the OM642 engine. You can perm EGR Valve Gasket (NCV3 OM642) $2. Oct 25, 2013 · And when star plugged in, you can command flaps open and close via system. 50. Feb 4, 2023 · Common Mercedes OM648 Engine Problems. Turbo inlet pipe leak. comforumshowthread. Aug 21, 2022 · 1) i think the linkages were reattached to the motor with the left side closed and right side open. Jun 26, 2012 · Swirl flap: swirl in axial direction of the piston. co. After swirl flap deletion as part of the oil cooler seal leak repair (see OM642 oil cooler leak fix videos 1-10), the check engine light came on test drive. It is meant to be preventative for when these flaps break when the manifold starts getting gunged up . Have you check fuses (there is no separate fuse for swirl flap motor but it may blow another one - usually cause engine fan constantly on while ECU is not having voltage). https://www. I recently fitted recon turbo and oil cooler seals and swirl flaps still moving ok despite 20,000 miles with resistor fitted so I fitted new aluminium runners and new mounting caps so they are capable of being used if I want them working. Any turbulence or 'swirling' they generate would decrease the airflow and result in lower power production. blanked off both sides of the EGR chambers in the manifold. #3. universal-diagnostics (9710) Swirl Toy Marbles, Whirlpool Bypass Plugs Parts, Dec 22, 2019 · New swirl flaps mechanism designedNew flaps made of anodized aluminumNew steel shafts, levers and connecting rodNew seals At light engine loads the flaps close, causing the air to swirl into the combustion chamber. Problems with the variable intake manifold flaps. According to the dealer, they said it would be very rare if both position sensors were faulty. E350 CDI Estate W212. Does anyone know where I can purchase a Swirl Flap Delete/Blanking Swirl flaps are designed to aid with low down torque and fuel economy. You will be able to reuse your parts onto the om642 core engine. uk/shop/davesterl Jan 26, 2013 · I disconnected the linkages from the swirl motor to the valves and wired the valves in the open position, which means the EKAS sensors always register the valves as open. " Position a thin flat head screwdriver under the head of the clip and lever it upwards and out of its position. Apr 2, 2023. The shape and rate of flow of the Plenum can make a large improvement to fuel engine efficiency on the OM642. This engine has found application: Bluetooth technology, an intercooler and a new generation turbocharger. The intake plenum take the air from the filter and allow it to be sucked into the engine and mixed with fuel. QTY. eve Mar 24, 2013 · 606 posts · Joined 2007. The CDI control module reads signals from the following components: Jan 10, 2015 · Those orange seals are bad news on that engine. Now it gets close to 34. 38518 posts · Joined 2005. Basically dry joints from the heat of the turbo on the old board as the bloke who fixed it showed me what he removed. Four different swirl flap positions (ranging from fully open to fully closed) were investigated using standard cams and valve timings. Oil leaks. Apr 9, 2010 · Car. TWC Temperature sensor issues. The swirl flap is made from stainless steel and is Jan 31, 2023 · Just like the OM646 engine or the V6 OM642 engine, the OM612 experiences problems with the swirl flaps inside the intake manifold. Affected vehicles include: Mercedes ML 320. #7 · Dec 7, 2020. Apr 24, 2013 · gutted it of swirl flaps, welded all the holes underneath where the shafts were. 9 cdti swirl flap 10 o oclock Feb 1, 2018 · Yes, I will remove the bypass because I am installing a new swirl flap motor. EGR valve problems. 9mpg. Swirl flaps are designed to aid with low down torque and fuel economy. Nov 22, 2010. Mar 24, 2012 · * Charge intake port (with flap) * Swirl intake port The charge intake ports can be closed by means of flaps. E350 CDI. Jul 15, 2024 · THE FAULT. OM642 turbo is notorious for dropping oil on motor and seizing it. Went to a dealer workshop, they changed M55 part to a new one. GBP 12. Car & LCV. I recently developed a bad swirl motor on my WK 07 CRD. Hi All. #7. That could just be an inlet port shut off motor fault. Failure puts the truck in limp mode - bad. Swirl Flap Explained. The thermostat on the M57 is designed to fail in the “open” position which means your car will have a hard time warming up to the normal operating temperature. The lawsuit alleges that the following Mercedes models powered by BlueTEC diesel-fueled engines are affected by the unlawful, unfair, deceptive and otherwise defective emission controls utilized by Mercedes. Will fix issue as long as swirl has failed with flaps in default open position which in our experience is almost always (unfortunately no way of knowing unless swirl motor is inspected). 06 E280 CDI w211 Estate. With that said, you can do two things. After 2000 rpm the flaps are generally activated to a fully open position and have very little effect on engine performance and emissions. Told me that the flap there stuck in one position and after small tap they went in to the right position moving freely. Mar 31, 2018 · This video shows how to disconnect the swirl flaps actuator from the drive circuit in a Chrysler 300C (and any car using the Mercedes-Benz OM642 engine). My manifold is new so if I can disconnect the flap drive motor and secure the flaps in the open position and either plug in a new motor (not under the manifold this time) or fit some sort of circuit that Oct 1, 2014 · https:www. This will work on most Jeep, Mercedes, Chrysler, vehicles with the OM642 engine from 2007-2009 without modifications or extra tuning. Sep 19, 2022 · engine is from a 2007 Mercedes r320, I had everything removed to do the oil cooler, so it only makes sense to remove the swirl flaps, and motor. New intake manifolds cost between $300 and $600 EACH. Jan 9, 2019 · Easily repair broken swirl flap rods with this all-aluminum replacement and upgrade kit. 7k ohm resistor from Maplins for 26 pence and as it was an experiment i didn't want to cut wiring so i inserted the resistor tails into the connector Sep 18, 2014 · On the OM642 (my car is a 2011), to put the flaps in the open position: DRIVER side swirl flaps -> The handle that moves the connecting rod should point to the driver. (12691) 99. 0L V6 Diesel connecting Jan 18, 2024 · Mercedes Om642 Diesel 3. Set of custom made replacement metal swirl flap rods and new bushings for the intake manifolds on the 2007-2009 Sprinter Van with the 3. ECU Remapping. The M57 engine is known to have problems with the thermostat, however, there are no issues with the water pump as is common on other BMW engines, like the N53. . Swirl flaps are used to change the way the air moves inside the cylinder, so it mixes more efficiently with the fuel being injected, they do this by partially/fully blocking one of the two intake ports going to each cylinder. Basically one side was closed and the other side was open and it was the only position i could get clips in so i assumed it was the normal position. #6. Swirl flaps are small butterfly valves located within the inlet manifold on modern diesel and petrol engines, they are designed to help regulate the fuel to air ratio, improve emissions and help generate better torque at low engine speeds. Inlet port shutoff positioner-M72 connects the Left and Right EKAS rods. 6% positive. My engine is already tuned to not have the swirl Mercedes M642 V6 350 Inlet Swirl Flap Motor Kit A642 150 05 94 by mail order or collection from SPR Autos, Mercedes Benz & Smart Car Servicing in Stockport, Manchester & Cheshire. Screw it into the tapped flap hole and tighten until you feel the locking washer bite into the plastic. Mechanical Failure: Dec 10, 2022 · Automotive Tuning. [1] The engine features common rail Direct injection and a variable nozzle turbocharger. com, 1. Mercedes Benz OM642 V6 Diesel Intake Inlet Manifold Swirl Flap Repair Connecting Runner Rod Fix Kit Install Instructions Guide: Page 5 Jun 14, 2020 · That’s exactly what the “resistor mod” is on the om642 engine, a 4. Is this normal please. 0L V6 Repair Kit OM642 Item specifics Condition: New Brand: GSKMOTOR Material: Plastic Fitment Type: Direct Replacement Interchange Part Number: 642 090 38 37 / 642 090 29 37 Mounting Hardware Included: Yes Warranty: 1 Year The Swirl valve arms drives the entire motion of the OM642 intake manifold 3. 82. Feb 17, 2023 · The OM642 has a 72-degree camber angle and is equipped with a 3rd generation Common Rail piezo injector capable of delivering 1600 bar. 920 OM642. The idea of the mod is that it should be done whilst the swirl flaps are all working which means they are locked in the open position . Arms were in 2 o clock position on the right and 7 o clock on the left. Feb 14, 2023 · Removal of both intake manifolds on 2009 Mercedes E320 Bluetec with OM642 V6 diesel. amazon. Swirl flap position is adjusted by an electrical or vacuum-actuated servo. They are held in the open position by spring force. Mercedes Pierburg V6 350 Inlet Swirl Flap Motor A6421500594 Inlet switl flap motor A6421500594 Inlet motor Clips (x4) A6420910150 Turbo Green Seal A0149976445 THIS WILL NOT FIT 280/320 ENGINES If you have any queries Jun 8, 2020 · Find many great new & used options and get the best deals for 1x PIERBURG CONTROL UNIT ACTUATOR SWIRL FLAPS FOR MERCEDES M-CLASS W164 280-350 at the best online prices at eBay! Free delivery for many products. These engines do not have a flap position sensor. No need to physically blank the EGR outlet port if all working as it should. My first post on here. Jul 5, 2020 · GSKMOTOR Intake Manifold Swirl Valve Arms for Connecting Rods Diesel 3. 0 litre, diesel, intake manifold, swirl flaps, operating rod, worn, broken, snapped, clogged, sticking Nov 21, 2018 · My very limited understanding is that if the swirl flaps are still connected to the motor via the arms and the inlet port motor hasn't totally failed then the flaps are maintained in the open position . After driving 10miles engine went in a a limp mode check light came up. Oct 17, 2023 · ( vehicle went in to limp mode and diagnostic revealed it was the swirl flap ) 2) replaced a small pipe bend within the engine bay that turned out to be a diesel return pipe. In trying to determine why, during actuations, my left EKAS sensor reads OK one way, NOT OK the other. This also fits early model Mercedes with the OM642. You can then put a 4. “Black Death” around fuel injectors. Swirl Flap Failure YOU WILL RECEIVE. 1 x aluminium rod with sensor pick up points. Mercedes Pierburg V6 280/320 Inlet Swirl Flap Motor A6421500594 Inlet switl flap motor A6421500494 Inlet motor Clips (x4) A6420910150 Turbo Green Seal A0149976445 THIS WILL NOT FIT 350 ENGINES If you have any Oct 30, 2017 · I have noticed no change to how the car drives . Typically, the flaps will be closed at idle speed, creating additional turbulence in the intake. if you have issues with the c-clips breaking. Hi, this 'how to' video shows an in depth installation of an emulator (resistor mod) on a OM642 engine (3. B47 and B57 engines don't exist here in the US, so if they removed the swirl flap on those, great, but we don't get those engines. Pulling more air and fuel into your OM642 is the main goal to any engine performance tuning project. Product Description Manufacturer Info Vehicle Applications. 921 Engines: OM611 OM612 OM613 OM642 OM646 OM647 OM648 Download: 36. its a common fix on the Chrysler 300 forums , with the om642 engine . At light engine loads the flaps close, causing the air to swirl into the combustion chamber, the swirling affect aids combustion and helps to improve emissions and generate more torque. Place a locking washer over each bolt and put the instant gasket into the threads. Transform your vehicle, and reignite your love of driving with an Avon Tuning remap. #546 · Mar 3, 2017. Unfortunately part number 000-905-50-04 (sensors) are $197 each. This plug will allow you to disable your swirl motor without a check engine light. Dec 6, 2020 · Like. php211493-Swirl-flap-open-position, swirl flaps open position, 1. Repeat the process for each flap hole. They fail in the open position - good. 7kOhmm resistor inserted to om642 swirl flap motor actuator plug, after replacing the turbo actuator, removing the 4. You have pulled the cable off the stepper motor, it will be in limp mode, at least put a resistor on the plug. This version includes the swrl flap motor and is on the right side. With the GDE tune, the codes are gone, in spite of inoperative EKAS sensors. This device can be found in most of the modern diesel and petrol automotive engines. The flaps are smaller than the intake runners and therefore allow air to pass around them even when "closed". 3 x Insert retaining clips. removed all the swirl flap motor and bits associated with it! opened up the CAT and removed internals! re-welded up (looks standard). Nov 1, 2018 · This is an upload i shot last year, i forgot to post it then!This is a major problem with om648's, and almost ALL E320 CDI's i've worked on has had this exac Nov 4, 2023 · Dont know if BMW stopped using swirl flap, from what I see here they still use swirl flaps all the way to N47 and N57 engines. I took it to the dealer and got a quote of $1235 to replace the swirl motor (actuator) but they added that it may cost $1600 to $3000 extra if Apr 25, 2023 · Thermostat Failures. Jul 20, 2019 · We offer discounts for length of ownership, where the vehicle is kept overnight and limiting the mileage and can also cater for those clients who need higher mileage and business use. Fuel pressure control valve failure. MERCEDES E320 CDI OM642 SWIRL FLAPS. Inlet Port Shut Off Motor A6421500494. OP: limp mode may have caused by blown motor. Right - my turbo fault is fixed ! - it was the actuator, found a place to fix it (replace the circuit board and motor). May 12, 2021. CCV to Intake Grommet (OM642) $5. eb pn bq th zf xp ku lt kn my