Swirl Flaps deterioration please do not ignore

theglennster · 09-10-2023, 06:51 AM

I have just found a disturbing issue with the swirl flaps on my E92 335D 2011 LCI (96k miles) I was under the impression any swirl flap problems were fixed on this model, boy how wrong was this information.

I had two failed glow plugs so had to take off the intake to do a 6 plug swap and while I was at it do some cleaning to the intake. Looking at the plenum it has the usual oily carbon build up however looking at the swirl flaps they have all started to break up with the majority of the rubber covered and sealing surfaces missing!

This red rubber coating has gone very brittle with the surrounding sealing flap edge deteriorated to the point it breaks off and then gets ingested. Another more disturbing observation is the flaps are still screwed onto the shaft again something I thought they had stopped doing??

Needless to say I'm now performing a swirl flap delete for peace of mind.

I hope this information helps somebody please do not ignore as these things are still a ticking time bomb.

Cheers
Glenn

https://drive.google.com/file/d/1hZV...usp=drive_link

https://drive.google.com/file/d/1Y2k...ew?usp=sharing

Andy198712 · 09-12-2023, 04:27 AM

It’s the N57 engine they are “more” sorted i belive, they use a sphere design instead of a flap.
I still removed mine

Tambohamilton · 09-12-2023, 04:55 AM

They are still screwed on, but the screws are swaged so they can't come out. I had noticed a chunk of the rubber had come off mine too. I opted to replace the manifold with a Febi one...maybe not my brightest moment, but it hasn't killed the engine yet.

jacbo · 09-15-2023, 08:46 AM

Yeah it's a little bit confusing as the 335d had the M57 engine no matter the model year.

Only 325 and 330 switched to n57

however even then they can become brittle and the plastic arm on the swirl flap actuator can break as it did on my engine so still not perfect by any means

Andy198712 · 09-15-2023, 08:48 AM

No true, but Atleast you don’t need a lot or anything to remove them, pull the rod out, remove the spheres and then re attach the motor which plugs the hole and just turns as normal but doesn’t know it’s not moving anything

09-10-2023, 06:51 AM	#1
theglennster New Member 2 Rep 6 Posts Drives: E92 335D M-Sport (+RaceChip) Join Date: Apr 2018 Location: Manchester iTrader: (0)	Swirl Flaps deterioration please do not ignore I have just found a disturbing issue with the swirl flaps on my E92 335D 2011 LCI (96k miles) I was under the impression any swirl flap problems were fixed on this model, boy how wrong was this information. I had two failed glow plugs so had to take off the intake to do a 6 plug swap and while I was at it do some cleaning to the intake. Looking at the plenum it has the usual oily carbon build up however looking at the swirl flaps they have all started to break up with the majority of the rubber covered and sealing surfaces missing! This red rubber coating has gone very brittle with the surrounding sealing flap edge deteriorated to the point it breaks off and then gets ingested. Another more disturbing observation is the flaps are still screwed onto the shaft again something I thought they had stopped doing?? Needless to say I'm now performing a swirl flap delete for peace of mind. I hope this information helps somebody please do not ignore as these things are still a ticking time bomb. Cheers Glenn https://drive.google.com/file/d/1hZV...usp=drive_link https://drive.google.com/file/d/1Y2k...ew?usp=sharing
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09-12-2023, 04:27 AM	#2
Andy198712 Major 145 Rep 1,011 Posts Drives: 2010 E91 325d Join Date: Mar 2017 Location: Cornwall iTrader: (0)	It’s the N57 engine they are “more” sorted i belive, they use a sphere design instead of a flap. I still removed mine
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09-12-2023, 04:55 AM	#3
Tambohamilton Brigadier General 3058 Rep 3,911 Posts Drives: E91 330d Join Date: Apr 2019 Location: Herefordshire iTrader: (0)	They are still screwed on, but the screws are swaged so they can't come out. I had noticed a chunk of the rubber had come off mine too. I opted to replace the manifold with a Febi one...maybe not my brightest moment, but it hasn't killed the engine yet.
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09-15-2023, 08:46 AM	#4
jacbo Second Lieutenant 79 Rep 287 Posts Drives: E90 330d LCI Join Date: Sep 2020 Location: Cheshire iTrader: (0)	Yeah it's a little bit confusing as the 335d had the M57 engine no matter the model year. Only 325 and 330 switched to n57 however even then they can become brittle and the plastic arm on the swirl flap actuator can break as it did on my engine so still not perfect by any means
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09-15-2023, 08:48 AM	#5
Andy198712 Major 145 Rep 1,011 Posts Drives: 2010 E91 325d Join Date: Mar 2017 Location: Cornwall iTrader: (0)	No true, but Atleast you don’t need a lot or anything to remove them, pull the rod out, remove the spheres and then re attach the motor which plugs the hole and just turns as normal but doesn’t know it’s not moving anything
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