instructables
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug
Bung Repair Fix Kit Install Instruction Guide
by x8rltd
Symptoms double Viton seal (Viton is the correct material to use
here to prevent future issues, check what you buy)
Smoke and fluttery/uneven idle when starting up, perfectly seals the manifold after removing the swirl
"misfire" or engine rocking. Rough running even flaps stopping any boost leaks.
under a light load, lack of power, boost leak from
manifold, engine ‘hunting’. The swirl flap actuating motor is left connected and
running as normal so will not trigger any fault codes.
Fault Removal of these parts does not affect vehicle
performance and in some instances performance is
The swirl flaps within the intake manifold become improved as these components (and lumps of carbon
covered in carbon deposits restricting air flow and can build up attached thereto) are removed.
fail.
Our kit also comes with a aluminium spacer. This is
BMW introduced swirl flaps into all of their diesel essential as in some instances a small piece of
engines from 1998. The swirl flaps are designed to plastic is missing from the actuator motor. If this is
close at lower speeds to improve torque and then to missing without this spacer the bung will not work.
open at higher revs for an improved fuel to air ratio. Please check you will receive this if buying
However, over the years soot builds up on these elsewhere, many don’t understand what they are
moving parts and within the intake ports. Images can selling.
be seen across the internet showing these manifolds
completed coked up with carbon deposits, putting Vehicles Affected
excess stress on the swirl flap components. Not only
does this restrict air flow and performance in some N47 2.0 ltr engines
instances it has led to failure of the swirl flap
components and these parts entering the engine. 1 Series E81 (02/2006 — 12/2011)
Solution 1 Series E81, 120d, 3 doors, N47
Remove the swirl flaps and seal with our kit, improve 1 Series E81, 123d, 3 doors, N47S
air flow and prevent any future issues.
1 Series E87 LCI (01/2006 — 06/2011)
Remove the swirl flaps and never worry about your
engines swirl flaps ever again! Our part is designed to 1 Series E87 LCI, 118d, 5 doors, N47
block the hole created by the removal of the swirl
flaps. Please check out our instructions and video 1 Series E87 LCI, 120d, 5 doors, N47
showing this process. Our unique bung with its
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 1
1 Series E87 LCI, 123d, 5 doors, N47S 5 Series E61 LCI, 520d, Touring, N47
1 Series E88 (09/2007 — 10/2013) X1 E84 (09/2008 — 06/2012)
1 Series E88, 120d, Convertible, N47 X1 E84, X1 20d, SUV, N47
1 Series E88, 123d, Convertible, N47S X1 E84, X1 20dX, SUV, N47
1 Series E82 (11/2006 — 10/2013) X1 E84, X1 23dX, SUV, N47S
1 Series E82, 120d, Coupe, N47 X3 E83 LCI (11/2006 — 08/2010)
1 Series E82, 123d, Coupe, N47S X3 E83 LCI, X3 1.8d, SUV, N47
3 Series E90 (03/2007 — 09/2008) X3 E83 LCI, X3 2.0d, SUV, N47
3 Series E90, 320d, Sedan, N47 To check if your vehicle is affected:
3 Series E90 LCI (07/2007 — 03/2010) Visit real OEM website, input vehicle VIN, select
Engine, then “Intake manifold AGR with flap control”,
3 Series E90 LCI, 320d, Sedan, N47 Item 1 on the list shows the part number, please
compare this to the part numbers listed below to
3 Series E90 LCI, 320xd, Sedan, N47 confirm compatibility.
3 Series E91 (02/2007 — 08/2008) Associated part numbers
3 Series E91, 320d, Touring, N47 11618507239, 11617811214, 11614728712,
11617797384
3 Series E91 LCI (07/2007 — 02/2010)
7797384, 7810178, 7810179, 4728712, 7811214,
3 Series E91 LCI, 320d, Touring, N47 8507239.
3 Series E91 LCI, 320xd, Touring, N47 You will receive
3 Series E92 (06/2005 — 02/2010) 1 x aluminium plug with Viton o-rings (this material is
essential for this application)
3 Series E92, 320d, Coupe, N47
1 x aluminium spacer
3 Series E92, 320xd, Coupe, N47
4 x replacement intake manifold gaskets
3 Series E93 (09/2007 — 02/2010)
3 Series E93, 320d, Convertible, N47
5 Series E60 LCI (04/2006 — 12/2009)
5 Series E60 LCI, 520d, Sedan, N47
5 Series E61 LCI (04/2006 — 05/2010)
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 2
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 3
https://youtu.be/lIVwD5KwyGc
Step 1: Remove Actuator Motor
Using a T30 Torx screwdriver remove the 3 screws that hold the motor in place.
You can remove the hanging arm on the motor (this should just pull off) as this will not be needed during
reassembly.
You can now turn the swirl flap rod by hand and see the swirl flaps moving in the manifold (note the carbon deposit
build up).
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 4
Step 2: Remove Rod
Remove the Silver colour retaining clip that holds the may take some effort. The plastic end of the rod will
rod in place. This can be done by pulling downwards likely pop off, use a pair of pliers to grip the end of the
and then outwards. rod and pull it out. You will likely need to hold the
manifold firm in a vice to do this.
Once this clip is removed you can pull the rod out. It
is likely to be quite sticky because of the deposits so
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 5
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 6
Step 3: Remove Small Seal
Once the rod is out, use a pick tool to hook out a small rubber seal left behind in the hole. If this is not done our
replacement bung will not seat correctly.
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 7
Step 4: Remove the Swirl Flaps
Lightly tap near the edge of the swirl flaps where the rod would have once been to loosen them. Do this with a flat
head screwdriver and a mallet. Take care to remove ALL remnants of the swirl flaps from the manifold.
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 8
Step 5: Install Our Bung
This is a simple push fit install. Insert the bung into the hole and push firmly until it stays in place on its own. The
twin o-rings not only make it secure, they also provide a good seal for the manifold, you should feel this.
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 9
Step 6: Reattach Motor and Install Small Spacer (If Needed)
You can now reinstall the actuator motor. Our bung Fitted correctly, the spacer should line up and then
should fit tightly against the motor casing but if it press against the actuator motor.
doesn't, as shown in the pictures, it means that the
motor casing has broken over time. Once the motor is on and the spacer is securely held
in place, screw back in the 3 x T30 torx screws from
This is where our supplied small spacer is used. earlier. Make sure the screws are done up tightly so
that the spacer and bung are held in position
Install our small spacer by pushing into the end of the securely.
metal bung as shown in the photos. Making sure this
stays in place, line up the actuator motor to the
manifold to make sure of fitment.
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 10
Step 7: Install New Manifold Gaskets
Fit the new gaskets. Once again, these are a simple push fit design.These will only go in one way as there is a
small notch on the gasket which fits into a small cut out on the manifold. Push these into place securely.
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 11
Step 8: Modification Complete
This concludes the modification to remove the swirl on +44 01843 446643 or email us at
flaps from the manifold. [email protected]. Please also check out our
instruction guide on YouTube. www.x8r.co.uk
When refitting the manifold to the engine, make sure
the electrical connection is refitted to the actuator Installation is carried out at installers risk, if unsure
motor. This will make the ECU think that the flaps and please contact us or a professional, X8R Ltd cannot
motor are working as they should and will not bring be held responsible for any adverse result of installing
up error codes or warning lights. this product or any injuries caused by install, if in
doubt ask a professional. All images and texts are
If you need any further guidance on this install or copyright X8R Ltd 2019.
would like to purchase the parts shown please call us
BMW N47 Intake Inlet Manifold Swirl Flap Removal Delete Metal Blank Plug Bung Repair Fix Kit Install Instruction Guide: Page 12
