Swirl flap solutions

What is a Swirl Flap?

Swirl flaps are small butterfly valves fitted to the intake manifold just before the cylinder head intake ports of many modern vehicle engines.

Swirl flap position is adjusted by an electrical or vacuum-actuated servo. Typically, the flaps will be closed at idle speed, creating additional turbulence in the intake. As the engine speed increases, the flaps gradually opens until, at around 2,000 rpm, they are fully open and present virtually no resistance. Their purpose is to ensure that the air entering the cylinder is sufficiently turbulent for good fuel-air mixing at low engine speeds. This aids in reducing certain toxic emissions and may also improve low-end power and torque.

What are the problems?

The problems with swirl flaps are mainly associated with fouling caused by Exhaust Gas Recirculation (EGR). The EGR which mixes together with the oil vapors from the breather leaves tar-like carbon deposits on the flaps and the inside of the intake manifold.

Over time the flaps become stuck 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. In more serious cases, the flaps or their mountings can fracture under the strain and parts can enter the cylinder chamber and cause serious damages to the piston, valves, injectors, turbo, head etc.

How we delete Swirl Flap?

We write new software specifically designed to switch off the function of the Swirl Flap, which will allow the owner to safely remove the flaps, without getting any ECU error codes or future problems.