Removal of swirl flaps
Disabling vortex flaps
- Work takes up to 1 working day, we edit the software ourselves
- Input and output control of all car systems before and after the service
- Test period of 2 weeks and lifetime warranty on software
- We have experience in performing non-standard solutions
- Professional equipment
Choose a car
Top Cars for Chip Tuning
Alfa Romeo
159
Brera
Giulia
Giulietta
GT
MiTo
Stelvio
Audi
A1
Audi A1 2010 2014 8x 16 Tdi 105 Hp
Audi A1 2015 2017 10 Tfsi 82 Hp
Audi A1 8x 2010 2014 14 Tfsi 185 Hp
A2
A3
Audi A3 8l 1996 2003 18t 20v 180 Hp
Audi A3 8p 2003 2008 19 Tdi 105 Hp
Audi A3 8p 2008 2012 14 Tfsi 125 Hp
Audi A3 8v Mk1 2012 2016 14 Tgi G Tron 110 Hp
A4
Audi A4 B5 1995 2001 19 Tdi 110 Hp
Audi A4 B5 1995 2001 19 Tdi 90 Hp
Audi A4 B6 2001 2004 19 Tdi 130 Hp
Audi A4 B6 2001 2004 20 Fsi 150 Hp
Audi A4 B7 2004 2008 18 T 163 Hp
Audi A4 B7 2004 2008 20 Tdi 140 Hp
Audi A4 B8 2008 2011 20 Tdi Cr 136 Hp
Audi A4 B8 2008 2011 20 Tfsi 211 Hp
Audi A4 B8 2012 2015 20 Tdi Cr 120 Hp
A6
Audi A6 C5 1997 2004 25 Tdi 180 Hp
Audi A6 C6 2004 2008 30 Tdi 225 Hp
Audi A6 C6 2008 2010 20 Tdi 163 Hp
Audi A6 C7 2011 2018 20 Tdi 190 Hp
Audi A6 C7 2011 2018 30 Tfsi 300 Hp
Audi A6 C8 2018 45tfsi 20t 245 Hp
Audi A6 C6 2004 2008 42 Fsi 335 Hp
Audi A6 C7 2011 2018 20 Tfsi Hybrid 245 Hp
A7
Audi A7 4g 2010 2014 30 Tdi Quattro 204 Hp
Audi A7 4g 2014 2017 30 Tdi Fwd 190 Hp
A8
Audi A8 D2 1999 2003 25 Tdi 180 Hp
Audi A8 D3 2003 2010 42 Fsi 350 Hp
Q5
Audi Q5 8r 2008 2011 20 Tdi Cr 163 Hp
Audi Q5 8r 2008 2011 20 Tdi Cr 170 Hp
Audi Q5 8r 2012 2016 30 Tdi 258 Hp
Q7
Audi Q7 2006 2010 42 Fsi 350 Hp
Audi Q7 2010 2014 60 V12 Tdi 500 Hp
Q8
TT
BMW
M4
X1
Bmw X1 E84 2009 2012 18d 143 Hp
Bmw X1 E84 2012 2015 18i 150 Hp
Bmw X1 F48 2015 Sdrive18d 150 Hp
Bmw X1 E84 2009 2012 18d 143 Hp
X3
Bmw X3 E83 2004 2010 20d 163 Hp
Bmw X3 E83 2004 2010 30d 218 Hp
Bmw X3 F25 2011 2017 18d 143 Hp
Bmw X3 G0108 2017 Xdrive18d 150 Hp
X5
Chevrolet
Cruze
Orlando
Chrysler
Citroen
Berlingo
C-Crosser
C3
C4
C5
C5 Aircross
Jumpy
Nemo
Dacia
Dokker
Lodgy
DAF
Dodge
Fiat
Doblo
Ford
Fiesta
Ford Fiesta Mk5 2001 2008 14 Tdci 68 Hp
Ford Fiesta Mk6 2008 2012 14 Tdci 70 Hp
Ford Fiesta Mk7 2013 2017 15 Tdci 75 Hp
Ford Fiesta Mk8 2017 10t Ecoboost 100 Hp
Focus
Ford Focus 1998 2005 16i 16v 100 Hp
Ford Focus 2004 2010 16 Tdci 109 Hp
Ford Focus 2011 2014 10 Ecoboost 125 Hp
Ford Focus 2011 2014 20 St Ecoboost 250 Hp
Ford Focus 2014 2017 15 Tdci 105 Hp
Ford Focus 2018 10 Ecoboost 125 Hp
Fusion
Kuga
Honda
Civic
Hyundai
Infiniti
FX
Q30
Q50
QX70
Iveco
Jaguar
Jeep
Cherokee
Grand Cherokee
Jeep Grand Cherokee 2005 2011 30 Crd 218 Hp
Jeep Grand Cherokee 2005 2011 57 Hemi V8 357 Hp
Renegade
Kia
Lexus
Mazda
CX-3
CX-5
CX-7
CX-9
Mercedes-Benz
GLK
ML
SL
SLK
Mitsubishi
Nissan
Pathfinder
Opel
Astra
Corsa
Insignia
Signum
Vectra
Vivaro
Peugeot
208
Peugeot 208 2012 2015 16 T Hp 155 Hp
Peugeot 208 2015 16 Bluehdi 8v 100 Hp
Peugeot 208 2012 2015 Gti 16 T Hp 200 Hp
3008
406
407
508
Peugeot 508 Ph1 2010 2014 20 Hdi 163 Hp
Peugeot 508 Ph2 2014 2018 20 Bluehdi 150 Hp
Partner
RCZ
Renault
Seat
Ibiza
Leon
Toledo
Skoda
Subaru
Toyota
Volvo
S40
S60
V40
V50
VW
Amarok
Golf
Volkswagen Golf Golf 5 2003 2008 14i 16v 75 Hp
Volkswagen Golf Golf 5 2003 2008 20 Tfsi Gti 200 Hp
Volkswagen Golf Golf 6 2009 2012 20 Tdi Cr Gtd 170 Hp
Volkswagen Golf Golf 7 2012 2016 12 Tsi 105 Hp
Volkswagen Golf Golf 7 2012 2016 14 Tsi 125 Hp
Volkswagen Golf Golf 7 2012 2016 14 Tsi Gte 204 Hp
Passat
Volkswagen Passat B5 1996 2005 19 Tdi 90 Hp
Volkswagen Passat B6 2005 2010 20 Tdi 140 Hp
Volkswagen Passat B7 2010 2014 20 Tdi Cr 136 Hp
Volkswagen Passat B8 2014 2019 16 Tdi Cr 120 Hp
Phaeton
Polo
T-Roc
Tiguan
Volkswagen Tiguan 2007 2011 20 Tdi Cr 110 Hp
Volkswagen Tiguan 2011 2015 20 Tdi Cr 140 Hp
Volkswagen Tiguan 2016 14 Tsi 150 Hp
Volkswagen Tiguan Nz 2007 2011 20 Tfsi 200 Hp
Touareg
Volkswagen Touareg 2002 2007 30 Tdi 211 Hp
Volkswagen Touareg 2015 2018 30 Tdi 204 Hp
Volkswagen Touareg 2018 30 Tdi 286 Hp
Touran
Where to find us
Brands we work with
Removing Swirl Flaps
Constantly changing and increasingly stringent environmental requirements are forcing car manufacturers to introduce new devices previously unheard of. These components reduce engine emissions but often become a source of inconvenience for drivers. They begin to work incorrectly or completely fail. Why is it better to get rid of problematic aggregates and how to correctly remove swirl flaps in Warsaw? Specialists from STS will answer these questions.
Swirl Flaps - What They Are and Why They Are Necessary
One of the main factors polluting the environment is incompletely burned fuel that flies out with exhaust gases into the atmosphere. According to engineers, the combustion process can be improved by optimizing the mixture flow into the cylinders. Swirl flaps create a specific fuel swirling when it enters the engine's working chamber. This allows the fuel to mix better with air, burning more efficiently and completely.
To achieve this, the intake manifold channels that lead directly to the engine are divided into two for each cylinder. One line remains empty and straight, in the other an rotary flap is installed, which is usually located on the same axis as other similar devices for each cylinder head block. When one channel is blocked and the mixture flows only through the second, due to the collector's geometry, a swirl is created. This occurs at low revolutions, at high speeds the flap opens completely. The degree of opening and closing is regulated by the electronic engine control unit (ECU) based on sensor readings.
Causes of Swirl Flaps Damage
Despite a good idea and a well-thought-out design solution, the flap control system has a very small resource. On average, already after 100,000 km of mileage, removal of swirl flaps becomes necessary. There are several main reasons for their failure:
- Failure of the flap position sensor.
- Failure of the electric drive motor.
- Damage to the drive linkage or its displacement from the axis.
- Loss of mobility and blocking of the flap axis due to carbon buildup in the manifold.
In most cases, these problems will be signaled to the driver by the Check Engine light on the instrument panel, and the car's ECU during diagnostics will show an error related to swirl flaps. Additionally, node malfunctions can be suspected from the following symptoms:
- Rattling, knocking sounds in the upper part of the engine;
- Hissing due to leaks in the intake system;
- Reduction of the car's power;
- Increased smokiness;
- Increased fuel consumption.
All of this is a reason to go to an auto repair shop to solve the problem. If this is not done in time, with the appearance of the first signs, faulty swirl flaps can cause more serious damage. It is not excluded that metal or plastic parts (blade fragments, axes, and fittings) may enter the cylinder's working chamber, which can lead to damage to the piston and valve group components, and thus to an expensive repair or even replacement of the cylinder block or its head.
Removal or Restoration - What to Choose
In case of swirl flaps failure, there are three repair methods:
- Installation of new parts with manifold cleaning.
- Purchasing a complete intake manifold.
- Removal and software disable of the flaps.
Replacement and cleaning are expensive solutions that do not always lead to a complete problem solution. Carbon deposits often occur due to the EGR system (exhaust gas recirculation) valve. If it is not disabled, cleaning the flaps will be necessary every 20-30 thousand kilometers. The cost of a new manifold significantly exceeds the price of removing swirl flaps, and the old one may also require repair.
How Swirl Flaps Removal Happens at STS
Our company's services include a full cycle of node disable, which consists of several stages:
- Diagnostics of parameters and error reading.
- Visual performance check.
- Software correction, loading the necessary firmware.
- Mechanical removal of swirl flaps, replacement with plugs if necessary.
We conduct a full check of the car's operation both before and after the procedure. We provide the client with a two-week test period, after the end of which we give a lifetime guarantee for our work.
Frequently Asked Questions
Is Swirl Flaps Removal Legal?
STS Parts does not engage in illegal operations. We simply fix the node in one of its standard modes.
What is the Cost of Swirl Flaps Removal?
The price depends on the class and specific model of the vehicle. In any case, it is much lower than the cost of eliminating problems that may arise due to faulty flaps.
Problem: A well-known logistics service provider brought in three electric vans for repair after their high-voltage batteries failed. In one of them, the battery was dismantled.
Problem: The high-voltage battery is discharged and cannot be charged. The car does not accept a charge because the electronics do not recognize the connection of the charging gun.
Problem: A sharp drop in driving range and the vehicle switching to emergency mode with reduced power (“turtle mode”).
Problem: The problem with the car was the incompatibility of the Chinese GB/T standard charging system with European charging stations. This created difficulties for the owner of the Audi Q4 e-tron, since the car, produced for the Chinese market, could not charge at European stations with the required speed and reliability.
Problem: Failure of Toyota hybrid batteries is a common problem that our customers come to us with. The battery cells degrade, making it impossible for the car to operate normally.
Problem: We received an electric car with very discharged traction batteries. The problem is typical for the Fiat 500. During idle time, the batteries discharged below the permissible level, and the car's electric motor stopped starting.
Problem: The Hyundai Kona made a rather loud noise. The customer diagnosed the malfunction on his own - in his opinion, the gearbox was the cause of the extraneous sounds.
Problem: We received an electric motor manufactured by Continental, which was installed on an Opel vehicle for the Chinese market. The motor seized after the car was involved in an accident.
Problem: There was water and rust inside the rail, which damaged both the needle bearing in the cover and the torque sensor, i.e. both the mechanical and electrical parts
Problem: Two electric vehicles arrived at our workshop: a 2018 Kia e-Soul with noise in the motor area and a Mercedes-Benz EQC with an "insulation fault to ground" error. In both cases, the faults turned out to be quite typical and caused by design flaws in the vehicles.
Problem: We received a Hyundai Ioniq EV with complaints of whining noise during driving. An initial inspection revealed that the sounds are coming from the motor, on the side opposite to the gearbox.
Problem: In the case of a critical discharge of a low-voltage battery (12–48 V), the electronics prevent charging because it is dangerous with Li-Ion batteries. The manufacturer recommends discarding fully functional batteries and replacing them with new ones. This is expensive.
Problem: Failure of Toyota hybrid batteries is a common problem that our customers come to us with. The battery cells degrade, making it impossible for the car to operate normally.
Problem: Land Rover Range Rover Sport 3.0 SDV6 Hybrid AT AWD - the hybrid system did not work, the VBB was in emergency mode. The car was running only on diesel fuel, the low-voltage battery was not charging.
Problem: None of the car's systems were working at all, it wasn't even possible to raise it on a lift because the air suspension didn't activate either. I had to install the Porsche near the repair box on "goat" stands.
Problem: In Opel Astra H vehicles, the electric power steering pump often fails. The cause can be either corrosion or damage to the unit due to careless driving.
Problem: IThe specific placement of the steering rack in many Audi models allows moisture to penetrate the control unit of the electric power steering, causing corrosion of components and failure of the unit.
Problem: Steering rack leakage from under the tie rod dust cover
Problem: Steering rack leakage from under the tie rod dust cover
Problem: The owner of a Citroen C4 Picasso car came to us with a complaint about poor engine performance. The car literally could hardly drive: the engine would not rev above 2000 rpm and did not develop the necessary power. Fuel consumption increased significantly. The problem lies in the car's clogged particulate filter.
Problem: We were approached by the owner of a 2017 Citroen Berlingo with complaints of a knocking steering rack.
Problem: A Mercedes-Benz B250 electric vehicle, equipped with a Tesla motor, arrived at the service center with insulation fault errors and coolant ingress inside the electric motor.
