VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD

VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD

Engine management light (EML) lit, High fuel consumption, Rough idling, Rough running, Poor power and torque, Smoking from exhaust, Error P2279-11 Intake system air leak, P2075 fault code?

Models Affected:

 

£23.99
 
Description

Additional Information

Ebay Text
Ebay Text 2 No
Model Affected No
The Problem

 

 

                                      

The Problem

 
     

The bearing bushes on the swirl flap operating rod wear and the rod pops off causing the symptoms noted above.


All of these symptoms can be caused by the swirl flap operating rod bushes wearing making the operating rod pop off; stopping the swirl flaps from operating, you will often see the rod lying on top of the intake manifold.

 
 

VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD

 

 

 


 

The Solution
 

The Solution

 
  VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD BUSH REPAIR KIT  
 

Replace the operating rod with our improved design rod fitted with brass bearing bushes designed to not pop off again!

Rather than having to remove the manifold and replace at great cost with the problem reoccurring in the future our rod replacement solves this issue, replace the unreliable bush bearings with our improved design bearings which will not fail again.

Our self lubricating bushes are made from billet Brass, fitted with a Viton O-ring and Stainless steel fasteners, designed to never fail again.

 
     
     
Vehicle Compatibility

 

   

VEHICLES AFFECTED

 
   VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD REPAIR KIT

Our rod will only repair the original Pierburg inlet manifold. It is worthwhile checking the inlet manifold is as illustrated above.

 
     

 

  Vauxhall - Engines Z19DTH & Z19DTJ  
 

Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 150]

Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 120]

Astra Mk V (H) Estate - 1.9 CDTi 2004-2009 [HP 150]

Astra Mk V (H) Sports Hatch - 1.9 CDTi 2004-2010 [HP 150]

Astra TwinTop Mk V (H) - 1.9 CDTi 2006+ [HP 150]

Astravan (H) - 1.9 CDTi 2005+ [HP 150]

Signum - 1.9 CDTi 16v 2004-2008 [HP 150]

Vectra MK II (C) - 1.9 CDTi 16v 2004-2005 [HP 150]

Vectra MK II (C) GTS - 1.9 CDTi 16v 2004-2005 [HP 150]

Vectra MK II (C) Estate - 1.9 CDTi 16v 2004-2005 [HP 150]

Zafira MK II (B) - 1.9 CDTi 2005-2011 [HP 150]

 

 
  Fiat - Enigines M91 & M92  
 

Croma - 1.9 D Multijet 2005+ [HP 150]

Stilo - 1.9 D Multijet 2005+ [HP 150]

Stilo Multi Wagon - 1.9 D Multijet 2005+ [HP 150]

 

 
  Alfa Romeo - 939A200 ( 1.9 MultiJet JTDM 16V 110 kW / 150 PS)  
 

147 - 1.9 JTDM 8v 2005+ [HP 120]

147 - 1.9 JTDM 16v 2005+ [HP 150]

147 - 1.9 JTD 16v 2004+ [HP 136]

156 - 1.9 JTD 2003-2005 [HP 126]

156 - 1.9 JTD 2004-2005 [HP 150]

156 Sportwagon - 1.9 JTD 16v Q4 2004-2006 [HP 150]

156 Sportwagon - 1.9 JTD 2005-2006 [HP 150]

156 Sportwagon - 1.9 JTD 2003-2006 [HP 126]

159 Saloon - 1.9 JTDM 8v 2005+ [HP 120]

159 Saloon - 1.9 JTDM 8v 2005+ [HP 115]

159 Saloon - 1.9 JTDM 16v 2005+ [HP 136]

159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 120]

159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 115]

GT - 1.9 JTD 2003+ [HP 150]

 
 

Saab - Engines Z19DTH & Z19DTJ

 
 

9-3 Saloon - 1.9 TiD 2004+ [HP 150]

9-3 Convertible - 1.9 TiD 2006+ [HP 150]

9-5 Saloon - 1.9 TiD 2006+ [HP 150]

9-5 Estate - 1.9 TiD 2006+ [HP 150]

 

 
  2.03462.03, 55210201, Pierburg inlet manifold, 93179055, 55206459, 55182684 GM, Z19DTH  
FAQ
 

Instructions

 
     
     
     
     
 

Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment Instructions

 
     
   Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
 

 Step 1: Remove old bushes

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
   

Cut away old plastic bushes. This can be done with hand cutters as illustrated or with a power tool such as a Dremel. Take care when removing plastic parts that you do not bend the operating rod. We also recommend eye protection for this step.

Some remnants of the plastic may remain in the holes in the rod, remove these using a drill so that there is a hole where each bush once was.

 
     
 

 Step 2: Add countersink

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
   Orientate the rod as shown, using a countersink drill bit add a countersink to the second hole from the right as shown. Do this slowly and in increments and keep checking if the countersunk head of the bolt from the bush fits flush with the rod.  
     
 

 Step 3: Attach bushes to rod

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
 

Add thread-lock to the countersunk screw and attach the bush to the rod as shown.

Add thread-lock to the bolts and set screws and fit the rest of the bushes. Make sure the locking washer is installed under the bolt on top of the rod, not under the rod.

 
     
   

 Step 4: Refit operating rod

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
   The rod should now look as illustrated, refit the rod to the manifod.  
     
     
 

 Video Instructions

 
     
     
     
     
     
     
     
     
     
     
     
     
REVIEWS
For Car No

 

 

                                      

The Problem

 
     

The bearing bushes on the swirl flap operating rod wear and the rod pops off causing the symptoms noted above.


All of these symptoms can be caused by the swirl flap operating rod bushes wearing making the operating rod pop off; stopping the swirl flaps from operating, you will often see the rod lying on top of the intake manifold.

 
 

VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD

 

 

 


 

 

The Solution

 
  VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD BUSH REPAIR KIT  
 

Replace the operating rod with our improved design rod fitted with brass bearing bushes designed to not pop off again!

Rather than having to remove the manifold and replace at great cost with the problem reoccurring in the future our rod replacement solves this issue, replace the unreliable bush bearings with our improved design bearings which will not fail again.

Our self lubricating bushes are made from billet Brass, fitted with a Viton O-ring and Stainless steel fasteners, designed to never fail again.

 
     
     

 

   

VEHICLES AFFECTED

 
   VAUXHALL Z19DTH Z19DTJ 1.9 CDTi INTAKE INLET MANIFOLD SWIRL FLAP ROD REPAIR KIT

Our rod will only repair the original Pierburg inlet manifold. It is worthwhile checking the inlet manifold is as illustrated above.

 
     

 

  Vauxhall - Engines Z19DTH & Z19DTJ  
 

Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 150]

Astra Mk V (H) - 1.9 CDTi 2004-2009 [HP 120]

Astra Mk V (H) Estate - 1.9 CDTi 2004-2009 [HP 150]

Astra Mk V (H) Sports Hatch - 1.9 CDTi 2004-2010 [HP 150]

Astra TwinTop Mk V (H) - 1.9 CDTi 2006+ [HP 150]

Astravan (H) - 1.9 CDTi 2005+ [HP 150]

Signum - 1.9 CDTi 16v 2004-2008 [HP 150]

Vectra MK II (C) - 1.9 CDTi 16v 2004-2005 [HP 150]

Vectra MK II (C) GTS - 1.9 CDTi 16v 2004-2005 [HP 150]

Vectra MK II (C) Estate - 1.9 CDTi 16v 2004-2005 [HP 150]

Zafira MK II (B) - 1.9 CDTi 2005-2011 [HP 150]

 

 
  Fiat - Enigines M91 & M92  
 

Croma - 1.9 D Multijet 2005+ [HP 150]

Stilo - 1.9 D Multijet 2005+ [HP 150]

Stilo Multi Wagon - 1.9 D Multijet 2005+ [HP 150]

 

 
  Alfa Romeo - 939A200 ( 1.9 MultiJet JTDM 16V 110 kW / 150 PS)  
 

147 - 1.9 JTDM 8v 2005+ [HP 120]

147 - 1.9 JTDM 16v 2005+ [HP 150]

147 - 1.9 JTD 16v 2004+ [HP 136]

156 - 1.9 JTD 2003-2005 [HP 126]

156 - 1.9 JTD 2004-2005 [HP 150]

156 Sportwagon - 1.9 JTD 16v Q4 2004-2006 [HP 150]

156 Sportwagon - 1.9 JTD 2005-2006 [HP 150]

156 Sportwagon - 1.9 JTD 2003-2006 [HP 126]

159 Saloon - 1.9 JTDM 8v 2005+ [HP 120]

159 Saloon - 1.9 JTDM 8v 2005+ [HP 115]

159 Saloon - 1.9 JTDM 16v 2005+ [HP 136]

159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 120]

159 Sportwagon - 1.9 JTDM 8v 2006+ [HP 115]

GT - 1.9 JTD 2003+ [HP 150]

 
 

Saab - Engines Z19DTH & Z19DTJ

 
 

9-3 Saloon - 1.9 TiD 2004+ [HP 150]

9-3 Convertible - 1.9 TiD 2006+ [HP 150]

9-5 Saloon - 1.9 TiD 2006+ [HP 150]

9-5 Estate - 1.9 TiD 2006+ [HP 150]

 

 
  2.03462.03, 55210201, Pierburg inlet manifold, 93179055, 55206459, 55182684 GM, Z19DTH  
 

Instructions

 
     
     
     
     
 

Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment Instructions

 
     
   Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
 

 Step 1: Remove old bushes

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
   

Cut away old plastic bushes. This can be done with hand cutters as illustrated or with a power tool such as a Dremel. Take care when removing plastic parts that you do not bend the operating rod. We also recommend eye protection for this step.

Some remnants of the plastic may remain in the holes in the rod, remove these using a drill so that there is a hole where each bush once was.

 
     
 

 Step 2: Add countersink

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
   Orientate the rod as shown, using a countersink drill bit add a countersink to the second hole from the right as shown. Do this slowly and in increments and keep checking if the countersunk head of the bolt from the bush fits flush with the rod.  
     
 

 Step 3: Attach bushes to rod

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
 

Add thread-lock to the countersunk screw and attach the bush to the rod as shown.

Add thread-lock to the bolts and set screws and fit the rest of the bushes. Make sure the locking washer is installed under the bolt on top of the rod, not under the rod.

 
     
   

 Step 4: Refit operating rod

 
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
     
  Vauxhall CDTI SAAB TID Alfa Romeo MultiJet Inlet Manifold Swirl Flap Rod Repair 1.9 150BHP Diesel Fix Install Fitment  
   The rod should now look as illustrated, refit the rod to the manifod.  
     
     
 

 Video Instructions