The SwirlRepair 4-/5-cylinder Swirl Rod Repair Kit

The SwirlRepair Kit is a repair for the swirl operating rod of the following engines:

  • Opel Vauxhall Holden Saab Cadillac Z19DTH (1.9 CDTI 16V, 110kW/150hp)
  • Opel Vauxhall Holden Z19DTJ (1.9 CDTI 16V, 88kW/120hp)
  • Fiat Alfa Romeo 939A2000 (1.9 Multijet / JTD(M) 16V, 100kW/136hp)
  • Fiat Alfa Romeo 939A2000 (1.9 Multijet / JTD(M) 16V, 110kW/150hp)
  • Fiat Alfa Romeo 939A2000 (1.9 Multijet / JTDM 16V, 125kW/170hp)
  • Fiat Alfa Romeo 939A3000 (2.4 Multijet / JTDM 20V, 129kW/175hp)
  • Fiat Alfa Romeo 939A3000 (2.4 Multijet / JTDM 20V, 147kW/200hp)
  • Fiat Alfa Romeo 939A3000 (2.4 Multijet / JTDM 20V, 154kW/210hp)

On these engines the swirl flaps are mostly OK. But the rod, which connects the swirl flaps, often falls off. The officially suggested repair is to replace the entire inlet manifold, and since half of the engine needs to be disassembled for this, the repair costs a fortune. In fact, the quote for a new manifold on an Opel Astra was the reason to develop SwirlRepair. Rather than replacing the intake manifold assembly including swirl flaps if just the operating rod is damaged, the rod can be fixed with SwirlRepair.

SwirlRepair uses bushings made from high quality brass and stainless steel. Inside the bushings there is an o-ring, which is located in a groove. The o-ring is made from temperature resistant material and works as a snap feature, thus keeping the bushing in place on the swirl flap’s ball joint.

By design the bushings sit more firmly on the ball joints and cannot tilt off as the standard plastic bushings do.

SwirlRepair Function Detail


for REPAIR of defective inlet manifold swirl rods

Extra Narrow Special Bushing

In some cases there is very little space at one of the swirl flaps. Then a countersink needs to be drilled into the rod, and a countersunk bolt must be used. Because there is also very little clearance in such cases, SwirlRepair includes a special bushing that comes with the countersunk bolt.

Five Bushings Make a Kit

The SwirlRepair Kit comes with five bushings. For a four-cylinder engine only four bushings are needed, but we supply the special bushing in addition to the four standard bushings. This makes the installation easier, because the swirl rod only needs to be drilled and the special bushing only used when really needed. On five-cylinder engines there is a fairly narrow section anyway, so the complete kit can be used.

Tested Lubrication

The SwirlRepair bushings are not just made with highest precision and tight tolerances. They are also filled with a special grease, which we have endurance tested extensively to ensure optimum durability.

Diagnostics and Recommendations

Is SwirlRepair the solution you need? How do the problems occur?
And what else can be done to keep the engine happy? Click here to find out more.


Installing the SwirlRepair Kit just takes a few steps. First the worn plastic ball joint bushings are removed from the operating rod, and remaining plastic is drilled out from existing holes in the rod. In some cases it is then necessary to drill a countersink in one of the holes. After that the SwirlRepair bushings are attached with a standard 5.5mm key. Finally, the swirl flaps are turned to a specific position, and the swirl rod is attached to the ball joints of the swirl flaps.

SwirlRepair Kit Installation


SwirlRepair is much cheaper than an exchange of the complete intake manifold assembly.

Also, if the swirl operating rod has come adrift and your vehicle should not yet have recognized the defect, a repair with SwirlRepair will still pay off quickly. Smoke is reduced for the benefit of the engine and the environment, and also the performance increases while the fuel consumption drops back to its usual, low level, so the expense on SwirlRepair can be returned after just a few weeks.

Even if you should consider replacing the intake manifold assembly due to worn swirl flaps, SwirlRepair helps as a temporary fix as it gives you time to find an affordable garage and/or cheap parts while you can still use your car.

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