Non-swirl flap inlet manifold

Last month we made the discovery that contrary to popular opinion, the good old 1.9’ in the TTiD Saab is, in fact, a smaller capacity (1910cc) version of the unloved CDTi Vauxhall engine as used in the Astra, Insignia and others in 2.0 form. This made finding parts for our car a bit tricky, but by the power of the internet and comparing photos, I deduced that our 2008 Saab engine used lots of CDTi type parts – plastic inlet manifold, thermostat, EGR valve and sadly, that stupid sump oil pick-up О-ring that we will have to renew.

So, we managed to remove our manifold with an almost ludicrous amount of dismantling and thought that unless you did a lot more dismantling – either taking the head off or stripping the whole gearbox end of the engine – the manifold would not come off intact. We had to chop the bottom of the swirl flap linkage off – ridiculous!

This, of course, was a learning process and having done the job once and known that a replacement manifold is the best solution, we would have just chopped the corner off the manifold with an air saw as it was going in the bin anyway. This would still be our preferred way of doing the job, but upon