C5 2.2 Hdi Swirl Valve Actuator

[MagicMark]

The plastic ball joint on the top of the push-rod that connects the "diaphragm" to the swirl valves has broken - a common problem.
The standard fix is to replace the diaphragm unit - quite a cheap part. However, Citroen no longer supply it.
The solution would seem to be to 3D-print a ball-joint connector. Has anyone done this yet? Or found another solution?
Mark

[wheeler]

I’d personally just fix the flap lever either one way or the other, cant imagine it matters which way as sometimes these things have been broken for ages & you dont really know its broken until you actually see it broken.
You could experiment with it either fully open or fully closed to see if you notice any difference but i doubt it. Then just disconnect & block the vacuum pipe to it.

[MagicMark]

Thank you for your thoughts.
I didn't realise it had failed until I looked at that part of the engine. However I had noticed a while ago that the engine does not feel quite right at high revs, and especially around 2500. This failure could account for it. It had failed in the "at rest" position, that is to say that the ball was as far towards the front of the car as it could go. I've therefore assumed that this is the correct setting for low revs. I therefore intend to leave it pulled forward until I find a solution to the problem. Hopefully that's the right setting to pass the MOT later this month.

[leithant]

Alvadi says they still have 5 in stock. Worth a try. I'm read somewhere recently someone found something suitable to replace the plastic socket, but I can't remember what or where atm.

[MagicMark]

Thank you for the suggestion. I've tried looking in https://alvadi.ee/en/spare-parts/citroen/c5-dc-de-2001/, but couldn't find a swirl valve actuator or diaphragm.
Doing a part number search for 036387 found this page: https://alvadi.ee/en/kataloog/varuosa/82958464/?sv=1 which shows none in stock.
However I found one with a stock of 5 here: https://alvadi.ee/en/original/12251858- ... -OPEL?sv=5 showing delivery in November. Ouch but it's expensive... but I've ordered one.

Thank you again for the suggestion. I hadn't previously come across this supplier.

Mark

[leithant]

Yes, was about twice the cost it used to be. Hope it works out for you!

[MagicMark]

Sadly, I just received this...

Dear customer!
Please find credit note in the attachment.
Unfortunately this spare is no more manufactured.

Mark

[leithant]

I did wonder if that might happen...

[Rp0thejester]

My C8 has the tube blocked off with a screw, never had any problems with it. Didn't even know it was done till I spotted it. Photos are on the forum somewhere.

[MagicMark]

Thank you. My latest idea is to coat the ball with oil, and then try to mould an extension to the broken connector with Milliput. That way I shouldn't even have to remove the actuator. I'll let you know whether it works.
Might have to wait for a dry day, though!
Mark

[Rp0thejester]

Please take photos as I'd be interested in seeing the result. I can tell you that my C8 has never failed an MOT having the screw in the pipe to block it.