Place your bets - what will I find- swirl flaps jammed

[echazfraz]

The swirl flaps of my Saab 9-5 1.9TiD are jammed.

The actuator started throwing fault codes and I suspect the jammed flaps have caused the actuator to fail as it can't move them on command. I can't move the flaps by hand (well, I perhaps could, but I don't want to force them).

The rod still connects them all to each other.

EGR still operational, doesn't look overly sooty.

A quick peer into the manifold via the EGR port shows soot but nothing caked up blocking channels.

Throttle body not caked up and is working normally.

There is some oil coming out of the turbo, which is now whining, and will be replaced this weekend.

There is a splash of oil coming through the bottom of the inlet manifold seal.

I will be taking the manifold off this weekend to see what I can see.

What will I find?!

Btw it's an 18 month / 5k mile old "uprated" manifold that's got metal flaps, stronger rod, and can't be split in half like the Pierburg OEM one. The flaps looked poorly made when I checked before installation and one of the EGR mounting holes has lost most of its thread, so I fear I have bought cheap ste and am now paying the price.

[randomeddy]

Car Mechanics magazine did the swirl flaps on this car over a couple of editions.

Online back issues are available.

[Smint]

Can't you simply remove them, as was done to two 320d E46 BMWs in the family as preventative measure, cars ran better without.