Swirl Port Actuator Removal and Replacement - Chrysler 300C Forum: 300C & SRT8 Forums
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post #1 of 86 (permalink) Old 07-18-2012, 01:29 AM Thread Starter
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Swirl Port Actuator Removal and Replacement

Hi People

I've just recently experienced the dreaded swirl port actuator failure problem. Reading other threads on here and also speaking to an ex-Chrysler mechanic..this is a common problem on the 3.0 Diesel. After speaking with him, he told me that the part is about £155+VAT, and labour is 5 hours at about £100 per hour! Chryslers way is to basically remove everything at the engine top..injectors, inlet manifolds, turbo, etc. Well I can confirm this is not necessary. I managed to remove the swirl port actuator last nite in about an hour without removing any of these parts. It's a bit fiddly, but possible. I'm just waiting for the new one to fit now. Once the job is complete I will post step by step instructions and hopefully some photos so everyone else can do it them selves and save yourself hundreds of pounds.

Signing out for now.
Chris Ormond

Last edited by cormond; 07-19-2012 at 02:14 PM.
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post #2 of 86 (permalink) Old 07-18-2012, 01:55 AM
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Hi Chris
Welcome! virtually everyone here with a CRD has had swirl trouble. Mine was done under warranty. There is a sticky thread about by-passing the swirl with a 4.7 ohm resister. It sure will be helpful to the rest of us having pic by pic instructions. Your a brave man for trying it yourself - but not the first!
I think the real tricky bit is attaching the tiny rod to the new swirl. Others have found a method, Have a good search whilst waiting - it may help you refit yours!


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post #3 of 86 (permalink) Old 07-18-2012, 05:56 AM
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It's a 4700 ohm resistor (aka 4k7) that should be used. You might find a 4.7 ohm one gets a bit warm :-).
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post #4 of 86 (permalink) Old 07-19-2012, 02:21 PM Thread Starter
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Haha..yes I have to agree with you there talldave. You don't want warm resistors. :-P. I'm still waiting for the part, should hopefully have it tomorrow or Saturday. Yer I am brave but I know what I'm doing as I have actually taken the top end of one of these engines apart before a few years back for a different reason when I was an apprentice mechanic at Chrysler. I no longer work there as it wasn't the job for me. Very repetitive doing services and PDIs all day. But I still have the skills and knowledge and a few friends I can call on if things get sticky.

Keep posted for my progress updates
Chris Ormond
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post #5 of 86 (permalink) Old 07-22-2012, 09:36 AM Thread Starter
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Hi People. This is the procedure for the swirl port motor/actuator removal and replacement.

1. Remove engine cover.

2. Disconnect plug from the breather pipe to plastic turbo pipe. You need to pull the grey bit up before you can disconnect it.

3. Remove breather pipe, it just pulls out. Place it out the way.
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post #6 of 86 (permalink) Old 07-22-2012, 09:39 AM Thread Starter
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4. Remove turbo pipe. There's a large jubilee clip at each end and a plastic pop viet half way along the pipe (all circled in picture).
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post #7 of 86 (permalink) Old 07-22-2012, 09:47 AM Thread Starter
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5. Undo all the bolts shown in the picture. If you don't have the correct socket for these bolts, a 6 sided 8mm socket will do the job. Remember where they all go though as some are different lengths.
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Last edited by cormond; 07-22-2012 at 10:47 AM.
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post #8 of 86 (permalink) Old 07-22-2012, 09:53 AM Thread Starter
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6. Prize open the plastic cable cover underneath the turbo, on both sides using a flat bladed screwdriver, then remove and clean off oil and dirt residue. You can pull the wires up and place them up on top of the tubo inlet to get them out the way.
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post #9 of 86 (permalink) Old 07-22-2012, 10:00 AM Thread Starter
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7. Undo both ends of the fuel pipe connecting both injector rails using an 18mm spanner. Shown in pics 1 & 2.

8. Use a prybar (where the red square is in pic 3) to remove the left hand side from the injector rail (left hand side as you stand looking at the engine), then pull the pipe towards you to move it out the way. You won't be able to fully remove the pipe because of the metal turbo pipe, you just need to move it out the way.
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post #10 of 86 (permalink) Old 07-22-2012, 10:04 AM Thread Starter
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9. Pull up fuel filter and pull it forward as shown in the picture. There is no need to disconnect any pipes, just be careful not to split any pipes when you twist it around.
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