BMW X5 40d 2010. When starting from cold after about 10 seconds there is a chattering noise which can be heard from the nearside of the engine. Using a stethoscope it seems to be coming from the inlet manifold. I did look at removing the swirl flap actuator today, however it would appear that the manifold has to be removed to do this so left for another day. I did however notice some green corrosion deposits on the pins within the actuator control plug and when moving the wiring the chattering would change.
Has anyone experienced issues with the swirl flap actuator on the N57? Its almost as though the arm from the actuator is not fixed to the rod maybe.
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Swirl flap chattering noise
Swirl flap chattering noise
If I were you, I'd just whip the manifold off and get rid of the flaps, you will need to purchase the delete kit, plenty on flea Bay 
, its not a bad job takes about 1hr ....one thing the nuts on one side of the manifold are easily dropped so undo them to nearly the top the use a magnet to unscrew them off the bolts on the other side they are captive in the manifold so no worries there, put plenty of rags around the engine bay in case you drop one, they are not a common size, think theyre 9 or 11mm...., also would be a good idea to fit a new set of manifold seals also readily available on the bay.
, its not a bad job takes about 1hr ....one thing the nuts on one side of the manifold are easily dropped so undo them to nearly the top the use a magnet to unscrew them off the bolts on the other side they are captive in the manifold so no worries there, put plenty of rags around the engine bay in case you drop one, they are not a common size, think theyre 9 or 11mm...., also would be a good idea to fit a new set of manifold seals also readily available on the bay.Swirl flap chattering noise
I did consider this however reading online this can have detrimental effects on low end power and fuel usage so decided not to.
I have found the issue it seems though. The wiring plug to the swirl flap actuator has a poor connection as when I moved it slightly I could hear the motor operating. Unplugging it revealed some green terminal corrosion, so a quick clean and seems to have fixed it.
I have found the issue it seems though. The wiring plug to the swirl flap actuator has a poor connection as when I moved it slightly I could hear the motor operating. Unplugging it revealed some green terminal corrosion, so a quick clean and seems to have fixed it.