<sighs>... This whole swirl throttle business really doesnt seem to have been thought out very well. There is a good thread on here about repairing the control arm so that it doesn't pop off. I have made such a modification which has worked well until now. Now the plastic socket on the end of the swirl throttle has 'melted' so I am now in the process of making a Mk 2 repair involving using epoxy putty and a male ball joint made of metal on the end of the swirl arm. That will then require a link arm to be made which has 2 female ends.
Your post here indicates that any repair to beef up the outside may be ultimately futile due to the build up of deposits within the top of the engine.
As a matter of interest, did you replace the swirl throttle assembly with the upgraded version which is supposed to be built to a higher (stronger) standard? Would be very interested to read about the difference between old and new if you did.
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2006 V70 D5 SE 185
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