Any advise Manifold flap problems

[pazoruk]

Hi all great forum you guys got :)

Anyway im having some probs with as the header says my manifold flaps.

Purchased a 2008 A6 3lt TDI 68k, On the way home the light came on and the fault was bank 2 flap not reaching lower limit.

Took it back to dealer and he purchased a set of the rods from ebay, Seemed to work until a week later light was back :( with the same fault code.

We then went half of a set of the reinforced manifolds on ebay cost around £390 these again worked for this time 3 weeks and the feckin light is back.

Differnt error code but bank 2 again this time its sporadic upper limit exceeded..

Took it back and the dealer said it was stiff and prob just needs wearing in...but he would contact the ebay seller and get them to send another manifold.

This was fitted last night and all seems well again..

Do you chaps think that a simple lubrication of the flaps would of fixed this ? as the dealer said bank 2 was just stiffer then bank 1.

He advised me to buy a unit to plug into the car to clear the fault if it happends again and hopefully the flap with get better with use but ive no idea what this unit is or if its a good idea...Im just unhappy and 13k down with maybe a poorly car :zx11:

[MarkTM]

Hi Pazor and welcome!

Good thread here:

Audi V6 TDi 2.7 & 3.0 Inlet Manifold, Swirl Flap Repair Kit. (http://www.vwaudiforum.co.uk/forum/showthread.php?140390-Audi-V6-TDi-2-7-amp-3-0-Inlet-Manifold-Swirl-Flap-Repair-Kit&highlight=swirl)

[pazoruk]

Thanks for the thread link Mark..My probs is i think i have done everything that they have listed on that thread and it still went faulty :(
Im after some advise really on

Can anyone post any pics instructions on how to get to the manifolds for me to lubricated them ?
And if i should purchase a diagnostic tool to clear the error if it happends again ?
Ive also seen somwhere that this can be mapped out but ive not been able to see any other info on who how much etc

[gupsterg]

Hi Pazoruk :) ...

Welcome to VWAF! :beerchug:...

Have you had new motors as well?

Has repairer provided you with any fault codes?

[Doctle Odd]

You need to scan the car with VCDS look here for authorised sellers Ross-Tech: Distributor List (http://www.ross-tech.com/distributors.html)

[pazoruk]

Hi yes when they orderd the remanufactored/reinfored manifolds from ebay they also come with motors.

Re the fault codes i took it to my friends garage and watched the diagnostic tool work , it did show the error codes (but i didnt take note)
But it also shown text saying what the faults was.
As before
Bank 2 intake manifold flap not reached lower limit
Bank 3 intake manifold flap sporadic upper limit exceeded

[Doctle Odd]

Can you get the codes off your friend he probably saved automatically

[pazoruk]

P1018 was deff the first code, the 2nd may not be correct as i wrote it on a scrap paper
4119 but there was also a 001 somewhere is there lol

[Doctle Odd]

And the motors were properly tested with diagnostic equipment?

[gupsterg]

@Pazoruk ...

I've seen posters mention adapting the motor's see post 1 here Link:- Intake Manifold Runner adaption (http://www.vwaudiforum.co.uk/forum/showthread.php?121538-Intake-Manifold-Runner-adaption)

Also reader Crasher's post 3 ...

[pazoruk]

Nope the only thing that was done was to plug the tool in and read why the light had come on.

[MarkTM]

Update

I just had the 'lower limit not reached' fault come up on bank 2 and MIL is on. Took the cover off and moved the linkages a few times and when I then start the car the fault's cleared for the next drive...one after that MIL's back on. So to my limited mind it's time to apply the repair kit to remedy.

Now I purchased the swirl flap repair kit some time back, luckily am having an ex VAG specialist come over to change the sparks on my XK8 (and a few other bits Thurs) so he'll have the job of doing it.

I've yet to see a link where someone's done a video of the swap...or have I missed it?

[Guest 2]

There is a thread in the How To section with loads of pics from memory and maybe a vid.

Search for manifold as is think Crasher posted a video of some sort.

[gupsterg]

I just had the 'lower limit not reached' fault come up on bank 2 and MIL is on. .... I've yet to see a link where someone's done a video of the swap...or have I missed it?

Bank 2 is the right one ...

http://i1247.photobucket.com/albums/gg629/gupsterg/2_7%203_0%20TDi%20stuff/SwirlFlapMotorLabelled_zps7c13e1cd.jpg

Bank 1 is a PITA to do in situ but here's a video on bank 2 ...


http://youtu.be/o97yPYwebhE

[MarkTM]

Bank 2 is the right one ...

http://i1247.photobucket.com/albums/gg629/gupsterg/2_7%203_0%20TDi%20stuff/SwirlFlapMotorLabelled_zps7c13e1cd.jpg

Bank 1 is a PITA to do in situ but here's a video on bank 2 ...


http://youtu.be/o97yPYwebhE

Surely better to say 'Bank 2 is the one on the drivers side for us in the UK, Bank 1 (passenger side UK) is a PITA'

Well mechanic did work at Audi and then a specialist and now he's mobile his rates are a mere £35 per hour and no VAT :smile:

Am guessing bank 1 requires some dismantling, bank 2 looks easy but do wish the German in Vid had used to some long nosed pliers and ensured the focal point was center shot. :)

[gupsterg]

Surely better to say 'Bank 2 is the one on the drivers side for us in the UK, Bank 1 (passenger side UK) is a PITA'

LOL ... I think you have got a bit mixed up there :) , bank 1 for a uk car is driver's side bank 2 is passenger side.


Am guessing bank 1 requires some dismantling

Seen one or two post of it done in situ on VWAF they must of had very small and nimble hands! :D ...

[MarkTM]

Bank 1 is a PITA to do in situ but here's a video on bank 2 ...


http://youtu.be/o97yPYwebhE

The one he does in the vid IS the one on the UK drivers side...so the confusion a little exacerbated by your good self no? :biglaugh:

Or have I completely lost the plot:confused:

[gupsterg]

Please Mark view the video again, he takes the motor off the bank next to the coolant expansion tank. So for the German guy Bank 2 is drivers side and bank 1 passenger when sitting in the car.

The engine bay photo is mine, so when sitting in car bank 2 is passenger side and bank 1 is drivers side.

But regardless of LHD or RHD Bank 1 & 2 will be same location on engine/engine bay.

[MarkTM]

Gup, apologies I'm an idiot :P