A6 2.0TDI - Setup new intake flat manifold motor

[roflynn]

Hi, I'm fairly new to this site but hoping someone can point me in the right direction. I own a 2009 A6 Avant 2.0 TDI 170bhp. The engine management light came on about a month ago and a local garage diagnosed the fault to be the intake manifold flap motor. They took it out and cleaned it but the light quickly came back on. They then said I'd need a new motor. The price from Audi was high so I got one myself on the internet a lot cheaper and they agreed to fit it for me. So far so good. However, the new part is fitted but for some reason their software doesn't allow them to 'configure/setup' the new part and as a result it's throwing an error and the engine management light is back on. Apparently, you need the software which only an Audi/VW dealer has and whatever they have isn't detailed enough. I saw them try adn when they go into the module to configure the intake flop manifold the says something relating to security and you can't go any further. The car drives fine but from what they said the new part needs to be setup or 'told' how to work. Anyway, they don't have the right software and I'm a bit loathe to go to a main dealer. I live in NW London (close to West Hampstead) and wondering is there anyone around who may have the right software to setup the new part? Happy to travel. Thanks, Rob

[sam2k01]

Hi mate, you need an genuine VCDS to set it up. Have a look at the VCDS map on the forum and see if anyone's local to you, the good guys here usually get it done for some beer tokens. 👍👍

Sent from my SM-N9005 using Tapatalk

[Crasher]

If this is the V157 manifold flap, they do not require setting up.

[roflynn]

Hi, not sure if it's a V157. This is the part I bought and they fitted. Audi VW Seat Skoda 2.0 TDI Intake Manifold Flap Actuator Motor 03L129086 | eBay (http://www.ebay.co.uk/itm/Audi-VW-Seat-Skoda-2-0-TDI-Intake-Manifold-Flap-Actuator-Motor-03L129086-/121636689950?hash=item1c521c981e) Although, I didn't pay £1000! £165 instead. The car seems to drive perfect. In fact, I've just done a 200 mile motorway trip and it's fine. Thanks

[roflynn]

actually it did say on the packaging that it needed to be setup. This is what they couldn't do. If the car is running fine is it important at all? Hate to think I wasted £165 but I do need to get the amber light off.

[MarkTM]

Did they also replace the arm off the back of the unit pictured? The fault often presents itself either

1) if this arm wears out (£14 for a new one from Audi and a doddle to DIY)

2) If the swirl flaps are sticking due to a gunked up intake.

Certainly from what I've seen of the 3.0 it's usually one of the above 90% of the time and and actuator 10%

Annoyingly for you I was in NW6 for the last 3 days leaving at 10pm yesterday and (as always) had VCDS and my laptop with me :(

PS: I've had the light on for the last 20k miles with no ill effects, but then I scan my car weekly to ensure that nothing else arises (and simply applied some permenant marker to stop the symbol burning out my retina).

[roflynn]

Unless the arm was part of the unit I bought then no they didn't replace it..so maybe the motor wasn't the problem after all?

[Crasher]

It is almost unheard of for a new motor to solve the problem, the flap system is usually worn. Yes there is a setup procedure using a special VAG tool but even the dealer does not bother.

[roflynn]

hhhm. So maybe my £165 for new motor + £75 for cleaning the original one + £30 has been wasted. They are now telling me that to get someone with the VAG to setup the new part will be another £80...not getting a comfort level that they know what they're doing. Maybe at this stage I need to take it to the main dealer but I just know they'll be looking to replace even more parts!. Anyone around North London or within say 50miles drive of North London able to help? Happy to pay someone who knows what they're talking about to get this sorted once and for all.

[dan2485]

You need to get the car scanned to make sure that the fault is an Swirl Flap fault now.

It may be something else.

A new Intake manifold will cost around £400-500 dependant of where you get it.

It is about and 2 hours work to remove and refit it.

You will need VCDS or a decent tool that can prime the fuel system as the fuel lines to the common rail need to be disconnected.

Are you confident that they actually cleaned the intake manifold and they should have done the EGR valve and throttle body at the same time.

[roflynn]

Thanks Dan. Sounds like it could be any number of things and possible that the new motor was a waste. As you say, I need to get a new scan done. The car runs perfect but I'm driving to Ireland next weekend so don't want to run any risks of being left on the hard shoulder with family! It is very risky to do a long drive?

[dan2485]

It should be fine, the worst thing would be the car going in to limp mode that would be rare.

Your fuel economy may be down due to the flaps being stuck.