Fault Code : Motor Intake

[fourier2008]

first post so hello to everyone :)

was googling some fault codes and this forum came up, so hoping you can help me !

Emissions warning light came on a few weeks ago in my 04 A3 2.0 TDI... its done 112K with harldy any trouble at all.. took it to a mates garage and he read back the fault code :

19557 - Motor for Intake Manifold Flap (V157): Open or Short to Ground

I have no obvious lack of power, or change in the driving characteristics.. and its still doing the economy i expect (55-60mpg nearly all motorway)

Does anyone have an idea where the intake manifold flap may be? or any ideas on what to look for? thinking I may have a look see before probably taking it back to the garage on Saturday...

Thanks in advnace

Jon

[Crasher]

It is in the middle of the front of the engine on the inlet manifold and has the boost pipe going to it. This is a very common problem on the BKD and is normally accompanied by a fan controller fault code and also a blown fuse at position 8 on the under bonnet fuse board which is just behind relay 4 and I think has 458 printed on top. If this fuse is blown your cooling fan will not work either and so you need a new regulator flap unit 038 128 063 G (for a 2004 BKD) and these are also available from Pierburg the manufacturer under the part number 7.14393.16.0 as well as other companies but I would only recommend genuine or Pierburg.

[fourier2008]

hi.. thanks for your reply :)

the fan is still operational so i guess no blown fuse (yet) - we did note another fault code, so maybe the fan one as you say but i dont recall the number.

I'm guessing these are non-servicable units then? dont suppose a squirt of the old WD40 will work in this instance?? :P I guess if it has failed then it must have done so in a way which isnt affecting the performance so much.. do you know if thats typically the case or have i just been fortunate in the failure state?

any ideas on how much the flap units aretypicall? (pierburg or genuine)

cheers

Jon

[Crasher]

The cooling fan will be working on A/C operation but it should not be working on engine temperature operation but check that fuse. I can’t tell you the price of the valve as it is not on my system but I think they are around £200 genuine.

[fourier2008]

well... i guess you know what you're talking about ! sure enough, fuse has blown...

24spares reckon they can get the pierburg unit for £95+vat so not too bad... going to investigate whats needed to fit one after my tea.. :)

seems this is a pretty common fault on the TDI unitss going by the amount of topics i've looked over....

thanks for the help .. keep the tips coming !

Jon

[Crasher]

So 25 years of working on VAG cars hasn’t been wasted then! The unit is easy to fit, just clear the codes and replace the fuse after the new unit is on.