Installed Stage 2 pulley - now P2007 intake manifold flap stuck closed

[kr3w45]

[Edit: Problem fixed see below]

Removed my supercharger today to instal the CTS pulley. Everything was cake until I took the car out for a test drive and after 2 key cycles, CEL P2007. Checked for pinched vacuum lines under supercharger, none, all hoses in correct order. If it were a pinched line I would suspect both banks to throw codes?

What are the chances one of the flaps is actually stuck closed? When I had the blower off, I started pulling the covers off the valves so I could carbon clean them but didn't feel like dealing with the fuel injectors so I put it back together. Only thing I can think of. Also the purge valve seems to be clicking loud enough to hear but this would typically throw a p0441?

Any help would be great
Thanks,

[Rez90]

did you pull the blower or put the car in service mode?

[kr3w45]

I pulled the blower


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[Rez90]

Odds are you did exactly what i did. The top two vacuum hoses are likely switched. They are at about 1 o'clock in this picture.

[kr3w45]

Which hoses? I only see 2 solenoids in your photo I have 3


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[Rez90]

Not sure. our cars must be different years. but my gut tells me something is reversed/switched. Maybe make another thread with your pic asking for another member with a B8 to take a pic of those hoses to see the order. Mine is a 2015 so i guess something changed along the line....

[kr3w45]

Oh okay. Thanks for the input. Did you have the same code and just 1 bank?


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[Rez90]

Oh okay. Thanks for the input. Did you have the same code and just 1 bank?


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after 24 hours i had 2 codes. One was the same as yours and the other was for flaps stuck open....made sense that something was reversed. I was so lucky i took that pic before pulling everything apart.

[kr3w45]

Everything seems to line up is why I'm so stumped


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[Rez90]

hmm. me too. looks correct. Maybe check all the connections one more time?

wish i could have been more help. best of luck.

[kr3w45]

Tripled checked .. Looks like I'll have to take the blower off again and see what's going on. Thanks man


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[skiptowncat]

Everything seems to line up is why I'm so stumped


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Did you reconnect the two hoses that are underneath and to the right of no.3 in the picture

[kr3w45]

Yes I did, thank you for checking. I've had the supercharger off twice before for the thermostat so I'm pretty confident all hoses are connected in the right order. Just about to take the blower off again to check out the manifold flaps


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[schirm]

I received this code Friday P0004 same CEL BAnk 1. on a cold start. I received a new motor from Audi last week too. I cleared the CEL, and it has yet to come back.

Edit, mine says stuck open not closed.

[AudBoost]

I got this code when I got my car back from having fuel rail recall done. The tech's missed installing the vacuum line to the purge valve. The best way to get to it is from the driver's side and it's right behind the oil filter.

[kr3w45]

Thanks for all the replies everyone. I've confirmed my left side bank manifold flaps are in fact not working properly. Has anyone replaced the vacuum pump for the flaps? Can't even find parts online.


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[kr3w45]

Fixed:

The left side manifold flaps were in fact stuck closed as suspected. I figured that if it were a vacuum line problem I would get P2007 and P2006 because there is only one vacuum line that splits to both vacuum actuators.

What happened was when I removed the supercharger, I had started removing the fuel rail assembly to clean the valves. When doing so, without applying vacuum to the flap actuator the flaps popped up over the lip when they should be on the other side. I will post photos with my phone so you can see what I'm talking about here to help anyone in the future if this happens to them after removal of the supercharger.

Thanks for the input!

Edit: that shiny line is to stop the flaps when vacuum is pulled. The flaps were stuck above the line keeping them closed and not allowing them to open.

[schirm]

Fixed:

The left side manifold flaps were in fact stuck closed as suspected. I figured that if it were a vacuum line problem I would get P2007 and P2006 because there is only one vacuum line that splits to both vacuum actuators.

What happened was when I removed the supercharger, I had started removing the fuel rail assembly to clean the valves. When doing so, without applying vacuum to the flap actuator the flaps popped up over the lip when they should be on the other side. I will post photos with my phone so you can see what I'm talking about here to help anyone in the future if this happens to them after removal of the supercharger.

Thanks for the input!

Glad you figured it out!

Any idea why mine would be stuck open? P2004

[kr3w45]

Glad you figured it out!

Any idea why mine would be stuck open? P2004

I would be willing to bet its a mechanical issue (if it's only a code for 1 bank, if not vacuum related). Are you comfortable removing the supercharger? I would recommend removing the blower and use a vacuum pump to actuate both of the manifold flaps and you will easily be able to tell what's going on.

I attached a video too you can check it out

[schirm]

I would be willing to bet its a mechanical issue (if it's only a code for 1 bank, if not vacuum related). Are you comfortable removing the supercharger? I would recommend removing the blower and use a vacuum pump to actuate both of the manifold flaps and you will easily be able to tell what's going on.

I attached a video too you can check it out

Yeah I would be comfortable doing that.,.but my motor was replaced by Audi last week So if it keeps happening I will bring it in. Just curious to what can cause it to happen. I cleared the CEL Friday, it has not came back.

[kr3w45]

Yeah I would be comfortable doing that.,.but my motor was replaced by Audi last week So if it keeps happening I will bring it in. Just curious to what can cause it to happen. I cleared the CEL Friday, it has not came back.

Why was your motor replaced?

[schirm]

Why was your motor replaced?

My story is here.

http://www.audizine.com/forum/showth...ht-running-bad

[kr3w45]

My story is here.

http://www.audizine.com/forum/showth...ht-running-bad

What a nightmare. Did they ever figure out what the initial problem was? If they swapped the original supercharger on the new motor chances are they screwed something up from the sound of that dealership after reading your thread haha

[Rez90]

glad it all worked out

[Wreckm]

Cleeaaar.
Revived.
Wondering about the intake flaps anyone have info if you can tuck them back in easily?
or you have to take that intake manifold part off as well and do it with part off?

[theweebabyseamus]

‘Intake manifolds’ off

[Wreckm]

dug into alldata.

Generate vacuum using hand vacuum pump.
¤ The intake flaps are opened.
¤ If the intake manifold flaps are not opened, they may get jammed when installing the lower intake manifold on the cylinder head.
Remove hand vacuum pump from intake manifold runner control vacuum actuator.

So my guess for the fix is take the lower intake manifold off create vacuum make sure flaps are below ridge and reinstall?

[theweebabyseamus]

Just move them into position by hand. They’re all tied to the same rod so you only need to move one.

[JaB6]

Just move them into position by hand. They’re all tied to the same rod so you only need to move one.

+1

Hold the the flaps open a little as you tighten the assembly down, sometimes they'll want to come back to the wrong side before it's all tight

[03redgti]

Bump had my charger off and got these two codes as well. 2006 and 2007 both runners stuck closed . Going to get a vacuum pump tomorrow and Hold them open while I re install the charger. What causes them to get stuck?
And the line circled in red..is that the one that actuates the flappers?

[eurotic]

Bump had my charger off and got these two codes as well. 2006 and 2007 both runners stuck closed . Going to get a vacuum pump tomorrow and Hold them open while I re install the charger. What causes them to get stuck?
And the line circled in red..is that the one that actuates the flappers?

The cause is improper installation. When you are putting the manifolds back in you need to hold the flaps open as you are setting it in place, which you can just do by either pressing on the flaps or using the armature that is attached to the diaphragm at the front. No need for a vacuum pump. A lot of people, including myself, have hit this snag...thankfully I remembered the warnings people gave before I got my supercharge back on and just had to pull the manifolds back off and reinstall.

Once your manifolds are all tightened down, you should be able to press the flaps open. If you can't do that, you have it wrong.

[proxemus]

This is really good info once i do t-stat and water pump!

[03redgti]

The cause is improper installation. When you are putting the manifolds back in you need to hold the flaps open as you are setting it in place, which you can just do by either pressing on the flaps or using the armature that is attached to the diaphragm at the front. No need for a vacuum pump. A lot of people, including myself, have hit this snag...thankfully I remembered the warnings people gave before I got my supercharge back on and just had to pull the manifolds back off and reinstall.

Once your manifolds are all tightened down, you should be able to press the flaps open. If you can't do that, you have it wrong.

I didnt touch my manifolds and they did move by hand before I put my charger back on. My issue was I had two vacuum lines reversed. all is well now

[hmc2261]

Fixed:

The left side manifold flaps were in fact stuck closed as suspected. I figured that if it were a vacuum line problem I would get P2007 and P2006 because there is only one vacuum line that splits to both vacuum actuators.

What happened was when I removed the supercharger, I had started removing the fuel rail assembly to clean the valves. When doing so, without applying vacuum to the flap actuator the flaps popped up over the lip when they should be on the other side. I will post photos with my phone so you can see what I'm talking about here to help anyone in the future if this happens to them after removal of the supercharger.

Thanks for the input!

Edit: that shiny line is to stop the flaps when vacuum is pulled. The flaps were stuck above the line keeping them closed and not allowing them to open.

I know this is super old but I just had the same thing happen during my stage 2 install, shop pulled the supercharger so I’m guessing I’ll need the same fix you had to do.
The car doesn’t seem to produce much power at all, it doesn’t pull. When you fixed the issues I’m assuming all of the power came back as normal?

[wes8398]

I feel like I've read that there needs to be some kind of reset / vcds / coding type thing that happens to these intake flaps when the lower manifolds are removed... am I wrong?

[rrated]

I feel like I've read that there needs to be some kind of reset / vcds / coding type thing that happens to these intake flaps when the lower manifolds are removed... am I wrong?

Bump for interest

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[mkl101]

I'm having the exact same problem. I pulled it all apart replaced pcv and thermostat. Put it all back together and getting the same code. I have plans of pulling it all apart again today and doing a carbon cleaning on the valves. I need to reset the intake flaps. It's a 2012 A7 111k miles stage 2. I was chasing down a mystery coolant leak. Hoping I fixed it.

[wes8398]

I'm having the exact same problem. I pulled it all apart replaced pcv and thermostat. Put it all back together and getting the same code. I have plans of pulling it all apart again today and doing a carbon cleaning on the valves. I need to reset the intake flaps. It's a 2012 A7 111k miles stage 2. I was chasing down a mystery coolant leak. Hoping I fixed it.

Fingers are crossed for you!

[Mpharm]

I'm having the exact same problem. I pulled it all apart replaced pcv and thermostat. Put it all back together and getting the same code. I have plans of pulling it all apart again today and doing a carbon cleaning on the valves. I need to reset the intake flaps. It's a 2012 A7 111k miles stage 2. I was chasing down a mystery coolant leak. Hoping I fixed it.

Have you sort that mate ? Im also after pcv waterpump and thermostat replacement and got p2006

[wes8398]

Have you sort that mate ? Im also after pcv waterpump and thermostat replacement and got p2006

Have you done ANY of your own reading on this? It's literally one Google search away. Your intake runners weren't re-installed correctly. The flaps are stuck, so your intake runners is only allowing about 30% of the airflow it would when the flaps are open.