S4 B6 intake manifold flap failure.

[waarna]

I bought s4 b6 with broken flap actuator...
I replaced it with new one and it doesn't work. In video you can see that actuator is trying to move flap but something is holding it.

Maybe there is current position in witch flap must be installed? Is there any manual, could anyone please post it here?

[gautam]

There's a DIY somewhere in the forum, Squiddy wrote it up, it shows you how to remove the flap mechanism and fix it so that it moves more freely between the high rpm and low rpm position. I'd suggest looking into it.

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There's a DIY somewhere in the forum, Squiddy wrote it up, it shows you how to remove the flap mechanism and fix it so that it moves more freely between the high rpm and low rpm position. I'd suggest looking into it.

NVM just realized you're talking about the flap actuator and you installed a new one.

[waarna]

Yes. I have installed it. But looks like possition isn't correct!

[waarna]

Anyone, please?
Tried to disconnect rod and move pivot with hand. It moves but quite hard.

But really I don't know how hard or easy it must move.

[gcoy]

I am no expert on this subject but I moved mine and it is also quite hard to move.... Hope more will chime in as I now am curious.

[waarna]

Then maybe I have installed my in incorrect position. Maybe anyone know how to install pivot in right possition? Maybe flaps must be turned in at the one end position or other?

[TarlCabot]

arm should be pointing straight down with engine turned off... with that in mind, flapper will be in OPEN position
when you start the engine, arm will turn about 80 degrees to close flapper, then at 6500 rpm, electric actuator will cut vacuum to the box and allow the spring to close the flapper very quickly

you can always have someone watch this while checking all actions

B7 you can actually (should be able to) move the flapper to CLOSE position (with engine OFF of course) with your finger
B6 its a little tight, but may be able to

if it doesn't move or able to move it (by hand) freely, then it is most likely stuck and your going to have to free it up

[waarna]

It means - before I'm installing pivot. I have to turn engine ON, move flaps with pivot straight down and then in this possition I have to install pivot with spring - correct? Then connect pivot with actuator and test.

[TarlCabot]

you will have to coil the spring somewhat before putting it and the arm back on (main bolt will hold that in place).... flapper should be in OPEN position at this time and arm will be pointing straight down

it would be very hard to do this incorrectly if you were the one to take it off in the first place, i recommend take pictures of everything before any job... just in case

i would doubt original owner would have taken it off, just to put it back on incorrectly...

so, going by your video, either your flapper is stuck or the vacuum line going to the actuator is NOT supplying enough vacuum or the actuator diaphragm is busted <<< have not seen this last problem often, more likely your vacuum line is cracked and leaking (should have a code!!!) or could be the electronic part that controls the vacuum going to it...

[TarlCabot]

this is the hard brittle vacuum line those goes across the top of the intake mani and around back to connect to a few others, those plastic lines/connectors are common to fail from heat and time

[waarna]

Ok, thanks for your answers.

I didn't have any pivot on my flaps. Those were broken(bought car without). I will try to install in correct possition - OPEN, stright down. and then I will make new video. I will post here. Maybe there is somewhere vacum leakage or flaps is stuck. Will search for this.

My car for now have mutch power loss. I hope that its becouse of flaps...

[TarlCabot]

Ok, thanks for your answers.

I didn't have any pivot on my flaps. Those were broken(bought car without). I will try to install in correct possition - OPEN, stright down. and then I will make new video. I will post here. Maybe there is somewhere vacum leakage or flaps is stuck. Will search for this.

My car for now have mutch power loss. I hope that its becouse of flaps...

absolutely... with the engine being NA the variable length intake gives us power and torque in the low RPMs and high... however, since yours is stuck/broken in the OPEN position... THIS is for above 5200 (high) RPM range, so your losing a lot of hp and tq right now...

[TarlCabot]

Hopefully... these images may help you get yours back to correct position.... this is stock/OEM and in working condition











As you can see, with the intake off of the car... the stock/OEM and the upgraded JHM intake (flapper) is in the OPEN position, in which the spring holds it there when engine is turned off or engine is running ABOVE 5200 RPM...

[waarna]

Yes i see. Thank you. Will do this in few days.