Audi S4 4.2 V8 Intake Manifold Re assembly

[Urban Tank]

Good evening! Could one of you wise folks inform me as to the starting position of the manifold flap prior to placing under Spring Tension?
Im FINALLY about to reassemble and seal and install a fully serviced and cleaned intake manifold and couldnt seem to find a good video or diagram on the position the flap should start on and or the sequence to best assemble under spring tension. Much obliged as always!

Freshly cleaned ports, new gaskets, throttle body, valve cover gaskets and significant grime and sludge weight reduction :) Almost there!

[Urban Tank]

Sorry if this seems so obvious but the actuator spring and flap rod was busted when i bought it so im trying to understand how much tension the spring is supposed to be under and what the starting position is for the flap???

[Zolli]

On mine, the cam thing that connects the shaft to the actuator arm points straight down, and it looks like the actuator arm is fully extended - when off.

The vacuum that then actuates the arm and cam presumably then pulls the arm toward the actuator and the cam in a clockwise direction from its 6 o’clock rest position to maybe the 9 o’clock position.

I can fire it up in the morning to see if it’s any different at idle. My exhaust note is delightful but I don’t want to wake the neighbors 😉

With that information, I imagine you’ll have only one option which way the interior flap can go.

- - - Updated - - -

Oh and the spring has a lot of tension

[Atomic Avant]

Here is what it looks like with just the spring assembly done. This is on a working manifold.IMG_20221104_095002.jpgIMG_20221104_095009.jpgIMG_20221104_094955.jpg

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[Atomic Avant]

On mine, the cam thing that connects the shaft to the actuator arm points straight down, and it looks like the actuator arm is fully extended - when off.

The vacuum that then actuates the arm and cam presumably then pulls the arm toward the actuator and the cam in a clockwise direction from its 6 o’clock rest position to maybe the 9 o’clock position.

I can fire it up in the morning to see if it’s any different at idle. My exhaust note is delightful but I don’t want to wake the neighbors

With that information, I imagine you’ll have only one option which way the interior flap can go.

- - - Updated - - -

Oh and the spring has a lot of tension

Correct, it sits at the 6 o'clock. Once you start the car it should move to the 9 o'clock (closed) position.

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[Urban Tank]

Update: Thank you ALL......After a ton of cuss words , two broken flaps and a box of plastic levers I FINALLY figured out what has been causing me to pull my hair out!

The BOTTOM RIGHT TRIANGLE "BUMP STOP" WAS MISSING FROM THE ACTUATOR "COUPLER HOUSING " SO THERE WAS NOTHING PREVENTING THE PRESSURE OF THE SPRING FROM CAUSING THE FLAP ROD TO DAMAGE ITSELF FROM BOTTOMING OUT.........HENCE I COULD NEVER GET THE FLAP LEVER TO SIT AT 6 O CLOCK..........AS THE SPRING WOULD PUSH IT TO 4PM.

Temp fixed by spinning the coupler 180° until a new one arrives...... The donkey is strong with this one.......I simply didn't notice it was missing the one triangular ear!

[Urban Tank]

Thanx again Zolli! Really appreciate it. I also enjoyed your review of the rebuild kit I ordered on JHM

[Urban Tank]

Here is what it looks like with just the spring assembly done. This is on a working manifold.IMG_20221104_095002.jpgIMG_20221104_095009.jpgIMG_20221104_094955.jpg

Sent from my GM1917 using Audizine Forum mobile app

Thank you Sir! It was your pics that made me realize I was fighting a broken part! Someone must have tried to jb weld it as it wasn't until a chunk came off while inspecting that i even realized it was broken. The previous owner I suspect of numerous molestations only owned it for a week thank God!

[Atomic Avant]

Thank you Sir! It was your pics that made me realize I was fighting a broken part! Someone must have tried to jb weld it as it wasn't until a chunk came off while inspecting that i even realized it was broken. The previous owner I suspect of numerous molestations only owned it for a week thank God!

Glad you found the issue, it sucks finding other peoples screw ups.

[Urban Tank]

I think its either hit or miss with these kinds of cars...... Either they are enthusiasts owned and reasonably cared for or "Spalding" owned and neglected or molested.........Part of me thinks one needs to be a little crazy owning one of these 40v timing chain guide eating liquid cooled alternator fine peices of German engineering.......especially the C6 and B6 V8s requiring engine out service for a plethora of known issues which even having a shop and the space im not sure I wish to do Again lol........
I think im going to part out my A6 C6 being I have to pull the engine which has good drivetrain and dealer performed timing done less than 10k ago...... but one broken guide :( Turn key fully serviced V8 engines seem to have some demand and almost higher value than the cars themselves :)

[Zolli]

Well I always knew mine would be a labor of sex appeal...I mean love.

Nips and I are happy to help, of course.

Probably it was the previous previous owner that participated in some of these problems, if the more immediately previous owner only had it for a week.