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Thread: 1.4 TDI 90bhp ATL engine intake manifold flap motor fix (?)

  1. #21
    Join Date
    Jun 2003
    Location
    Melton Mowbray
    Posts
    248
    Got one for 183 - VDO (Siemens).

  2. #22
    Join Date
    Sep 2007
    Location
    Walthamstow East London E17
    Posts
    2,649
    The one on my new project (2005 BHC engine) was showing the Motor for Intake Manifold Flap (V157)

    I removed the intake manifold and opened it. Below are the pictures of the inside, it is immaculate inside it.

    However, what I found was that there was so much gunk around the EGR valve that it had completely blocked up the airflow therefore car wasn't able to get any any air and hence unable to start!


    A thorough clean out of the EGR valve worked a treat and no errors now!


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    I shall pass through this world but once. Any good that I can do or any help that I can give to my fellow beings; let me do it now; for I shall not pass this way again.


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  3. 2 users that liked this post:

    BiggDogg (20-05-2017), JIGSAW (13-05-2017)

  4. #23
    Join Date
    May 2013
    Location
    Aberdare, South Wales
    Posts
    3,897
    Jeez Sarge. That egr was unbelievably dirty. Good work.
    Steve
    0779zero965448

    Lots of parts/spares for sale - please click the link

    http://www.a2oc.net/forum/showthread...equest-A2Steve



    Project TDI150 on its way :-)

  5. #24
    Join Date
    Jun 2017
    Location
    Kelty Fife
    Posts
    326
    Wow just found this great info in here.

    Better not driving the car i guess until I've had a chance to see if I can salvage the intake manifold before I wreck it by not fixing. Hopefully as above its just full of oil!

    Future reference I have an ATL engine reporting intake flap motor issue
    Last edited by cheechy; 12-10-2017 at 12:29 PM.

  6. #25
    Join Date
    Jun 2017
    Location
    Kelty Fife
    Posts
    326
    Would I get away with using brake cleaner for cleaning up the cogs?

  7. #26
    Join Date
    Jun 2017
    Location
    Kelty Fife
    Posts
    326
    ok in the end I've just used a bit of kitchen towel and some metal cleaner for the stubborn bits on the outer casing along with the inside of the manifold itself (where the actual air goes through as there was a lot of stubborn oil marks in there).

    I did find some oil in there and it was in amongst the cogs which I cleaned up with a dry kitchen roll and finished off with silicon lubricant once all was back in place.

    i am finding though at the extreme closed off position even when clean it is sticking closed at times - is this normal? if not it might explain the issue and I'm not sure if I'm able to fix it.

    On the electronics side there wasn't a massive amount of oil either but what there was I cleaned up with combo of kitchen roll and cotton buds dipped in acetone then dried off.

    Will reinstall over the weekend and find out what happens - at least if it doesn't work I know how to put the new one in

  8. #27
    Did you take the motor out and clean it? Mine is still working fine by the way. The spring-return on my is quite strong, and did not stick when tested by hand. All the best. Matt


    Sent from my iPhone using Tapatalk
    2004 TDI 90 sport

  9. Users that liked this post:

    cheechy (13-10-2017)

  10. #28
    when you had it apart , you say the flap was sticking , firstly were there any burs on the brass flap or any sideways movement as posibly sticking on the sides of the alloy casing , after i modified my amf one and had it welded up i noticed my flap would stick slightly at fully closed position , on inspection i found a tiny bur on the outer edge prob from me porting out the insides i must of knocked against it and being brass its very soft , i used some wet and dry and curved the whole flaps edges very slightly and it cured my issue .. may be of some help to you
    Audi A2 TDI SE , Working sky , Bose , Dis , rear electric windows , Red leather .... Daily Driver

    Audi A2 1.4 16valve

    AUDI A2 SE 1.4TDI dirty diesel dog, Rebuild in progress , next stage custom stainless manifold and VNT Turbo

    Project A2 Quattro Twin bike Engined Transplant, custom paintwork, bodykit front and rear bumper update with A6 sport Grill .

  11. Users that liked this post:

    cheechy (13-10-2017)

  12. #29
    Join Date
    Jun 2017
    Location
    Kelty Fife
    Posts
    326
    Spring return does seem strong it just sticks if you put it to the extreme closed position and it will stay there until you start to move it back- it then springs back quickly. I followed the excellent guide and took the top off the main gear and cleaned off the oil I could see.

    Will take a look at the inside again as I suspect it could be hard to get at crud (oil).

    I'm tempted to use a fairly strong solution of degreaser but any gotchas on that - could I cause indirect issues?
    Last edited by cheechy; 13-10-2017 at 10:14 PM.

  13. #30
    i always use brake cleaner to remove the gunge in those throttle valves with a tooth brush ... never had or heard of anybody having issues
    Audi A2 TDI SE , Working sky , Bose , Dis , rear electric windows , Red leather .... Daily Driver

    Audi A2 1.4 16valve

    AUDI A2 SE 1.4TDI dirty diesel dog, Rebuild in progress , next stage custom stainless manifold and VNT Turbo

    Project A2 Quattro Twin bike Engined Transplant, custom paintwork, bodykit front and rear bumper update with A6 sport Grill .

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