Manifold issue but not stuck flaps?

kel

Member
Engine light on dash.. previously mechanic checked all basics he could for function and vcds indicated sticky flaps.. (don’t have screenshot) car currently has manifold out while sorting death pipe etc.
Manifold wasn’t overly dirty and mechanic convinced flaps were free moving before cleaning (I only saw it after clean and flaps work smooth) any ideas?
Rather replace items while half stripped or is the ecu really that sensitive?
 

Andrew

A2OC Donor
Hi,

I intended to give an extensive reply to your previous thread requesting 'How To's' on inlet manifold removal and other requests , sorry just no time at the moment, but you are past that stage now with the manifold out.

Normally flap problems are due to carbon buildup but you are not the first person to report this is apparently not their case. Over the years I can remember four reports and it boiled down to the flaps fouling on the block ports. If you look at the manifold now it is out you will see the flaps protrude a little from the lower inlet about 5 millimetres at rest, increasing to a little more as they traverse their full range of movement therefore part of flap motion the end of the flaps must be (theorising) within the block inlet port. For some reason they foul, carbon buildup? 'wobble' due to wear? (I'm guessing).

I remember one member resolved the issue by 'bending the flaps a bit more' (memory vague). Another case related first hand on my doorstep by an obviously experienced member who had a spare engine wiring loom and wired up a dry run of the flaps in situ and managed to pinpoint this mechanical fouling with the block port - he resolved it by removing 1 mm of flap with a Dremmel! The block port is divided into two by a horizontal bar (to create air turbulence apparently) and another member in the last few weeks reported on here just one flap was catching on this bar - outcome not reported. If the flaps bench test fine this is something to think about.

In answer to your question I do not think the ECU is that sensitive to flap movement, in fact I have the impression it only tests the integrity of the flaps for full range of motion at startup, three such failures within some defined time period and you get an EML

I would refit just the lower inlet manifold somehow and use the rubber tube technique test/observe the flap motion - (pull off rubber tuber on the vacuum actuator and replace with rubber tube and suck, flaps should move normally, vacuum actuator arm should move about 15 mm - tippex!). Worth reading for diagnostics info on flap movement...


Andy
 
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kel

Member
Hi,

I intended to give an extensive reply to your previous thread requesting 'How To's' on inlet manifold removal and other requests , sorry just no time at the moment, but you are past that stage now with the manifold out.

Normally flap problems are due to carbon buildup but you are not the first person to report this is apparently not their case. Over the years I can remember four reports and it boiled down to the flaps fouling on the block ports. If you look at the manifold now it is out you will see the flaps protrude a little from the lower inlet about 5 millimetres at rest, increasing to a little more as they traverse their full range of movement therefore part of flap motion the end of the flaps must be (theorising) within the block inlet port. For some reason they foul, carbon buildup? 'wobble' due to wear? (I'm guessing).

I remember one member resolved the issue by 'bending the flaps a bit more' (memory vague). Another case related first hand on my doorstep by an obviously experienced member who had a spare engine wiring loom and wired up a dry run of the flaps in situ and managed to pinpoint this mechanical fouling with the block port - he resolved it by removing 1 mm of flap with a Dremmel! The block port is divided into two by a horizontal bar (to create air turbulence apparently and another member in the last few weeks reported on here just one flap was catching on this bar - outcome not reported. If the flaps bench test fine this is something to think about.

In answer to your question I do not think the ECU is that sensitive to flap movement, in fact I have the impression it only tests the integrity of the flaps for full range of motion at startup, three such failures within some defined time period and you get an EML

I would refit just the lower inlet manifold somehow and use the rubber tube technique test/observe the flap motion - (pull off rubber tuber on the vacuum actuator and replace with rubber tube and suck, flaps should move normally, vacuum arm should move about 15 mm - tippex!). Worth reading for diagnostics info on flap movement...


Andy

thanks Andy, that’s worth investigating! 😀
 

Andrew

A2OC Donor
I had another thought.

Reading some of your posts I gather you bought the car in the summer from a neighbor's neighbor and it came with dash warnings then. I assume this includes the EML and I wonder if the seller (had) cleaned the flaps in the recent past, hence you discovering relatively clean manifold, but then reassembled wrongly and/or not then performing the flap adaptation with VCDS. The outcome being the EML was not cleared so they gave up and decided to sell. Might be worth an enquiry with the seller and ask if any recent manifold work was undertaken.

Andy
 

kel

Member
I had another thought.

Reading some of your posts I gather you bought the car in the summer from a neighbor's neighbor and it came with dash warnings then. I assume this includes the EML and I wonder if the seller (had) cleaned the flaps in the recent past, hence you discovering relatively clean manifold, but then reassembled wrongly and/or not then performing the flap adaptation with VCDS. The outcome being the EML was not cleared so they gave up and decided to sell. Might be worth an enquiry with the seller and ask if any recent manifold work was undertaken.

Andy
Neighbour did bare basics to get through ‘dodgy’ mot’s over the years.. no chance manifold was pulled out 😂😂.
He had it 9 years and literally to corner shop and back .. it had water pump and belt done ( auxiliary belt was almost split in two which I got sorted ASAP) and coils in last year but maintenance was done purely for mot ( 58k on clock)
 

kel

Member
It’s fixed! 🤪😂 looks like manifold cleaned and refit has done the job!

Fingers crossed that eml light stays off (apart from start up!) coolant stuff all replaced too.. looked like it was the seal and thermostat housing that was knackered.

unfortunately due to postal issues and stuck without car for a week I had to go Audi so parts ended up double cost 😤 but it lives! 😀😀😀
 

Clackers

Member
I had another thought.

Reading some of your posts I gather you bought the car in the summer from a neighbor's neighbor and it came with dash warnings then. I assume this includes the EML and I wonder if the seller (had) cleaned the flaps in the recent past, hence you discovering relatively clean manifold, but then reassembled wrongly and/or not then performing the flap adaptation with VCDS. The outcome being the EML was not cleared so they gave up and decided to sell. Might be worth an enquiry with the seller and ask if any recent manifold work was undertaken.

Andy
Hi Andy, just jumping on to this thread as I now own Lucy the fsi....
EML is back on sadly, and having cleared the codes, the eml and P1031 pops back up after about 5mins of driving. When you say flap adaptation using VCDS, could you expand on this one please? Feel free to inbox the info if it gets technical....Car drives like a dream, but the EML will cause problems come MOT...she really does deserve a chance and not give in on this fault....
 

PlasticMac

Member
You'll need a incensed version of VCDS. Basically, the process syncs the potentiometer and the flap mechanism, so the ECU knows where the flaps are.
If any work has been done in or around the manifold/actuator etc, the adaptation/calibration must be done.
When reassembling the manifold, it is vital to lock the actuator in the activated position, before reassembling. If you don't, the flaps/linkage can be damaged.
Mac.
 

Attachments

  • fsi man actu.pdf
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PlasticMac

Member
Here's a how to :
Turn the key on but do not start the car.
[Select]
[01 - Engine]
[Measuring Blocks - 08]
Enter Group 060
[Go!]
[Switch to basic settings]
Once you do this you will see the top right display say ADP RUN. The TB adaptation is being done as soon as you
switch to basic settings. You will see the values change and hear the TB cycle for the first few seconds then it will
stop. Leave it in Basic Settings for about 30 seconds.
[Switch to Meas. Blocks] button and you're all set.
Be sure not to touch the accelerator and make sure the engine is NOT running when you do this!

NOTE: There must be residual vacuum for the actuator to work, as the engine is not running. Check that there are no vacuum leaks, with a vacuum gauge, just to be sure.
Mac.
 

Clackers

Member
You'll need a incensed version of VCDS. Basically, the process syncs the potentiometer and the flap mechanism, so the ECU knows where the flaps are.
If any work has been done in or around the manifold/actuator etc, the adaptation/calibration must be done.
When reassembling the manifold, it is vital to lock the actuator in the activated position, before reassembling. If you don't, the flaps/linkage can be damaged.
Mac.
Damn, I only have vcds lite, have messaged a chap i know locally that has it, hopefully he will be forthcoming with his services...my local indi doesn't have vcds, and the only other indi I know that has would charge just to speak to you!!!!!
 

PlasticMac

Member
Damn, I only have vcds lite, have messaged a chap i know locally that has it, hopefully he will be forthcoming with his services...my local indi doesn't have vcds, and the only other indi I know that has would charge just to speak to you!!!!!
Have you checked out the Free Scan Register on here?
Mac.
 

Andrew

A2OC Donor

Hi Andy, just jumping on to this thread as I now own Lucy the fsi....
EML is back on sadly, and having cleared the codes, the eml and P1031 pops back up after about 5mins of driving. When you say flap adaptation using VCDS, could you expand on this one please? Feel free to inbox the info if it gets technical....Car drives like a dream, but the EML will cause problems come MOT...she really does deserve a chance and not give in on this fault....
I think we had better start at the beginning. I understand from your post the you have aquired a FSI (Lucy) and she has the fault P1031 which keeps coming back when cleared. Surely this suggests a fault and needs investigating before any need of flap adaptation, unless you have?

Sorry to be a bit vague but just trying to establish the state of play.

Andy
 

kel

Member
I'm Op.. eml was on when bought last summer, car runs fine.. had it scanned (didn't get pic of vcds.. full version not mechanic lite) and mechanic checked all obvious possibilities that don't require engine out..(general audi/car issues not a2 specific and everything fine so he didn't have a clue. (Summer when auxiliarybelt replaced)..had back of engine leak in nov/dec death pipe to thermostat leak and replaced and with the posts showing issue on here about sticking flaps he showed me flaps are free moving while installing new parts.. eml came back on 2 days after fixing and cleared codes on vcds lite.

Driving fine until the snapped coolant y pipe which was a cheap fix in itself if you could wait on post (daily driving car for me so unaffordable).

clakers promptly replaced pipe on the drive and drove 150miles or so fine to get home.. mystery eml light.. could need a reset from previous fixes such as mentioned actuator etc?

I'll love to know if it gets solved!
 

PlasticMac

Member


I think we had better start at the beginning. I understand from your post the you have aquired a FSI (Lucy) and she has the fault P1031 which keeps coming back when cleared. Surely this suggests a fault and needs investigating before any need of flap adaptation, unless you have?

Sorry to be a bit vague but just trying to establish the state of play.

Andy
I think an adaptation would establish the "state of play" as P1031 relates to potentiometer position, so syncing that to flap position would provide a reference.
Mac
 

Clackers

Member
New update....damn eml is back on, will get it scanned again to see what it comes up with this time, I am going to stab in the dark and say P1031 again!!!
 
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