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air intake manifold, actuator and flap

Reddevil74 Jun 27, 2013

  1. Reddevil74

    Reddevil74 New Member

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    Hi for the past few months I have been experiencing intermittent limp mode with flashing glow plug and also lack of power without any alarms.
    Turning ignition off and on clears problem until next random time
    Car spent a few days in Audi and they were unable to replicate fault or diagnose without an alarm.
    I managed to get it in again with alarm showing and after a few days I was given a quote of £1200 to have "air intake manifold actuator and flap " replaced
    Also advised to have egr cooler replaced at a cost of £600

    my question is what is this part ( air intake manifold ) and is the price excessive ( I have since taken the car back without any work done)

    car is a 2007 2.0 TDI 170 s-line

    thanks
     
  2. hades-

    hades- Well-Known Member VCDS Map User

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    welcome
     
  3. Reddevil74

    Reddevil74 New Member

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    Thanks bez
     
  4. the old one

    the old one New Member

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    had this happen for a while now on my 1-9 a4 and it went after thrashing it for a good few miles but has started doing it again,i think its all the slow running causing soot !!!!
     
  5. mm707

    mm707 Member

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    Did you get a fault code ?

    If it is the vacuum actuator on the inlet manifold they are fairly easy to replace and only cost about twenty quid with gasgets.
     
  6. Reddevil74

    Reddevil74 New Member

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    To follow on from this story - a few days after getting the car back from Audi ( untouched ) the dpf light also came on and no matter how hard I tried I could not clear it. Took the car to an independent garage and had the dpf and egr deleted. The car feels better than ever so touch wood no more boost issues
     
  7. Big Duke

    Big Duke Member

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    Hi mate,
    Just read your post and have a similar problem I think. I do 500 miles a week in mine and have put up with the limp mode issues for about 40k now! it usually results in limp mode in heavy traffic in the fast lane of the M40 with a Vauxhall Vivaro coming up fast. I just flick the ignition off and on real quick and full boost is restored. Audi have said it needs a new intake manifold because of the split diaphram (£800). I also get the DPF light on quickly when doing town driving but it does still go off again once I do my commute. The car smells of fumes more than it did. What Id like more info on is how did you get the DPF and EGR deleted. im assuming its the EGR that has the diaphram. I cant seem to find a good specialist near me Worcester. Thanks for any advise.
     
  8. mm707

    mm707 Member

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    That is rubbish, typical main dealer con. You can buy the actuator which
    Has the diaphragm inside for about £10. The inlet manifold will just need a
    Good clean when it's off.
     
  9. Big Duke

    Big Duke Member

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    Ive heard that mm707. I cant seem to find anyone that would do the repair. Mines an A3 2.0TDi 170 2007
     
  10. mm707

    mm707 Member

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    The parts are available from tps, if you like ill dig out the part numbers
     
  11. Big Duke

    Big Duke Member

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    Great!. Dont supose you would have a procedure I can follow? Cheers mate.
     
  12. mm707

    mm707 Member

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    You need to find the thread on here that shows step by step how to remove the egr valve. The next step is to remove the inlet manifold, pretty straight forward to do that, it's just a case of removing the bolts, they come out easy. Once this is off you will be able to see how the vacuum unit is fitted, really easy to change that.
    You will need some carb cleaner spray to clean everything out before you put it all back together, the inlet manifold will be pretty much full of crud.
    Putting it all back is just the reverse procedure.
     
  13. theo289

    theo289 Member

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    exactly the same happened to me the other day, took the car to audi and the whole inlet manifold needs replacing...supposedly something happened to the flaps thus causing restriction to the turbo and a lack of power.

    hope you get it resolved :)
     
  14. mm707

    mm707 Member

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    The flaps in my manifold were totally caked in crud, cleaned them up and they were fine.
    I think they can become knackered on a 3 litre but even then you can buy a repair kit.
     
  15. theo289

    theo289 Member

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    Interesting to know :) guessing it was a lot cheaper than a new flap
     
  16. mm707

    mm707 Member

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    Big Duke - part number for vacuum unit S03G129061C ( £10.82 last year )
     
    Frostie333 likes this.
  17. Reddevil74

    Reddevil74 New Member

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    The funny thing with my car was my local mechanic said Audi's diagnosis of the faulty flap was rubbish and he never touched it.
    My DPF was completely blocked so had it removed and had the EGR removed at the same time
    One year on I have had no problems with the car at all
     
  18. Big Duke

    Big Duke Member

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    Thanks for the part numberm m707. A local specialist should be able to sort this if im not feeling confident I guess? Just found my Audi diagnostic sheet. £ 788 for new manifold. This is how they word it.
    'Carried out Diags for EML on dash( actually glow light) established fault with intake manifold change over valve which supplies vacuum for the turbo- diaphram is split so losing boost. £788.90 and then test turbo to see if required' Why cant they offer the fix?
     
  19. mm707

    mm707 Member

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    I've heard of people going to audi to buy a vac unit to be told by them that the part doesn't exist and they have to buy a new manifold !

    A garage shouldn't charge you any more than a couple of hours labour, only took me about that long and I'm a very basic diy-er
     
  20. Big Duke

    Big Duke Member

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    Hi, been researching removal threads etc. Noticed my intake manifold is plastic where all the other ones I see seem to be metal. Anyone elses? Maybe thats why AUDI recommends replacement?
     
  21. Big Duke

    Big Duke Member

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    Trying to attach picture!
     

    Attached Files:

  22. mm707

    mm707 Member

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    is yours a 2.0 tdi ?, mine is and it is brd engine.

    attached a pic hopefully which shows the location of the vacuum unit

    IMG_3147.jpg
     
  23. Big Duke

    Big Duke Member

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    Yes mines a 2.0TDi. Dont know if its Brd. Its an Audi A3 2.0TDI 170. SPORT 2007. Just thought the plastic manifold odd.
     
  24. mm707

    mm707 Member

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    Not seen a plastic manifold, maybe someone on here can shed light on it ?
     
  25. theo289

    theo289 Member

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    My old 2008 a3 170 sport had a plastic one. Suffered with the renoun juddering issue. Also the inlet manifold leaked a lot of air
     
  26. theo289

    theo289 Member

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    So since having the inlet manifold swapped out, everything seems good on the car. no issues, no reoccurances of the issue, no glow plugs - all drives perfectly. I have however found a mod which APR performance do which deletes the inlet manifold off the vehicle.. may be worth a read if anyone else has this issue http://www.goapr.co.uk/products/rfd_20t_ea113.html
     
  27. Big Duke

    Big Duke Member

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    Hey,thanks Theo 289. Beginning to think people were thinking I was insane claiming my Manifold was plastic.
    As of last weekend my A3 is now in permanent limp mode with the Particulate filter light on and the flashing glow light.
    It has smelt more sooty since the issues started, but up until now the filter has been regenerating once Im on the motorway for several hours.
    Now i may have to scrap it, as its of no use.
     
  28. Big Duke

    Big Duke Member

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    Well. My reaction in the last post was the result of frustration. Someone I trust at a local specialist managed to clear the filter and the car is now driving great.
    He didn't recon the manifold issues are causing the grief. He thought a sensor or software update was needed. Back to the filter. I do a lot of motorway travel.. Do I just need generally to keep the revs higher?
    Quite often Im in 6th gear between speeds of 50 in heavy traffic and the max motorway flow speed. is it better to change down to 5th. Interestingly when I told my mechanic that the reason I bought this car
    was the extreme reliability of my previous Golf mk4 1.9 TDi which I traded for this Audi at170k still going strong. He said, the 2.0 TDI is much more problematic. He said the old 1.9 is more reliable. His advise, by a 2005 1.9 with no DPF,
    the Skoda octavia being the best deal and you can send it up and down the motorway for ever.Trouble is I do love this Audi when all is well.
     
  29. stevegrass777

    stevegrass777 Member

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    try using a better quality fuel or putting millers additive in every time. get your torsion value checked (timing) using vcds if you can get it set to 0.5 degrees it could cut down on the soot in the exhaust gasses along with the other things this could make a real difference. I didn't used to think fuel was a problem until I started using millers and you can see the soot content is lower and it has unstuck a sticking turbo for me.
     
  30. stevegrass777

    stevegrass777 Member

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    I always us millers with supermarket fuel as this seems the worst
     
  31. Big Duke

    Big Duke Member

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    Millers additive. Ok thanks, Id never heard of that.Where do I get it? halfords?:
     
  32. stevegrass777

    stevegrass777 Member

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    It's only about £10 a bottle but this does quite a number of fill ups, so the cost is low per tank/liter it works out cheaper than shell advanced. Yes you can get it from halfords or eBay.
     
  33. Big Duke

    Big Duke Member

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    Thanks Stevegrass777. im going to go to Halfords today. I've researched this after you suggested it and Pretty much every review is singing its praise.
     
  34. Big Duke

    Big Duke Member

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    Well. I bought a new actuator and gaskets and bit the bullet. I found it really tricky to get to some of the bolts. lots of swearing and dropping tools into the engine later I got it to bits. The AGR and the manifold were absolutely crudded so horrendously, the manifold flaps had no chance of operating. what a horrible, horrible job cleaning it all up. Got it all back together, fired up first time took it for a drive and 6th gear on the dual carridgeway and limp mode! Chuffed! The only difference is it more consistently goes into limp mode! If the Turbo is as affected by crud then that is my suspicion. Im going to run it for a bit with the millers and hope it helps. Balls! Bloody fed up!
     
  35. Big Duke

    Big Duke Member

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    Ok, just digging this one up again. CAR NOW FIXED!! Please read as this could be helpful. As above I thought i could save money by fitting a new actuator to the manifold but Audi was right, the manifold was toast. The new actuator was working and the car started better etc but would go in to limp a lot more, even under hard acceleration in 3rd gear. Turns out the control rod which I spent ages cleaning inside the manifold was so knackered that pressure was leaking through the seals and out near where the actuator is. After turning the car off there was an audible hiss. So after much thought I decided to bite the bullet and buy a new manifold,(mines plastic!) which has the actuator and gaskets already fitted. Cost me £540 from Audi, they quoted £600 but gave me a discount without much hassle. its a few quid cheaper at TPS but my local Audi was much nearer. So for the second time the manifold was removed, not a fun job but the car is now great with much more power and torque, so at 138,000 miles the car is like brand new again, Ive done several weeks, my comute consists of a 115 mile journey down the M40 from Worcester to Maidenhead, an overnight then back again so has been well tested. Im now enthusiastic about the car again, as soon as the weather picks up I will give it a machine polish and valet.:)
     

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  36. evildream

    evildream New Member

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    Just found out this post. I also have a 2.0 TDI pd 170hp with plastic inlet manifold - replaced the original one (metal) which was cracked and leaking.
    I have a strong engine jolt/hesitation occasionally when starting, most pronounced when cold can this be related with the plastic manifold?
    Thanks.
     
  37. Big Duke

    Big Duke Member

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    Try getting some diesel additive from Halfords. If its got a DPF get some cleaner, also some that does the injectors.
     
  38. SDHA4SLine

    SDHA4SLine Well-Known Member Team Silver Audi Avant Owner Group S-line owners group

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    Holy thread resurrection!

    If you're still around big duke how did you diagnose that the inlet manifold seals were toast? Could you feel air rushing out by the actuator rod?
     
  39. soldier4313

    soldier4313 A4 Avant B9 2.0 Tdi

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    Buddy have the exact same engine and had the exact same problem, after Audi telling me it was the EGR and spending £100's on replacing it, it happened again so took it back to Audi and turns out it was the Manifold Actuator and they wanted stupid money to change an £11 part so bought the part and the gasket and did it myself. Easy job to do there is a link on one of my threads from YouTube showing exactly how to do it. The thing was stinking and considering the EGR was brand new less than 3 weeks ago that was pretty clogged up as well. Plenty of elbow grease and Mr Muscle and it was immaculate. Some people don't like to use Mr Muscle but I have had no issues with it as long as you use it properly and wear gloves.
     
    Last edited: May 21, 2016
  40. soldier4313

    soldier4313 A4 Avant B9 2.0 Tdi

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    This is the link I used
     
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