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Swirl Flap repair kits

Discussion in 'Audi S4/A4/A4 Cab (B7 Chassis)' started by Mr-C, Jul 10, 2013.

  1. Mr-C
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    Mr-C Active Member

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    [Jul 10, 2013]
    If by chance you need one dont pay over the odds on ebay they are only £9.26 from the dealers

    audi swirl flap | eBay
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  3. Emmo
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    Emmo Member

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    [Jul 13, 2013]
    I picked up the repair kit for both sides for £18 from VW, and it does the job no more engine management light since I fitted it.
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  4. A4_MaJiK
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    A4_MaJiK Azeem

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    [Jul 15, 2013]
    Wow, I was dreading coming across this issue as I thought it may be a really expensive fix. How easy/hard of a job is it to do? Do the manifolds require removal or can this be done in situ? Are the arms for the actuator easily accessible at all?

    Thanks, Az.
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  5. Emmo
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    Emmo Member

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    [Jul 15, 2013]
    The passenger side can be done with the manifold in place. The drivers side is a different story there is a clip that is fitted on the bottom of the arm which is impossible to remove/clip back without taking the manifold off.
    The swirl flap motor has to come off, the plastic air intake on top of the engine has to come off, couple of the metal fuel lines need moving then intake manifold comes off and it literally takes seconds to replace the parts.
    It took me about 2 hours or so to do it, a mechanic would probably do it in half that time.

    The arms can be done with everything in place, but I tried just changing the arms only at first and the engine management light came back on. The most wear when I took it apart was on the actual plastic shaft that sits in the manifold and drives the flaps.
    Once I replaced all the parts the management light has not been back on, its been about 2 months since.
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  6. MattUK
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    MattUK Member

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    [Jul 15, 2013]
    Hi - so how much in total were the parts you needed - did they all come in the repair kit (i.e the plastic shaft which I presumed you also replaced) ?

    cheers

    Matt
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  7. Emmo
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    Emmo Member

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    [Jul 15, 2013]
    The repair kit comes with everything you need, a new arm, new plastic shaft and metal clip, it works out around £9, to do both sides you will need two kits.
    I did replace the plastic shaft.
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  8. A4_MaJiK
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    A4_MaJiK Azeem

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    [Jul 15, 2013]
    I assume they don't NEED changing in pairs but it is just good practise? I'm guessing one side will fail before the other right?
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  9. Emmo
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    Emmo Member

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    [Jul 17, 2013]
    I replaced both sides as a precautionary measure as they were so cheap. When the car was originally plugged into diagnostics the error was showing only for one bank.
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  10. .Jas.
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    .Jas. Member

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    [Jul 17, 2013]
    What side is Bank 2? Is that the easy to replace side, or the hard to replace side?!
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  11. Emmo
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    Emmo Member

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    [Jul 18, 2013]
    Bank 2 is the passenger side bank which is just in front of the turbo. That is the easier side to replace.
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  12. .Jas.
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    .Jas. Member

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    [Jul 18, 2013]
    Cheers Emmo.

    I just phoned my local Audi, none in stock and a 4-week wait. Another dealer about an hours drive away had 60 in stock but can't or won't post them. Looks like eBay for me then!
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  13. Emmo
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    Emmo Member

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    [Jul 18, 2013]
    Have you tried a local VW dealer? I got mine from a VW dealer, they didnt have any in stock but ordered for next morning.
    The ones on ebay are one repair kit for around £20, whereas if you get it from the dealer you will get both sides for less.
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  14. .Jas.
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    .Jas. Member

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    [Jul 18, 2013]
    Yeah I asked my local, but they say they are on back-order and won't get them till late Aug. :(
    I'm only replacing 1 side so don't mind paying a few quid extra from ebay to get it soon or save an hours drive.
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  15. A4_MaJiK
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    A4_MaJiK Azeem

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    [Jul 18, 2013]
    Try and a find a Trade Parts Specialist (TPS) local to you. We have one in Leicester where the VW showroom is. Used them for all my genuine parts for my VW and now for my Audi too.

    HTH, Azeem.
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  16. gupsterg
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    gupsterg Active Member

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    [Jul 19, 2013]
    Hi peeps :) ...

    Thought I'd add some visual media to thread ...

    Item 1 in kit is the swirl flap link arm, item 2 swirl flap follower, item 3 locking clip ...
    Repair kit P/N 059 198 212 , same P/N for 19 different VAG's with V6 ...

    [​IMG]

    Red arrow highlight item 2 location and item 3 clip...

    [​IMG]

    Here is a video showing effect of wear on swirl flap follower/link arm ...



    Wear can also happen on the bearings for swirl flaps as well ...



    There is a TPI / TSB relating to this repair kit ...

    [TABLE="width: 100%"]

    Technical product information

    Transaction No.: 2016504/19


    Engine warning light on, intake manifold flap function - V6 2.7 l, 3.0 l TDI

    Release date: 28-Feb-2012


    [/TABLE]
    Last edited by a moderator: Aug 15, 2014
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  17. A4_MaJiK
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    A4_MaJiK Azeem

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    [Aug 1, 2014]
    Engine light is on! Looks like I'll have to schedule this in sometime in the near future. :keule:
    #16
  18. Mr-C
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    Mr-C Active Member

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    [Aug 1, 2014]
    I replaced the whole manifold with a recon unit about 6 weeks ago after the light came on again and I could tell by the play in the bottom joint that it was time for a new unit. Got one off VagParts79 on ebay £185 then you get £35 back when you fire the duff unit back to him.
    #17

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