DIY deflapping! What's involved?

[RichieRS]

So I am under way with my CC and to my surprise, had the intake off inside 3 1/2hrs!!!.

This is what I found which was to be expected!!


So the plan was to simply clean the ports and intake and reassemble. But seeing as how there is no rush now to get her back together (off the road and garaged) I was thinking of embarking on a bit of P+P and possibly deflapping as well.

Now I have read a few brief threads/posts regarding deflapping and how the everything should be left connected (actuators, arms) so no errors are thrown. What I want know is. What is actually required? How do you remove the flaps inside the intake manifold?

Also. If I decide against doing the whole deflapping. Is there any merit in simply removing the tumbler flaps inside the head?.

Cheers in advance for any help

[Lukes3]

You can remove the tumble flaps in the head no problem, some people say it will run a little lumpy from cold but i have never noticed this on mine. An to remove the flaps in the manifold you have to knock out the little core plugs an behind them are screws holding the flaps to the shaft.

[RichieRS]

You can remove the tumble flaps in the head no problem, some people say it will run a little lumpy from cold but i have never noticed this on mine. An to remove the flaps in the manifold you have to knock out the little core plugs an behind them are screws holding the flaps to the shaft.

Cheers Luke

Do you leave the threads from the screws out after removal?

Im guessing you just knock the core plugs through and replace?

Cheers

[Grandadg90]

If you fit a spacer kit, so the manifold sits slightly higher, you should have no issues from cold when removing the shims from the head.

Follow Rick_RS4's thread.

[RichieRS]

If you fit a spacer kit, so the manifold sits slightly higher, you should have no issues from cold when removing the shims from the head.

Follow Rick_RS4's thread.

Cheers buddy.

I was waiting in the spacer kits Rick was working in but might have to go the JHM route as I don't think he has had a chance to perfect them yet.

Will have a trawl back through his thread as I know from a previous read it's full of useful advice on intake work.

[Lukes3]

You can remove the tumble flaps in the head no problem, some people say it will run a little lumpy from cold but i have never noticed this on mine. An to remove the flaps in the manifold you have to knock out the little core plugs an behind them are screws holding the flaps to the shaft.

Cheers Luke

Do you leave the threads from the screws out after removal?

Im guessing you just knock the core plugs through and replace?

Cheers

I left the screws out of mine as no point putting them back in, With the core plugs im sure you cant get them from audi so maybe have to be sourced from else where, in my case i tapped the holes out when the inlet was removed an fitted tapered bungs as the core plugs can work loose an be sucked in.
Might be worth changing the 1way valve under the manifold while your there.
Hope this helps.

[RichieRS]

You can remove the tumble flaps in the head no problem, some people say it will run a little lumpy from cold but i have never noticed this on mine. An to remove the flaps in the manifold you have to knock out the little core plugs an behind them are screws holding the flaps to the shaft.

Cheers Luke

Do you leave the threads from the screws out after removal?

Im guessing you just knock the core plugs through and replace?

Cheers

I left the screws out of mine as no point putting them back in, With the core plugs im sure you cant get them from audi so maybe have to be sourced from else where, in my case i tapped the holes out when the inlet was removed an fitted tapered bungs as the core plugs can work loose an be sucked in.


Might be worth changing the 1way valve under the manifold while your there.
Hope this helps.

Cheers buddy.

Already provisioned for the one way valve and going to relocate aswel.

Gonna have a go at removing the screws from inside the manifold as I have read that a few people have done it. Will see what happens. Worse case is I have to knock the core plugs out and get some new ones

[Xiulaba]

Hey Richie, any updates on removing the screws from the inside? Easy job?

[RichieRS]

Hey Richie, any updates on removing the screws from the inside? Easy job?

Hello mate. Yeah successfully got them out. Very fiddly and took a while but they all came out with no problem. Used the small ratchet required for getting the screws out earlier in the manifold removal process and cut a T20 bit down o give clearance to undo them. I did give them a good bath in penetrating spray for a night before hand, whether that helped who knows!!!.

Carbon clean now complete and manifold deflapped. Now let the porting commence

[Xiulaba]

Cheers mate!