RS4 Flaps test

[ROY]

Hi
Just followed the flaps test and cycles with VCDS as per the instructions

Air box power flap no movement or clicking
Inlet manifold solenoid clicking Bank 1
Inlet manifold white actuator arms no movement Bank 1

Think I best take the air box out and change the solenoid under it just to eliminate it

But during the test what happened to the tests for Bank 2 is that on the other ECU section 11

[adsgreen]

there is only one solenoid and this is connected to two actuators for both flaps. No need to test anything else.

It would look like that the airbox flap has "gone bad" and a reasonable place to start looking for vacuum leak.
You can take the top of the airbox off, remove the airfliter and stick you hand in to see if you can unjam it. But no clicking is a bad sign.

If you take off the front carbon engine trim you'll find a number of black rubber hoses in a double t junction setup - these are the primary vacuum lines for the various bits.
The line for the airbox flap is the left hand one (as you look at the engine) and is the only one that goes off in the direction of the airbox. IIRC there is a join along this line (about 1.5 feet along) and you can disconnect this and plug the engine side of it without removing anything. That will allow you to rereun the vacuum tests to see if there is a leak elsewhere.

[ROY]

Cheers Ads, never thought of blocking it off, yep ive seen the joint nice one
Will try that tonight, i stuck my hand in and the flap moves ok
Ive ordered the airbox vacuum switch anyway just in case

I fitted new vacuum switch under the manifold and the one way valve when i did the de-coke and it was clicking ok on the test, but the actuating arms had no movement which explains my P2015 - 008 and P2020 - 008 codes.
Clear the codes and they both return again and then the EML light pops up

Is there any easy way to remove the airbox without removing the headlight n bumper ???

[ROY]

Just disconnected feed line from the manifold (line to the manifold is now plugged) to the air filter box cleared the faults and hey presto no fault codes so far.
The car feels mush smother than before nowhere near are jerky on the throttle at slow speeds and no loss of power so the problem lies in the line down to the air filter box or the vaccum valve next to it.

Cheers Adsgreen

Now to take the air box out

http://www.volkswizard.co.uk/airbox.htm

[adsgreen]

thats cool - at least it's a realtively simple if pita diy job.

[ROY]

All sorted the airflap vacuum solenoid was the culprit, it had split at the bottom
Its a bit of a pig of a job the main problem is getting the airbox in and out, its like getting a sqaure peg in a round hole almost impossible.
The most important tool you will need is a long T30 torx screw driver (and i mean long) to get at the hidden headlamp screw down through the wing, i tried a long 1/4 extension and socket but its to thick and lost my socket so had to remove the undertray.
Checked flaps ops with vcds and all clicking nicely and tested the car in anger, ive de-coked deflapped remapped and now fixed my air flap and vacuum system EPC and EML light so its all working and for the first time since ive owned it ive felt the full kick and boy it feels different

[ROY]

EPC Light has tripped again

ECU 2
Bank 2 Flap Sensor Implausible Signal
Cleared and appeared again a day later
Will run a scan again in the morning but i'm betting its the same error

Been running now for approx 2000 miles since i fixed the vacuum solenoid under the air box so i can only assume now that the sensor on bank 2 is fubar.
Previously Both Bank Flap sensors were tripped
Now Its tripping Bank 2 at low revs/speeds when using the V8's torque in high gears i.e. 4th 5th 6th
Will price one up tomorrow

Any of you guys changed one yet ????

[adsgreen]

log the actual and requested values using Vag Com.

the sensor might be good and the flap runner is stuck or bunged up with carbon.

redo the flap test and see if both the runners move about the same.

One of the sensors is at the back and is a manifold off job to switch.

Also

[ROY]

Hi ads
I'll run the flaps test again
All my flaps are removed when i did a de-coke 4000 miles ago so its possibly the mechanical movement of the arms on Bank 2 that may need lubricating
Its just strange how its been fine for at least 2000 miles


Fault Code
Address 11: Engine II Labels: 079-910-560-BNS2.lbl
Part No SW: 8E1 910 560 HW: 8E1 907 560
Component: 4.2L V8/4V FSI ª0080
Revision: --H15--- Serial number: XXXXXXXXXXXXXX
Coding: 010C0003180F0160
Shop #: WSC 00191 264 15243
VCID: E3CF1773229EAA00DC7

1 Fault Found:
008224 - Intake Manifold Flap Position Sensor (Bank 2)
P2020 - 008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 0
Fault Frequency: 2
Mileage: 111133 km
Time Indication: 0

Freeze Frame:
RPM: 2680 /min
Load: 30.2 %
Speed: 102.0 km/h
Temperature: 90.0°C
Temperature: 17.0°C
Absolute Pres.: 1020.0 mbar
Voltage: 13.716 V

[ROY]

Just been out running the flaps test - all ok
Checked the linkages on inlet manifold for wear or damage and all seem to be fine and working ok.
BUT whilst I was checking the R/H linkage as you look at the engine the plastic bar is rubbing on a vac line that comes from the t-piece at the front of the engine to the vac res, I can't get any more slack from the pipe it's pretty short as it is and stretching across the linkage.
Now is Bank 2 the R/H as you look at the engine ? So I can make sure I'm dealing with the Bank that's showing the error.

I've put some lube on the vac pipe where it's rubbing for the moment until I get a bit more time to maybe extend the pipe.

[Iain_S4]

http://www.volkswizard.co.uk/airbox.htm

This link for the airbox removal doesn't work anymore. Does anybody have one that does or can post the information again please.