Customer Statement / Workshop Findings

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Technical product information / Transaction No.: 2016504/10
Engine warning light on, intake manifold flap function - V6 2.7 l, 3.0 l TDI / Release date: 17-Aug-2009

Customer statement / workshop findings

Engine warning light on - V6 2.7L, 3.0l TDI

Technical background

Entries:

1.12597 intake manifold flap for air flow control, lower stop not reached

4120 intake manifold flap 2 for air flow control

Observe video.

2. 8200 intake manifold flap for air flow control

8209 intake manifold flap 2 for air flow control, electric complaint

logged in the engine control unit.

Several causes for the entries under 2. Electric and mechanical component complaints on the intake manifold regulator motor (E regulator).

Production change

1. -

2. Optimised electric regulator motor for intake manifold flap.

A4: 8E*7A200422

A6: 4F*7N123635

Q7: 4L*7N083156

A8: 4E*4N015849

Cabriolet: 8H*7K029553

Measure

1. A shaft of the intake manifold flap or a ball head may be worn out. Check ball heads between flap shaft and electric regular for connecting rods thoroughly for free play (if in doubt, remove the intake manifold and check the shaft bearing).

If necessary, replace the complete intake manifold flap. Replacing the regulator doesn’t fix the problem (see attachments).

2. Check the E-regulator according to the repair manual ( Note: At the moment the repair is only included in the A6 repair manual, the other models are still in preparation). Replace the regulator, if all points are completed in the guided fault finding and the regulator was diagnosed as incorrect.

If no complaint is found in the guided fault finding, check the environmental conditions of the above entry.

Example of environmental condition:

1. engine speed

2. torque

3. speed

4. battery voltage

5. feedback for bank 1 (E-regulator)

6. feedback for bank 2 (E- regulator)

7. specified value (E-regulator)

• / If "8 %" is logged in the specified environmental conditions in the 5th or 6th digit, this indicates an electric component complaint in the E- regulator (cylinder bank 1 or 2) . > Replace the E-regulator.
• / If "12%" is logged, this points to a feedback error from regulator to engine control unit, which is recognised by the diagnosis when driving. This points to a stiff adjustment. (Cause: for example intake manifold flap shaft seized. Replace the complete intake manifold.
• / If "88%" is logged, this points to an adjustment range complaint. The adjustment range of the E-regulator is checked when switching on the ignition. The diagnosis recognises deviations when moving to the inner stops. (Cause: could be stiffness of the adjustment in the regulator or the intake manifold flap shaft.) - Detach the rods of the regulator and check the intake manifold flap adjustment. If the adjustment is stiff, replace the complete intake manifold. If the adjustment is correct, check wiring, plug, loose pins; if no damage is found, replace the regulator.

The necessary tools are shown in the repair manual.

Important: Before starting work, install the correct software on the tester.

Warranty accounting instructions

Accounting with APOS:

A4/B7

Repair operation: / Designation: / Time units:
23 78 19 43 / Remove and install left air flap regulator / 70 TU
23 78 19 44 / Remove and install right air flap regulator / 90 TU
23 78 20 43 / Remove and install both air flap regulators / 130 TU
23 80 19 43 / Remove and install upper intake manifold / 70 TU
23 80 19 93 / Remove and install lower right intake manifold / 50 TU
23 80 19 94 / Remove and install lower left intake manifold / 160 TU
23 80 20 93 / Remove and install both lower intake manifold / 220 TU
01500000 / GFF/guided functions / TU according to diagnosis protocol
The labour times are correct at the time of publication. The information in the repair operations catalogue applies.

A4 Cabriolet

A6/C6

Repair operation: / Designation: / Time units:
23 78 19 43 / Remove and install left air flap regulator / 70 TU
23 78 19 44 / Remove and install right air flap regulator / 90 TU
23 78 20 43 / Remove and install both air flap regulators / 130 TU
23 80 19 43 / Remove and install upper intake manifold / 70 TU
23 80 19 94 / Remove and install lower right intake manifold / 40 TU
23 80 19 44 / Remove and install lower left intake manifold / 250 TU
23 80 20 43 / Remove and install both lower intake manifold / 290 TU
01500000 / GFF/guided functions / TU according to diagnosis protocol
The labour times are correct at the time of publication. The information in the repair operations catalogue applies.

Repair operation: / Designation: / Time units:
23 78 19 43 / Remove and install left air flap regulator / 70 TU
23 78 19 44 / Remove and install right air flap regulator / 70 TU
23 78 20 43 / Remove and install both air flap regulators / 110 TU
23 80 19 43 / Remove and install upper intake manifold: BUG, BUN / 70 TU
23 80 19 44 / Remove and install upper intake manifold: Euro 5 / 90 TU
23 80 19 93 / Remove and install lower left intake manifold: BUG, BUN / 160 TU
23 80 19 94 / Remove and install lower right intake manifold: BUG, BUN / 50 TU
23 80 19 95 / Remove and install lower left intake manifold: Euro 4 plus, Euro 5 / 50 TU
23 80 19 96 / Remove and install lower right intake manifold: Euro 4 plus, Euro 5 / 90 TU
01500000 / GFF/guided functions / TU according to diagnosis protocol
The labour times are correct at the time of publication. The information in the repair operations catalogue applies.

A8/D3

Repair operation: / Designation: / Time units:
23 78 19 43 / Remove and install left air flap regulator / 70 TU
23 78 19 44 / Remove and install right air flap regulator / 70 TU
23 78 20 43 / Remove and install both air flap regulators / 110 TU
23 80 19 43 / Remove and install upper intake manifold / 90 TU
23 80 19 44 / Remove and install lower left intake manifold / 250 TU
23 80 19 93 / Remove and install lower right intake manifold / 30 TU
23 80 20 43 / Remove and install both lower intake manifold / 290 TU
01500000 / GFF/guided functions / TU according to diagnosis protocol
The labour times are correct at the time of publication. The information in the repair operations catalogue applies.

Accounting with APOS/2:

A8, A6, Q7

Illustration: / Position: / Number: / Designation: / Activity: / Time units:
129-40 / 1 / 129086 / Replace left intake manifold flap motor / 55 / According to instructions
129-40 / 2 / 129086 / Replace right intake manifold flap motor / 55 / According to instructions
129-40 / 1 / 129711 / Replace left intake manifold / 55 / According to instructions
129-40 / 2 / 129712 / Replace right intake manifold / 55 / According to instructions
STA-02 / 2 / S00032 / Guided fault finding / 02 / TU according to diagnosis protocol
The labour times are correct at the time of publication. The information in the repair operations catalogue applies.

A4/B7 with Cabriolet

Illustration: / Position: / Number: / Designation: / Activity: / Time units:
129-60 / 1 / 129086 / Replace left intake manifold flap motor / 55 / According to instructions
129-60 / 2 / 129086 / Replace right intake manifold flap motor / 55 / According to instructions
129-60 / 1 / 129711 / Replace left intake manifold / 55 / According to instructions
129-60 / 2 / 129712 / Replace right intake manifold / 55 / According to instructions
STA-02 / 2 / S00032 / Guided fault finding / 02 / TU according to diagnosis protocol
The labour times are correct at the time of publication. The information in the repair operations catalogue applies.

1. Service number/damage code/manufacturer: 2380 / 0010

2. Service number/damage code/manufacturer: 2378 / 0040

Parts information

Air flap regulator - Part No.: 059 129 086 M

Customer information

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