My A4 blew its trachea - got a new intake manifold.

[Anthony]

I was getting the old bucking bronco and flashing engine light, something many of us longtime Audi owners are familiar with. It's usually a blown coilpack (B6/B7) or a bad fuel sensor (B5), but this time it was something different.

Seems the intake mani flapper is made of plastic, and the one in my car had busted and was stuck open. May be a weak link in the system if anyone is looking to add more power aftermarket.

I looked for other threads on this, and saw a few mentions of similar issues but nothing major. Of course not too many people out there are running bigger turbos and 300+ horses just yet.

Anyway the dealer has a new one coming from Back East. Should have it in and installed in the next few days. I'll report back with more info if/when I have it.

In the meantime she's had her 15K check-up and fluids.

[beemercer]

That's interesting they used the variable length intake manifold design on a turbo car. Or are they tumble flaps for the FSI?

[Blake P]

Sucks to see another one blow. Definitely seems to be a weak link in the new design.

[coolwater]

No tune for me and my flap blew around 15k miles also.

-cW

[Anthony]

That's interesting they used the variable length intake manifold design on a turbo car. Or are they tumble flaps for the FSI?

Not sure. I'm hoping to get my hands on the bad one, but I'm sure they're going to want to send it back to HQ. Hope to at least get a pic.

[Anthony]

No tune for me and my flap blew around 15k miles also.

-cW

This is good, and yet bad to hear. Supposedly the only other one my dealer saw was on a "chipped" car.

[Blake P]

This is good, and yet bad to hear. Supposedly the only other one my dealer saw was on a "chipped" car.

Yeah, mine crapped out long before I had my car APR'd.

[mattlqx]

Yikes, I'm turning the corner on 10k miles.

Did they give you hassles about warranty since the car is, uh, not exactly stock?

[gamer2k]

I was getting the old bucking bronco and flashing engine light, something many of us longtime Audi owners are familiar with. It's usually a blown coilpack (B6/B7) or a bad fuel sensor (B5), but this time it was something different.

Seems the intake mani flapper is made of plastic, and the one in my car had busted and was stuck open. May be a weak link in the system if anyone is looking to add more power aftermarket.

I looked for other threads on this, and saw a few mentions of similar issues but nothing major. Of course not too many people out there are running bigger turbos and 300+ horses just yet.

Anyway the dealer has a new one coming from Back East. Should have it in and installed in the next few days. I'll report back with more info if/when I have it.

In the meantime she's had her 15K check-up and fluids.

That sucks to hear :( On another note though, did you ever do that 2nd dyno after upgrading to K04?

[Anthony]

Yeah, mine crapped out long before I had my car APR'd.

Shit, I guess I didn't search far enough back. Blake, was yours bucking and flashing the CEL as well?

Yikes, I'm turning the corner on 10k miles.

Did they give you hassles about warranty since the car is, uh, not exactly stock?

For most people, they would have. Mine's stock though.

[coolwater]

I was driving the car pretty hard though.
Going 0-50 between lights.
Mashing it at every opportunity.
Did you notice any seepage from your cam cover seal?


-cW

[Anthony]

That sucks to hear :( On another note though, did you ever do that 2nd dyno after upgrading to K04?

I'll be touching on that in the next week or so.

[Anthony]

Did you notice any seepage from your cam cover seal?

-cW

I'll be asking about this, as well as inspecting it myself, when I pick the car up.

[Blake P]

Shit, I guess I didn't search far enough back. Blake, was yours bucking and flashing the CEL as well?

Yes, the idle was ridiculously rough and CEL was lit up light a Christmas tree! Oh yeah, if you haven't noticed the search function still needs some attention for use with multiple words.

[B8_Jim]

That's interesting they used the variable length intake manifold design on a turbo car. Or are they tumble flaps for the FSI?

Tumble flaps.

Saw it in the EA888 self study guide - I think there is a link to it in Blake's mega-thread... or the one he mentions his manifold problem (can't remember if they are the same).

[Anthony]

Yes, the idle was ridiculously rough and CEL was lit up light a Christmas tree! Oh yeah, if you haven't noticed the search function still needs some attention for use with multiple words.

We're actually working on that now. If you haven't see my comments about it before, the database search in its standard vB form is horrible for large sites. Having just a handful of multi-word searches going on at once will bring even a huge server to its knees, which is why we've had to limit it so. Even now, when the site hangs up, it's because of multiple searches being performed. Luckily I've got one of the best sys admin database geniuses in the world working on it (no joke), the only downside has been the lack of time such an in-demand guy has for me. Thankfully I can also call him a friend.

[Blake P]

Tumble flaps.

Saw it in the EA888 self study guide - I think there is a link to it in Blake's mega-thread... or the one he mentions his manifold problem (can't remember if they are the same).

Yup, here goes: http://www.audizine.com/forum/showth...=1#post5236300

[Blake P]

We're actually working on that now. If you haven't see my comments about it before, the database search in its standard vB form is horrible for large sites. Having just a handful of multi-word searches going on at once will bring even a huge server to its knees, which is why we've had to limit it so. Even now, when the site hangs up, it's because of multiple searches being performed. Luckily I've got one of the best sys admin database geniuses in the world working on it (no joke), the only downside has been the lack of time such an in-demand guy has for me. Thankfully I can also call him a friend.

Awesome, thanks for the upate Anthony! I just had to give you crap about it since you brought up your lack of search results...

[John4378]

My intake manifold suffered the same fate, and my car was (is) chipped. I simply put the car in stock mode before taking it in for servicing and I never got questioned. It took over a week to get the new intake though as the only one that existed in the system was in Canada at the time.

[inNout]

Is the replacement mani any different from the broken one?

[coolwater]

Don't think so. Same thing according to my SA when I had it replaced.
It's like a $800 job when out of warranty.

-cW

[SoCalS4Avant]

Is the replacement mani any different from the broken one?

Don't think so. Same thing according to my SA when I had it replaced.
It's like a $800 job when out of warranty.

-cW

I have to say, that's quite disappointing. If it's not an improved part, that means we'll be doing this sort of fix multiple times over the lifetime of the car (potentially).

[inNout]

I guess this is an opportunity for the aftermarket vendors to make money. I'm waiting.

[cory_can]

there could be some lot that had a bad version of the part or something.....the numbers have been low (not nearly B8 S4 pump regularity)

Any similarities of the cars that have failed? Looks like mostly '09's .....similar build dates?

EDIT...maybe it's time to have a "Common Issues" Sticky to see if we can identify anything systemic (OEM) including this manifold flapper ....Keeping it to Model Year, Build date, Mileage when fault occurred, fault detail, dealer fix etc. As long as "discussions" and "chit-chat" is kept out it would be a great place to quickly see all the faults together.

[Anthony]

I guess this is an opportunity for the aftermarket vendors to make money. I'm waiting.

I mentioned it to APR, so we'll see. It may become increasingly necessary as BT kits continue to be developed.

there could be some lot that had a bad version of the part or something.....the numbers have been low (not nearly B8 S4 pump regularity)

Any similarities of the cars that have failed? Looks like mostly '09's .....similar build dates?

EDIT...maybe it's time to have a "Common Issues" Sticky to see if we can identify anything systemic (OEM) including this manifold flapper ....Keeping it to Model Year, Build date, Mileage when fault occurred, fault detail, dealer fix etc. As long as "discussions" and "chit-chat" is kept out it would be a great place to quickly see all the faults together.

This is a great idea. If someone creates a good one, we will Sticky it.


Got a call from the dealer a little bit ago. The car is ready and I'm headed there soon to pick it up. I'm hoping to photograph the part and speak with the tech (if he's knowledgable on the issue).

[Anthony]

OK, here's the lovely culprit...







I am happy to say that the car is running as strong as ever, with no more engine warning lights glowing brightly in our eyeballs. We sure did miss her around here.

[Blake P]

Glad to hear it, Anthony! I'm sure mine will blow again any day now. This time, on my dime!

[Anthony]

Glad to hear it, Anthony! I'm sure mine will blow again any day now. This time, on my dime!

I wasn't able to note the codes on the new part, but I'm really hoping they've revised them since our 2009 build...

[MiracleWhips]

Glad to hear you are back on the road!

[Blake P]

I wasn't able to note the codes on the new part, but I'm really hoping they've revised them since our 2009 build...

Part #'s should be listed on your paperwork. Check it and I'll compare with mine.

[Anthony]

Glad to hear you are back on the road!

Me too. It made me realize that my ol' S6 Avant is no longer a daily driver... A shit-ton more fun than any other car I've had before but just not nearly as comfy, quiet, and poised as the B8.

[Anthony]

Part #'s should be listed on your paperwork. Check it and I'll compare with mine.

According to my work order, the new mani is 06H-133-201-AF. Similar but definitely different than what's on the old one (06H-133-185-AA), unless I was looking in the wrong place.

[Blake P]

According to my work order, the new mani is 06H-133-201-AF. Similar but definitely different than what's on the old one (06H-133-185-AA), unless I was looking in the wrong place.

Mine listed the same exact part number as your new one. I never got to see the one they replaced, but I assume it was the same part # as your broken one. Let's hope they actually improved the design! *fingers crossed*

Whoops, I noticed my part number ends with a "J" instead of "AF". Checked both at genuinevwaudiparts.com and only the "J" part number works.

[Alkivar]

plastic intake = fail

seen too many of them damaged

no amount of talking will ever convince me that it is not a ticking time bomb.

[coolwater]

Glad you are back in action.
Did you see any seepage near your seals?
On the same topic of broken things.

Now I have a coolant leak.
My G12 pink tank was down to 1/3!
Going in for service tomorrow to have that and the cam seal seepage looked at.
I bet they won't have the parts and I'll have to wait for them to come in. :(

-cW

[Blake P]

plastic intake = fail

seen too many of them damaged

no amount of talking will ever convince me that it is not a ticking time bomb.

Now I'm curious, does your 3.2 A5 have an awesome plastic intake manifold or is it just us 2.0T'ers?