P10A400 popping up again

[fastboatster]

I had a P10A400 code (Regulating flap for intake air Mechanical malfunction) some time ago (a month or a month and a half ago I think), which I've read is supercharger bypass valve related. I installed another bypass valve from a low mile used supercharger and the code went away. But now, only a month or so later, it's back:

OBDeleven data log Date: 2021-11-21 16:02 VIN: WAUBGxxxxxxxxxx
 Car: Audi S4 Year: 2010 Body type: Saloon Engine: CCBA Mileage: 247520 KM
--------------------------------------------------------------- 
01 Engine System description: 3.0T SIMOS84 
Software number: 8K0907551D 
Software version: 0003 
Hardware number: 8K0907551A 
Hardware version: H06 ODX name: EV_ECM30TFS0218K0907551D ODX version: 001003 
Long coding: 0104000A240F0128 
Trouble codes: P10A400 - Regulating flap for intake air Mechanical malfunction Intermittent 
Date: 2021-11-20 14:42:19 Mileage: 247444 km Priority: 2 Malfunction frequency counter: 1 Unlearning counter: 255 Engine speed: 0.00 1/min Normed load value: 0.0 % Vehicle speed: 0 km/h Coolant temperature: 94 °C Intake air temperature: 34 °C Ambient air pressure: 1000 mbar Voltage terminal 30: 12.796 V 
Dynamic environmental data: 209627117D0013E3B8135A02135B001355E313561A

I wonder if this is actually not supercharger bypass valve-related or maybe it's related to it indirectly. I took the old bypass valve apart and it seemed to be okay inside.
Also, notice that the code was set when the engine was warm and not running.
P.S. Ross-tech website says the following:

When found in the Audi A6 (4F) and Audi Q7 (4L) models with 3.0L supercharged gas engines such as CCAA, CJWE, CJWC and CJWB this DTC points to a problem with Supercharger Control Valve (J808). It is NOT an IMRC system DTC. :
- Check wiring to/from J808.
- Verify J808 is not oil soaked or dirty.
- See Basic Settings and Measuring Block group 168.
For UDS ECM, Basic Settings IDE02226 - Adaptation of regulating flap for compressor

Wonder if it got oil-soaked, perhaps PCV is still blowing too much oil into the intake manifold(s). I replaced PCV last year along with a new engine, but one crankcase vent hose was loose, I wonder if some dirt got into the PCV and pcv valve might not seal sometimes.

[Smac770]

P10A4 RFP Actuator, functional check
Absolute value of maximum deviation between predicted and real value: > 8%

P10A5 RFP sensor, short to B +
Signal voltage > 4.9 V

P10A6 RFP sensor, short to ground / open circuit
Signal voltage < 0.1 V

I presume RFP is supposed to mean recirculation flap something or another, the J808 basically. The J808 is laid out on pages 26-27 of SSP 437 (google search). Observe the activation chart on page 31.

So the DTC is saying the ECM is sending the signal to the V380 motor that should set the flap to angle X, but the G584 potentiometer is saying the angle is different, the DTC being tripped when the two are 8° or more in disagreement.

So is there a problem with the ECM motor circuitry, the wiring from the ECM to the V380 motor, the operation of the V380 motor, the physical movement of the flap, the operation of the G584 sensor, the wiring from the ECM to the G584 sensor, or the ECM sensor circuitry.

I'd start by logging values during a drive and determine if the specified vs actual deviation is all the time, idle, WOT, no particular pattern, etc. Also, physically move the flap and see if the sensor reads in line with what you're during. Check the flap itself for blockage. Etc.

[pewpewprince]

plastic gear in bypass worn out

[fastboatster]

I'll try to do these functional checks. As for the plastic gear, I took the old actuator apart and didn't see any wear on the plastic gears. "throttle plate" slop on the J808 was also very small. the bypass valve I installed has even less slop. It's very strange for 2 actuators in a row to quit in intermittent fashion, the code doesn't appear for weeks and very intermittent. I'm gonna have to pull the actuator out and see if it got dirty/oil soaked as a first quick and easy check.

[Thugmeet]

Please give an update if you figure anything out. I've replaced my bypass valve with a used one. Replaced the rear MAP sensor on the supercharger. Still no change. I've just been clearing the code like every couple of months and it seems like there's no ill effect. Might try replacing the other two MAP sensors.

[fastboatster]

Please give an update if you figure anything out. I've replaced my bypass valve with a used one. Replaced the rear MAP sensor on the supercharger. Still no change. I've just been clearing the code like every couple of months and it seems like there's no ill effect. Might try replacing the other two MAP sensors.

okay, I'll give an update if I figure this out. Haven't had a chance to deal with it yet, I'll need to pull the bypass valve out and see how it looks like. I have a feeling I'll need to pull the supercharger and redo the pcv. That's of course if I find out that bypass valve is very oily

[deejayh]

any update???

[SwankPeRFection]

These codes pop up when you’ve got a supercharger bypass valve that’s either starting to go bad or has gone bad. Replace it with a new or known good one that’s not an old revision code like D. If you’ve got serious miles on your car, chances are good it’s gone bad due to gearing or heat related failure to the motor inside it. Had mine set codes intermittently and eventually it fail (in full shut position). Yeah, didn’t think that was supposed to happen when they failed, but it did. Can’t even be opened by hand. Will be pulling it apart in the next day or so and taking pics of what’s up inside.

[fastboatster]

any update???

replaced it with another used one and it hasn't been popping up ever since.