Inlet manifold Co flap broken off

[spannerrash]

Hi all
After replacing my knock sensor I was in the process of replacing the inlet manifold when I noticed something in cylinder 6 runner (see pictures).

I have been chasing a slight miss fire / rough idle for a little while now and maybe this is it. I can't get the piece out and have checked the cylinder with an endoscope and can see no damage to the piston, cylinder walls or valves. It looks like I may have dodged a bullet there.

What are my options? It's clearly a piece of the variable inlet runner and even though the manifold looks like it should split I doubt very much it's going to want to. Even if I could split it would I be able to get parts?

Is this the correct part number? 077133185AS.

Honestly guys, I'm getting really fed up with this car. I try to do everything I can to maintain her correctly using only genuine parts where I can and yet she just keeps constantly kicking me in the nuts. Whatever happens her is going to be expensive, I can just feel it.

Thanks Frank

[spannerrash]

Will this do?

eBay
https://www.ebay.co.uk › itm
2004-2006 VW PHAETON 4.2L - Intake Manifold 077133185AT

[spannerrash]

After researching it looks like one of the aluminium brackets has broken. No piston damage would indicate a clean break.

Also, if I want to go brand new it looks like 077-133-185-CA is the replacement. Can anyone confirm this for me please.

[steamship]

Originally Posted by spannerrash

It looks like I may have dodged a bullet there.

Go buy a lottery ticket.

Originally Posted by spannerrash

It's clearly a piece of the variable inlet runner and even though the manifold looks like it should split I doubt very much it's going to want to. Even if I could split it would I be able to get parts?

There are posts on the Internet of people separating them (I think they're held together with some form of glue) and removing the internal mechanism completely when this starts to happen, but not replacing the parts as the internals are not listed separately.

Originally Posted by spannerrash

she just keeps constantly kicking me in the nuts.

Tell me about it. When I had mine apart last year, I decided to replace most of the sensors and windscreen washer motor, as it seemed like a good idea. Less than a year later, and the motor has failed and so has the oil sensor. Bumper off plus other bits job, and the weathers lousy!

Originally Posted by spannerrash

Also, if I want to go brand new it looks like 077-133-185-CA is the replacement. Can anyone confirm this for me please.

For the AQH, AVP, BCS and AYS engine codes, 077133185CA is the most recent version (2015). If you can find old 'new' parts, others to consider end in AT, BJ, BM or BT, as they are all the predecessors.

[spannerrash]

Thanks very much for the reply and the information. It looks like 2k for a new unit. That's a bitter pill for a car that's worth maybe 6k.

There are a few available of various prefix's for around the £400 mark. I might consider a little project and buy one to see if I can make a good one from the two. I'll keep looking for a while, see if anything pops up.

In all honesty I don't like fitting used or bodged parts, it usually comes back to bite me in the end.

[spannerrash]

Hi all again and apologies as I seem to be replying to my own thread here quite a lot. I just need some more info so I can plan my route forward.

Is this a common problem and does anyone know of any examples where it has ended in cylinder or piston damage? I ask because going down the repair or use of second hand parts route may simply mean I am setting myself up for failure again. Maybe I won't be so lucky next time.

If it is a common problem then brand new or removal of the flaps altogether seems to be the only sensible solutions. What will be the consequences of removing the flaps. Will I even notice the difference?

[The_Laird]

As you may have seen in another thread, I’ve just clocked up 200K miles and not had this problem. Fingers crossed!

[steamship]

Originally Posted by spannerrash

Hi all again and apologies as I seem to be replying to my own thread here quite a lot.

There's no need, as all you're doing is elaborating on the information you have on hand. It saves others from suggesting it.

Originally Posted by spannerrash

Is this a common problem and does anyone know of any examples where it has ended in cylinder or piston damage?

The only instances that I have heard of them disintegrating is on the 4.0tdi and 5.2 V10 engines in the D3.

Originally Posted by spannerrash

What will be the consequences of removing the flaps. Will I even notice the difference?

Not a D2 S8, but check out the first post in the following thread where M-A8 gives the pros and cons on doing this on a D3 S8. If you do go down this route, remember to leave the actuators in place with the electrical connectors in place.

https://forum.a8parts.co.uk/showthread.php?t=12128

[spannerrash]

Well I managed to pull out the broken part by simply removing the throttle body. It looks like a clean break so I am confident there are no other bits floating around.

Still not sure of my route forward yet. It's not a big job removing and replacing the intake Manifold so I'm considering fitting it back as is to see how she runs.

If I could get a new one for around £1500 I'd buy it but I just can't bring myself to spend £2500 which is what Audi quoted me, with a 10% discount.

Who knew these cars would be so expensive to maintain eh? Mmmmm.... Actually as I think about it, I think we all know that.

[Spanker]

You could consider this if you find it suitable:

https://www.ebay.de/itm/196296607848