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#1
29th December 2013, 10:53 AM
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Manifold flaps again
Well the little plastic connecting rods between the bellows and manifold on my newly acquired D3 are both broken.
i have no idea if its because the flaps are jammed, or they have just perished and failed. I don't seem to be able to move the flaps by hand, so either the springs are very strong, I am very weak or they are stuck. How easy/difficult should they be to move by hand?. My D2 still has a working system at 191K miles, but the D3 is stuck/broke at 129K miles.
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Manny 2004 A4 1.8T Sport Cabriolet, 89K Miles Past 2004 D3 A8 3.7 Quattro, Xenon, Bose, Blinds, Solar Sunroof, TV, ACC, phone and almost every option. 168K miles rising slowly with retrofit AMI and DVB-T in place of Analogue 2003 Volvo S60 D5 SE Manual, 197K miles. 2001 D2 A8 3.7 QS, Bi-Xenon, Bose, Blinds, Electric Everything, retrofitted RNS-D, 191K Miles 
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#2
29th December 2013, 11:06 AM
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Just took a few quick pictures of the D3 3.7 flap assembly, from these can it be determined the current state, and therefore the torque curve.
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Manny 2004 A4 1.8T Sport Cabriolet, 89K Miles Past 2004 D3 A8 3.7 Quattro, Xenon, Bose, Blinds, Solar Sunroof, TV, ACC, phone and almost every option. 168K miles rising slowly with retrofit AMI and DVB-T in place of Analogue 2003 Volvo S60 D5 SE Manual, 197K miles. 2001 D2 A8 3.7 QS, Bi-Xenon, Bose, Blinds, Electric Everything, retrofitted RNS-D, 191K Miles
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#3
11th January 2014, 02:20 PM
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I think my flaps are well and truly seized, I cannot move them at all by hand, unless they need more leverage than I can provide. They are currently on the spring stops, so the parked position. I've cleaned up the whole area, bellows working fine its just the flaps.
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Manny 2004 A4 1.8T Sport Cabriolet, 89K Miles Past 2004 D3 A8 3.7 Quattro, Xenon, Bose, Blinds, Solar Sunroof, TV, ACC, phone and almost every option. 168K miles rising slowly with retrofit AMI and DVB-T in place of Analogue 2003 Volvo S60 D5 SE Manual, 197K miles. 2001 D2 A8 3.7 QS, Bi-Xenon, Bose, Blinds, Electric Everything, retrofitted RNS-D, 191K Miles
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