Audi Workshop Service and Repair Manuals

Removing and installing intake manifold flap motor -V157- or intake manifold flap 2 motor -V275- Special tools and workshop equipment required t  Tester -VAS 6395/1- t  Connection lead -VAS 6395/4-2-

Removing   Note In the following the procedures for removing and installing are described for the intake manifold flap motor -V157- for cylinder bank 1 (right-side). The procedure for the intake manifold flap 2 motor -V275- is basically the same. Proceed as follows: –  Carefully pull engine cover panel off four retaining pins one after the other -arrows-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Remove air intake hose. To do so, release hose clip -2- and clamps -arrows-.

–  Open cover -arrow- above positive terminal. –  Connect tester -VAS 6395/1- with connection lead -VAS 6395/4-2- to positive terminal „+“ and negative terminal „–“.

Checking software version of tester -VAS 6395/1-:   Caution Risk of damage to intake manifold flap motor. Before continuing, check whether the correct software version is loaded in the tester -VAS 6395/1-. To do so, proceed as follows: Display on -VAS 6395/1- (2 seconds after connecting to power supply) if correct software version is loaded: 1 -  >TEST 2 -  LEARN   Note t  If the following appears on the display, an incorrect software version has been loaded: t  1. START t  2. NEXT t  If this is the case, download the correct software version from the „Audi ServiceNet“ under „Workshop Equipment“.

Continuation of procedure: –  Unplug electrical connector for intake manifold flap motor -V157-. –  Connect connecting wire -VAS 6395/4-2- to intake manifold flap motor -V157- and tester -VAS 6395/1-.

Display on -VAS 6395/1-: 1 -  >TEST 2 -  LEARN –  To continue, press v button -item 4-.

Display on -VAS 6395/1-: 1 -  CHECK 2 -  S: XX %    I: XX %   Note t  "S" means specified value t  "I" means actual value l  The tester -VAS 6395/1- runs through the adjustment range of the intake manifold flap motor -V157- and checks the feedback of the positions.

Display on -VAS 6395/1- if intake manifold flap motor -V157- is OK: 1 -  ACTUATOR OK l  The test is completed. –  Unplug electrical connectors for tester -VAS 6395/1-. Assemble in reverse order.

Display on -VAS 6395/1- if intake manifold flap motor -V157- is not OK: 1 -  PROBLEM l  Intake manifold flap motor -V157- must be renewed.

–  To do so, proceed as follows: –  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  >TEST 2 -  LEARN –  Press ↓ button -item 6-.

Display on -VAS 6395/1-: 1 -  TEST 2 -  >LEARN –  To continue, press v button -item 4-.

Display on -VAS 6395/1-: 1 -  STEP 1 –  By pressing buttons ↑-item 5- and ↓-item 6-, adjust intake manifold flap motor -V157- in such a way that coupling rod can be accessed easily for removal.

–  Unclip coupling rod -1- from intake manifold flap motor -V157-.   Note Disregard items -2, 3 and 4-.

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  STEP 2   Caution Power supply for tester -VAS 6395/1- must remain connected.

–  Unscrew connecting piece for air intake hose (pulsation damper) -arrows- from turbocharger.

–  If fitted, take electrical connector -arrow- for exhaust gas temperature sender 1 -G235- out of bracket.

–  Disconnect connecting wire -VAS 6395/4-2--item 3- from intake manifold flap motor -V157-. –  Remove bolts -2- and -4-. –  Detach and dispose of old intake manifold flap motor -V157-.

–  Install new intake manifold flap motor -V157- in reverse order of removal and clip coupling rod on.   Note On version with thread-forming bolt, proceed as follows: Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolts to torque. –  Connect connecting wire -VAS 6395/4-2- to intake manifold flap motor -V157-.

–  To confirm that a new intake manifold flap motor -V157- has been installed, press v button -item 4-. Display on -VAS 6395/1-: 1 -  STEP 3

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  WARNING 2 -  LEARNING

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  TEST 1 2 -  S: 84.0 %    I: XX % l  Specification = 84 %

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  TEST 2 2 -  S: 16.0 %    I: XX % l  Specification = 16 %

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  TEST 3 2 -  S: XX %    I: XX % l  Adjustment range of intake manifold flap motor -V157- is checked. Display on -VAS 6395/1-: 1 -  OK –  To confirm, press v button -item 4-. l  Adjustment is completed. –  Unplug electrical connectors for tester -VAS 6395/1-. Assemble in reverse order.