Stuck Intake Tuning Flap
 

I have stuck intake manifold "flap" valve. I have read the instructions for pulling off the levers and cleaning the bushing/seal housing.

Has anyone tried just repeated application of PB Blaster to try and free up the corrosion which supposedly causes the sticking?

I have not tried it but I can tell you that the build up is pretty tough. I actually grinded away some of it so that is could move up and down nicely. PB Blaster is good stuff but maybe not the best for this one - I guess you could try it out though.

I was concerned about it attacking the plastic but I rested it on the plastic of an Audi air valve and it was unaffected. I will give it a try.

Thanks.

Are the arms on the shafts metal or plastic? My lower one I cannot move by hand
and am thinking of prying against it to try to move it.

I guess they are plastic ast metal ones are $79 apiece. Pretty steep.

Indeed the metal ones are aftermarket - stock are always plastic. There are 2 ways to clean this out:
1) remove the entire intake manifold and take it apart (what I did while removing the engine to replace head gaskets, valve seals, etc.)
2) check this DIY out: quattroworld.com Forums: 40V Intake manifold fix for stuck or sluggish flap pivots ( w/no broken parts )...
- if I only wanted to fix the flaps I would have done this one! Great DIY with pictures that even explain the function.

Put blaster on it and moved back and forth. The Penetrating oil, moved and fregular oil.
Moving back and forth loosened it. Not full range yet but diaphragm moves it and spring returns it. I will assume itwill loosen up more as it is exercised while driving. Already notice quite a difference.