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Pelican Technical Article:

Intake Flap Motor Replacement

Steve Vernon

Time:

4 hours4 hrs

Tab:

$150

Talent:

**

Tools:

T30, T25 Torx, 10mm, 8mm wrench, flathead screwdriver

Applicable Models:

VW GTI (2006-09)

Parts Required:

New throttle body gasket

Hot Tip:

You will need to recode the throttle body

Performance Gain:

Smoother-running engine

Complementary Modification:

New fuel filter

The Volkswagen GTI MkV 2L uses an intake flap system to help with fuel efficiency and emission requirements, especially during cold starts. This flap system is controlled by an electrical motor. This motor is a stand alone component from the intake manifold and if it goes bad it can be changed out separately. The motor is buried underneath the intake manifold on the left side of the motor below the high pressure fuel pump. It is a little difficult to get at but almost impossible to get pictures of.

If you are replacing the motor you will need to remove the throttle body to get enough room to get the flap motor out. Please see our article on removing your throttle body for additional assistance.

Begin by safely jacking up and supporting the vehicle. Please see our article on safely jacking up and supporting your GTI MkV for additional information.

You will need to remove the lower engine tray.
Figure 1

You will need to remove the lower engine tray. A great many of these cars have had the engine trays and front side shields removed over the years and not replaced. If you happen to have a car that still has all the under trays and original hardware here is what you need to do. There are four T25 Torx screws (red arrows) on each side holding the tray on, remove them and slide the tray back out of the friction clips (yellow arrows) on the front air dam.

The charged air pipe and hoses run from the induction system and divert air before it reaches the throttle body (red arrow).
Figure 2

The charged air pipe and hoses run from the induction system and divert air before it reaches the throttle body (red arrow). This charged air runs through a pipe that is secured by an 8mm bolt (blue arrow) and T30 Torx (green arrow) and enters the interior by a quick release fitting (yellow arrow). Please see our article on removing the charged air pipe for additional information. If your engine does not have an after market air induction system you will need to remove the engine cover, please see our article for engine cover removal for further assistance.

There is very little room to work on the front of the motor between the engine and the fans.
Figure 3

There is very little room to work on the front of the motor between the engine and the fans. Removing the fans and shroud will free up some much needed space, just be careful working around the exposed radiator when the shroud is removed. Please see our article on fan and shroud removal for further assistance.

With the front of the vehicle removed you can see the components that you will need to remove to get access to the throttle body and intake flap motor.
Figure 4

With the front of the vehicle removed you can see the components that you will need to remove to get access to the throttle body and intake flap motor. Note; you do not need to remove the front of the vehicle to perform this work but if you would like to please see our article on lock carrier removal. You can get to all these components from either above or below with the front of the car attached. With the charged air pipe removed (yellow arrow) you will be removing the lower turbo pipe (red arrow) you will need to remove the fasteners (green arrows) for the induction pipe.

On the lower left side unclip the quick release clip from the lower turbo hose and separate the hose from the intercooler (red arrow).
Figure 5

On the lower left side unclip the quick release clip from the lower turbo hose and separate the hose from the intercooler (red arrow). You can leave it attached to the induction pipe and remove it with the pipe or remove it completely now.

Disconnect the wiring connection (red arrow) from the boost sensor (yellow arrow).
Figure 6

Disconnect the wiring connection (red arrow) from the boost sensor (yellow arrow).

Use a flathead screwdriver and loosen the clamp on the throttle body hose (red arrow).
Figure 7

Use a flathead screwdriver and loosen the clamp on the throttle body hose (red arrow).

Working from below remove the T30 screw holding the charged air pipe bracket to the engine (red arrow).
Figure 8

Working from below remove the T30 screw holding the charged air pipe bracket to the engine (red arrow).

Working from the top of the vehicle remove the 10mm nut (red arrow) holding the charged air pipe bracket on and remove the pipe.
Figure 9

Working from the top of the vehicle remove the 10mm nut (red arrow) holding the charged air pipe bracket on and remove the pipe. Use care to wiggle it and the intake hose off the throttle body and out through the bottom of the vehicle.

There is a linkage arm that connects the motor (red arrow) to the flaps (yellow arrow).
Figure 10

There is a linkage arm that connects the motor (red arrow) to the flaps (yellow arrow). Use a flathead screwdriver and gently pry this arm off

The linkage (red arrow) has plastic ball clips on each end.
Figure 11

The linkage (red arrow) has plastic ball clips on each end. They are different sizes so make sure you have it oriented correctly before installation.

Working from below the vehicle insert your 6 inch T30 Torx (yellow arrow) between the maze of wires and hoses and remove the three T30 Torx bolts (red arrow, one partially shown).
Figure 12

Working from below the vehicle insert your 6 inch T30 Torx (yellow arrow) between the maze of wires and hoses and remove the three T30 Torx bolts (red arrow, one partially shown). Make sure the bit is well seated as you do not want to strip these bolts.

With the throttle body removed disconnect the plug for the injectors (red arrows).
Figure 13

With the throttle body removed disconnect the plug for the injectors (red arrows).

Separate the vacuum hose (red arrow) from the engine.
Figure 14

Separate the vacuum hose (red arrow) from the engine. This will give you enough room to remove the flap motor (yellow arrow) from the center of the engine.

Disconnect the wiring harness from the motor (red arrow).
Figure 15

Disconnect the wiring harness from the motor (red arrow).

With the motor out of the car you can see the three mounting holes for the Torx bolts (red arrows) as well as the armature for the linkage (yellow arrow) Installation is the reverse of removal.
Figure 16

With the motor out of the car you can see the three mounting holes for the Torx bolts (red arrows) as well as the armature for the linkage (yellow arrow) Installation is the reverse of removal.

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Page last updated: Fri 12/9/2016 02:36:40 AM