Replacement of Tiguan Flap Valve.

[jets]

After purchasing our TDI Tiguan & while enjoying our drive from Brisbane back home in Adelaide a quick flash appeared on the dash saying ENGINE FAULT-----Workshop. Now I had no idea what it meant & everything else seemed to be fine with excellent economy etc. I thought before I posted here I should get the codes read. I currently have four VWs in our fleet so I thought it would be wise to update my diagnostic tool from VAG-COM to VCDS HEX+CAN. This showed Motor Circuit P2103- Signal High- Intermittent.
A quick Google & I found this.

FAQLoad - Tiguan 2.0 TDI Throttle Value Repair

I followed this write up & found the same problem with mine, J338 Throttle Valve Control Module swimming in oil.
There is no need for me rewrite his story but I would like to make a few comments.
The three bolts that hold the valve in place caused me lots of grief, particularly the long one on the LHS towards the rear.
You can only just see it with a light & your head in a certain position. The dipstick needs to be unbolted & I tied it to the left with a cable to give a little room. Although I had undone the large clamp on the inlet hose [from the IC] & using 1/4in drive tools still couldn't get in there. I moved underneath & decided to remove the pipe assy. as it needed a good clean anyway.
When I installed everything, I bolted the EGR & Flap valve together before offering the assy. to the inlet manifold. I put a thin smear of silicone grease on the O ring in the top of the EGR valve & then only had to deal with the long bolt that passes through both items into the inlet manifold.
The part no. for the flap valve on mine was 03L 128 063C & the one I bought is 03L 128 063E. It has been replaced by 03L 128 063AF but although these are on back order, haven't arrived yet. This same part is used on the Golf, Passat, Touareg, New Beetle etc. with CR TDI engines. They are a very common replacement part but I haven't seen anything on this forum about them.

I removed the EGR valve to give it a clean & thought it wasn't too bad for 79,000km.





This looking up into the inlet manifold.



Inlet hose from intercooler.


VW have moved back to jubilee style hose clamps instead of the wire clips on my Mk5 TDI.
Note the sensor part way along pipe. VW call it a Thrust sensor Anyone know what it does?

[Umai Naa!!]

Thrust sensor is pretty much a boost pressure sensor.

[jets]

Thanks. Have you had to replace many of these valves?

[Umai Naa!!]

The intake flap?

Yeah, I've done a few.