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I'm putting a new shaft - spring - washer - etc. in as well as new bearings.

By putting just a half wind of spring tension on it the flappy seems to snap shut nicely, not hard to move but it affirmatively shuts, just like my old one did. I'm wondering if I need to lube the shaft or any of the washers etc.

Also, I read in a thread here to adjust the "stop" so the edges of the flap itself doesn't quite dig into the walls but on mine the only possible stop seems to be the open position by way of the linkage that the actuator works off of. The flap seems to have two beveled surfaces on opposing edges that engage the sides of the wall and it doesn't quite sit perpendicular to the wall thus the bevel matches the angle the edge of the flap sits at when closed and nothing internal or external seems to be designed to adjust the closed position.

So...lube or not ? And...is there a "stop" on the S4 flappy for the closed position?

Thanks!

Rob Edwards

The 'stop' for the closed position is the 19mm (17mm?) hex bolt against which the 'cam' on the flappy shaft rests. The bolt head is eccentrically located, so rotating it adjusts the stop for the flappy shaft. I forget which way is which but it shoudl be self evident.

Tony

You have a quick review for the type of bearing used for the flappy and a source?

heinrich

Good question Tony .. and LUBE YES.

Rob Edwards

Tony-

The flappy bearings are HK 1012RS, search with that part # and at least 1 thread ought to turn up. I have an extra pair I could mail you if you're in a big hurry or I think multiple vendors have 'em. I got mine from Motion Industries (949) 752-0023, they were +/- $8 a piece.

Also: http://www.nichols.nu/tip801.htm

David L. Lutz

Craig,

I sure wish you would hurry up and get your ride back on the road. I have a few questions for ya!

I have just completed my Stage III install and am trouble shooting some small issues. 1) being; running a little on the "HOT" side, 2) high idle around 950rpm., etc.

Let us know when your back on the road and how the serging issue went?

Rob Edwards

Craig-

Are you installing new parts or good used parts? If the former, do you have the part numbers for all the flappy bits you're replacing? They're not in PET AFAIK and it would be great for reference.

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Wow, neither of my intakes have that hex bolt head! I have a roll pin in that spot that one end of the spring anchors to, could it be the hex head sits on that pin or is it a bonafide bolt and both of mine have been replaced with pins?!?

As to the flappy parts, I bought an intake from BrendanC and he sent it with a flappy assembly that looks pretty fresh so I was using it and planning to clean up my old stuff and sell it later. The bearings came from Roger at 928's Rus. Both my old intake and the one he sent are identical as far as the flappy assembly and the absence of a hex bolt for a stop.

David, I hope to be up and running tonight or in the morning all though the hex bolt being missing is an issue that may delay things
As to my symptoms, I discovered my WOT switch was not working so I'm replacing that as well as the Idle valve and of course refreshing all the rubber and vacuum lines that goes with R&R of the intake so hopefully my symptoms will be cured but since I used the scatter gun method of shooting everything that moves we may never know what it was...

I'll update on the progress but for now my emergency is the "Hex Bolt Head" that serves as a stop for the flappy!! Anyone have the specs for it? Maybe Porsche changed the part at some point? Mine is a 1988 S4....

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Mrmerlin

your hex stop sounds like has fallen off you could make one out of another bolt head and drill the correct size hole off center to let the new part be eccentric. use some green loctite on the head/pin after you have the flappy adjusted. the flappy bearing should be oriented so the rubber internal seal faces out, this will keep dirt out of the bearings Use some grease prior to installation on the bearings.
Make sure that the flappy door isnt binding in the intake housing, use loctite on the flappy throttle placte screws

BC

Craig - I sent you bearings. Alot of stuff was in that box - I wanted to warn you to make sure to look through it before you threw out the packing.

I have the seals as well and can send them in an envelope - including the side cover seals.

Did the polish hold on the side covers?

BC

The throttle body I sent also has the idle valve - and that only has 75k on it. It worked great...5 years ago.

BC

I don't ever remember a hex bolt.

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Brendan, thanks, I saved the box and packing but I'm pretty sure I retrieved everything...more stuff than you promised too and at a good price, thanks!
No, no hex and on both my old intake on on the one you sold me, from looking at the pins, it's hard to tell how long they have been that way but my guess is the hex didn't fall off of either one any time recently.
On the one you sold the flappy parts all looked relatively clean, more like 'new old stock' than used so I'm installing them instead of transferring over my stuff.

If you could send those side cover seals that would help, I put mine in there but they were so compressed I may not have a good seal there...easy enough to pop them off and replace later.

I'm starting to hate breaking the fuel rails down to do anything on the car so I decided to go with new Throttle Position switch and new Idle Valve just to lessen the chance of having to lift the intake again anytime soon.

The polish is pretty good, I figure I'll have to find a way to clear coat it or something if I want it to stay that way. For now I'll install it and think about how to maintain it. Since those two pieces are so easy to take off to deal with I'll refinish, paint or coat later when I'm sure what final look I'm after. For now it's function over form.

Mr Merlin (or anyone else who knows) The flappy bearings came with a slight layer of grease on them so I put them in without adding to it. Should I add some more to the bearings internal area? How about the spring and washer area...grease there?
And I did install the bearings with the seal towards the outside.

I'll probably fabricate something to take the hex bolts place for a stop, I'm too close to done to wait on another package in the mail now!!