Removing and installing intake manifold flap motor V157 or intake manifold flap motor 2V275 (engine codes BKS, BUN) — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

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• The following appears on display with incorrect software download:1. START2. NEXTIn this case the correct software must be downloaded via "“Volkswagen ServiceNet”", "“Workshop Equipment”".
• Disregard items (2, 3 and 4).
• The voltage supply for electronics boxVAS 6395/1 must remain connected. — Remove bolts (2) and (4).
• Proceed as follows on version with self-locking bolt: Start bolt by hand and screw in so that it can pick up the old threads. Then tighten bolts to prescribed torque.

🔧 Engine codes this applies to

📋 Procedure

1. Carefully pull engine cover panel off four retaining pins one after the other (arrows)
2. Disconnect electrical connector (3) at air mass meter G70.
3. Remove air hose (4) between air filter and turbocharger.
4. Open cover over positive terminal connector.
5. Connect electronics box VAS 6395/1 with connector cable VAS 6395/4-2 to positive terminal connector "“+”" and to earth terminal connector "“–”". [Note: The following appears on display with incorrect software download:1. START2. NEXTIn this case the correct software must be downloaded via "“Volkswagen ServiceNet”", "“Workshop Equipment”".]

6. ⚠ Risk of damage to intake manifold flap motors. Before continuing with the procedure, first check that the correct software has been installed in the electronics box VAS 6395/1 as follows: — Separate electrical connection for intake manifold flap motor V157.
7. Connect connector cable VAS 6395/4-2 to intake manifold flap motor V157 and to electronics box VAS 6395/1.
8. To continue, press v button (item 4).
9. Separate electrical connectors for electronics box VAS 6395/1.
10. To do this, perform the following procedure:
11. To continue, press v button (item 4).
12. Press ↓ button (item 6).
13. To continue, press v button (item 4).
14. Using ↑ button (item 5) and ↓ button (item 6), adjust intake manifold flap motor V157 so that coupling rod is accessible for removal.
15. Unclip coupling rod (1) off intake manifold flap motor V157. [Note: Disregard items (2, 3 and 4).]
16. To continue, press v button (item 4).
17. If fitted, remove electrical connector (arrow) for exhaust gas temperature sender 1G235 from bracket.
18. Separate connector cable VAS 6395/4-2(item 3) from intake manifold flap motor V157.
19. ⚠ The voltage supply for electronics box VAS 6395/1 must remain connected. — Remove bolts (2) and (4).
20. Remove and dispose of old intake manifold flap motor V157.
21. Install new intake manifold flap motor V157 in reverse order and clip on coupling rod. [Note: Proceed as follows on version with self-locking bolt: Start bolt by hand and screw in so that it can pick up the old threads. Then tighten bolts to prescribed torque.]
22. Connect connector cable VAS 6395/4-2 to intake manifold flap motor V157.
23. To confirm that the new intake manifold flap motor V157 was installed, press the v button (item 4).
24. To continue, press v button (item 4).
25. To continue, press v button (item 4).
26. To continue, press v button (item 4).
27. To continue, press v button (item 4).
28. To confirm, press v button (item 4).
29. Separate electrical connectors for electronics box VAS 6395/1.

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