Q7 Exhaust Flap Malfunction Causes Unwanted Sports Car Sound

Had the same exhaust valve issue on my 2017 Audi S5. The symptoms were identical, loud cold starts and permanently open exhaust flaps due to a faulty actuator in the exhaust system. The exhaust repair involved replacing the complete valve actuator unit since these components often fail as a complete assembly. The mechanic found corrosion inside the actuator housing which caused the exhaust valves to stick. This is actually a known weak point in several VAG engines. The fix required removing part of the exhaust system to access the actuator. While inside, they also checked the vacuum lines and electrical connections to prevent future exhaust noise issues. The repair was not particularly complex but required specific diagnostic equipment to properly reset the system. This was not a serious mechanical problem but needed prompt attention since the constant loud exhaust noise can be disruptive. If left unfixed, it could potentially trigger additional error codes or cause the valves to completely seize. The most important part was finding a shop with proper diagnostic tools and experience with VAG exhaust components. Would recommend asking specifically about their experience with exhaust flap actuator replacements before booking.

Thanks for the detailed explanation of the exhaust flap actuator repair. Dealing with the same issue on my Q7 now and your post really helps understand what to expect. Did you remember the total cost for the exhaust system repair? Also curious if any other exhaust noise problems came up since getting it fixed. Mine just started making these sounds last week but I want to get ahead of any potential issues.

Got the exhaust flap actuator fixed on my S5 about 6 months ago and everything has been running perfectly since then. The repair cost came to 190 Euro total, which covered both parts and labor. The exhaust noise completely returned to normal after they replaced the faulty actuator. The exhaust system has been working exactly as designed since the repair, with no unexpected sounds or problems. The flap motor now operates smoothly and the exhaust valves open and close properly, especially during those morning cold starts that used to be so loud. Just make sure your mechanic has experience with VAG exhaust components for the best results. The diagnostic equipment they used to reset the system was key to getting everything working correctly again.

Thanks for the input. Finally got my Q7 fixed last week and wanted to share my experience. Found a certified shop specializing in VAG vehicles and the exhaust repair went smoothly. Total cost was 220 Euro which seemed fair considering the work involved. The mechanic showed me the corroded flap motor they removed, it was completely seized up. They also checked all the exhaust valves and connections while they were in there. Engine performance is back to normal now and the excessive exhaust noise is gone. Cold starts are quiet again like they should be. Really glad I got this sorted quickly before it could cause any other issues. The shop actually had three other similar cases this month, so seems like a somewhat common problem. They were efficient and professional, took about 3 hours total for the complete repair.