I've followed this thread with interest and thank those contributors who provided the method of stripping down a seized Bosch AAV for possible refurbishment.
With a reluctance to (a) wreck my existing valve during dis-assembling without a safety net or (b) spend £400 on a re-manufactured replacement I set about producing a viable working alternative air valve system at low cost.
The attached pdf document gives a description of what I've done and includes a few photographs for clarification. It all works well and doesn't detract too much from the original engine bay appearance.
I've now just got to remove the original seized AAV, fit a blanking plate to the cylinder head and perhaps gently attack the valve for refurbishment. If it fails, at least I have a nice working 'choke' system on my Bosch D Jet for under £50!
Paul
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