TDI (CR170) Intake Manifold Flap Problem

Mr OCD · Post by **Mr OCD** » Wed Feb 24, 2016 10:03 am

Hi All

I had the MIL come up this morning ...

Codes: 008201 / 008196 / 008208

Intake manifold flap stuck open.

Any ideas?

dimexi · Post by **dimexi** » Wed Feb 24, 2016 11:19 am

I think Diesels are a bit different to petrols when it comes to manifold issues, so I feel a bit reluctant to open my mouth. Have you checked the codes on Ross tech?

dimexi · Post by **dimexi** » Wed Feb 24, 2016 12:30 pm

See the second post in this thread for diesel http://www.sciroccocentral.co.uk/forum/ ... 25&t=20099" onclick="window.open(this.href);return false;

Mr OCD · Post by **Mr OCD** » Wed Feb 24, 2016 1:08 pm

18436/P2004/008196 - Intake Manifold Flap; Bank 1: Stuck Open
Possible Causes
•Vacuum leak
•Faulty Intake Manifold Runner Position Sensor1 (G336)
•Intake Manifold Runner binding or sticking

Possible Solutions
•Replaced failed vacuum line
•Check Intake Manifold Runner Position Sensor 1 (G336) and wiring, see repair manual
•Check Intake Manifold Flap ◦Use Output Test
◦Perform Basic Setting (Switch Ignition OFF between Output Test and Basic Setting)

Special Notes
•When found in Engine: 2.0l TFSI ◦Perform Basic Setting.
◦Check TPL 2016420 (RoW)

Check Engine Control Module Software Version, if necessary perform Update.

Replace Intake Manifold Runner (V157) with updated part.

◦Check TSB 01-08-12 or 2018402 (NAR) North American Region vehicles only.

Check Engine Control Module Software Version, if necessary perform Update.

Replace Intake Manifold Runner (V157) with updated part.

Additional information may be found by searching RVU 24M2 / O3 (Exp. date November 30, 2011) or calling the VW dealer and checking the VIN.

Mr OCD · Post by **Mr OCD** » Wed Feb 24, 2016 1:12 pm

dimexi wrote:See the second post in this thread for diesel http://www.sciroccocentral.co.uk/forum/ ... 25&t=20099" onclick="window.open(this.href);return false;

Thanks for that... the car runs absolutely fine, but I did read about the 'fix' from Diesel Geek.

However, surely if the motor arm is over extending (hence the mod) this would point out wear?

Car is still under warranty, but is likely going to be involved to claim so want to be prepared with options!

dimexi · Post by **dimexi** » Wed Feb 24, 2016 4:32 pm

Mr OCD wrote:
dimexi wrote:See the second post in this thread for diesel http://www.sciroccocentral.co.uk/forum/ ... 25&t=20099" onclick="window.open(this.href);return false;
Thanks for that... the car runs absolutely fine, but I did read about the 'fix' from Diesel Geek.

However, surely if the motor arm is over extending (hence the mod) this would point out wear?

Car is still under warranty, but is likely going to be involved to claim so want to be prepared with options!

I don't know a lot about the diesel part, but you are under warranty, get straight to VW and let them sort it. It's a known problem on both diesel and petrol variants. My manifold was reporting Bank 1 as being stuck open, we took the manifold out and it was as free as can be, nothing sticking at all, so the position sensor must have been on the blink. My car ran fine with no rough idling too. Mind you, before I got the manifold changed, the EML did go off.... so dunno, still I think faulty sensor was my problem

Mr OCD · Post by **Mr OCD** » Wed Feb 24, 2016 8:15 pm

It's not a VW warranty but a company called auto protect / customer protect that was sold with the car ... Reading reviews I'm expecting wear / tear being mentioned!

I've cleared the code down and driven 50 miles ... It's not appeared.

Warranty runs out middle of next month so if the code appears before then I will see what can be done ...

New motor / sensor is £460 from VW yet £127 across the pond ...

dimexi · Post by **dimexi** » Thu Feb 25, 2016 8:22 am

Mr OCD wrote:It's not a VW warranty but a company called auto protect / customer protect that was sold with the car ... Reading reviews I'm expecting wear / tear being mentioned!

I've cleared the code down and driven 50 miles ... It's not appeared.

Warranty runs out middle of next month so if the code appears before then I will see what can be done ...

New motor / sensor is £460 from VW yet £127 across the pond ...

Get it from across the pond. If you can't fit in, get an indie to do it for you... That's what I did - I saved sooooooo much money doing that. VW quoted £336 for the part alone, and I got Part + indie fitting at £280!!!

Mr OCD · Post by **Mr OCD** » Fri Feb 26, 2016 6:58 pm

dimexi wrote:
Mr OCD wrote:It's not a VW warranty but a company called auto protect / customer protect that was sold with the car ... Reading reviews I'm expecting wear / tear being mentioned!

I've cleared the code down and driven 50 miles ... It's not appeared.

Warranty runs out middle of next month so if the code appears before then I will see what can be done ...

New motor / sensor is £460 from VW yet £127 across the pond ...
Get it from across the pond. If you can't fit in, get an indie to do it for you... That's what I did - I saved sooooooo much money doing that. VW quoted £336 for the part alone, and I got Part + indie fitting at £280!!!

That's the plan. No MIL yet after 200 miles ...

xjay1337 · Post by **xjay1337** » Fri Feb 26, 2016 9:01 pm

Or remove the flaps.

Mr OCD · Post by **Mr OCD** » Sat Feb 27, 2016 11:43 am

xjay1337 wrote:Or remove the flaps.

What do they actually do?

I don't think the flaps are the issue, but the motor ...

xjay1337 · Post by **xjay1337** » Sat Feb 27, 2016 5:19 pm

Regulate air flow into the intake manifold.
Often they get very gummed up with crap. Mine were caked but were still working.

dimexi · Post by **dimexi** » Sun Feb 28, 2016 7:41 pm

xjay1337 wrote:Regulate air flow into the intake manifold.
Often they get very gummed up with crap. Mine were caked but were still working.

Regulate airflow at high end of the revs scale I think

xjay1337 · Post by **xjay1337** » Wed Mar 02, 2016 9:33 am

It's low to mid RPMs, supposed to increase torque and improve combustion efficiency.

At high RPM the flaps are open. (over about 3000rpm and during engine start up)
They continuously adjust but they mainly work at low and mid RPM but causing the air to vortex in a given way.

They are also called swirl flaps because they cause the air to "swirl" in a given manner.

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