Hi Guys. I’m at my wits end with my P2015 inlet manifold flap issue. First tried the bracket which didn’t work so replaced the whole inlet manifold with flap controller and I still have the code come on after every 3 to 4 starts? Am I missing something? Where to go next? Is some kind of adaptation required? I have VCDS.

20 hours ago, Avinash said:

Hi Guys. I’m at my wits end with my P2015 inlet manifold flap issue. First tried the bracket which didn’t work so replaced the whole inlet manifold with flap controller and I still have the code come on after every 3 to 4 starts? Am I missing something? Where to go next? Is some kind of adaptation required? I have VCDS.

Hi yes the new unit has to be adapted so that its new values can be learned, was tan aftermarket/second hand manifold?

Steve.

50 minutes ago, Stevey Y said:

Hi yes the new unit has to be adapted so that its new values can be learned, was tan aftermarket/second hand manifold?

Steve.

The manifold and flap motor came together. Whilst the genuine Audi product was unaffordable, I went for a new EBay aftermarket unit which comes with 2 years warranty, thinking that I didn’t want to take a chance with a second hand unit.

i have a VCDS but no where does it give me an option to carry out adaptation of the unit. I am able to turn the flap motor on and off manually and do an overall test

Any ideas as to how to get the adaptation done and using what tool?

On 6/7/2024 at 7:08 PM, Avinash said:

The manifold and flap motor came together. Whilst the genuine Audi product was unaffordable, I went for a new EBay aftermarket unit which comes with 2 years warranty, thinking that I didn’t want to take a chance with a second hand unit.

i have a VCDS but no where does it give me an option to carry out adaptation of the unit. I am able to turn the flap motor on and off manually and do an overall test

Any ideas as to how to get the adaptation done and using what tool?

Hi should be able to do it in basic settings, but I will look at my VCDS Monday and try and work this out for you but in saying this I have not heard many glowing reports of aftermarket manifolds.

Steve.

Thanks very much Steve

15 hours ago, Stevey Y said:

Hi should be able to do it in basic settings, but I will look at my VCDS Monday and try and work this out for you but in saying this I have not heard many glowing reports of aftermarket manifolds.

Steve.

 

On 6/9/2024 at 12:09 PM, Avinash said:

Thanks very much Steve

 

Hi its all dependent on the type of engine you have, there is a setting on VCDS but I can't pin it down because I don't have your car to plug in to, therefore can you supply the information to narrow it down, also check the vacuum pipe to the unit as this can be the original problem as any loss in the air circuit will cause problems.

Steve.

Unfortunately for these all electric flaps and controllers there is no adaption so it either works or doesn’t. Save replacing the whole thing again which may or may not work, I am still unsure how to move forward.

5 hours ago, Avinash said:

Unfortunately for these all electric flaps and controllers there is no adaption so it either works or doesn’t. Save replacing the whole thing again which may or may not work, I am still unsure how to move forward.

Hi get a swirl flap delete kit, loads on the internet.

Steve.

Hi,

Any resolution on this problem? I have just had a swirl flap motor issue develop on my 2.0tdi. I am going to strip out the inlet manifold & clean all the build up out at the weekend. I'll get the codes cleared once cleaned & put back together.

I decided against stripping it myself as it involves the movement of the fuel rail. I will persuade my mechanic to strip it & refit it but I will clean it myself to save him that awful job & I can take more time & be a bit OCD. I will post my results. 

I have to laugh. I ended up doing it myself, I stripped it out cleaned it & put it back together. It was very satisfying & seemed resolved.

I found that the swirl flap was sticking closed because of the carbon & after cleaning half of it,it was totally free. I cleamed the rest of it & I thought job done, issue resolved. One of the reasons why I did it was because the car was booked for the passenger air bag safety recall & I didn't want any engine warning lights whilst it was with Bradford Audi, the main dealers. Low & behold no issues reported by the technicians other than a tire close to its legal limit, which I was aware of & a corroded centre exhaust clamp.

I picked up the keys & collected the car, started the engine & there it was, the damned yellow engine warning light. They kindly plugged it back in & there it was swirl flap issue. It was cleared & 3 days later it came back on again. I may have to take the inlet manifold off again & give it a clean with mr muscle oven cleaner & then power wash all the remaining carbon off. 

I'll report my results.

Update, I did notice after the first cleaning exercise that the arm of the motor became difficult to begin its movement to close the flap but thought nothing of it. It springs back perfectly on its own without sticking as intended every time, which was the original fault. One of the other known general faults on this part is when it springs back to the open position it can go too far & lock in position preventing the initial movement to close, thus throwing an engine warning light at start up when it goes through the checking procedure.

There's a video on YouTube showing how to fit it without removing the manifold but it's tricky & deceptively time consuming & of course you need specialy adapted, mini, ratchets to do it. As its only been 3 weeks since I took it off to do the original clean it's still fresh in my mind so I'll whip it off, apply some Mr muscle & rinse it, fit the modification & put it back on the car.

It'll have to wait until next weekend but I'll report further once complete.

Edited September 15, 20241 yr by FirstG

Update, 

Received the modification yesterday & fitted it. Completed the task & started the car to find engine management light was still on. 😱 I could hear the flaps being operated but the EM light stayed on.🤯😡

I gave up & went to bed!!

Started car this morning & lo & behold the EM light has gone out!!

Finally a result...

Hi could you post the YouTube video you was on about so I could have a look myself please?

And did the problem stay fixed?

It did stay fixed, right up to when it went. The car was running exactly as it should have when I part ex'd it but it developed an issue with the fuel tank shortly after or so the dealer told me. Great car whilst I had it & a bit of a looker in monza silver with its 19inch alloys. 

Did you manage to fix this problem, i have the same problem on an A5, i have put all new sensors on the car and a brand new manifold on it, the engine light went off for 4 days but its come back on again, every time i clear the fault code, it comes back a couple of days later, the type of manifold fitted to the car does not have the flap motor, so i cant see how it can be adapted.

11 hours ago, dakes2 said:

Did you manage to fix this problem, i have the same problem on an A5, i have put all new sensors on the car and a brand new manifold on it, the engine light went off for 4 days but its come back on again, every time i clear the fault code, it comes back a couple of days later, the type of manifold fitted to the car does not have the flap motor, so i cant see how it can be adapted.

Sorry, my only experience is with the 2011 A6 C6 2.0tdi 170 engine.

I have had this issue on a v6 both sides were causing issues one the arm was really loose and had fallen off also triggering a limit issue the other was hitting the limit too. I removed the arms warmed the ends up just a bit and squeezed them closed to make them a better fit on the balls. Refitted everything, light still on, then bought a set of limit brackets of Amazon the pressed kind https://www.amazon.co.uk/dp/B0DXFB8NLH?ref=ppx_pop_mob_ap_share

fitted those reset the DTC and so far it’s working great. 
I was prepared to have to bend them to create a new stop position but they just worked. Super cheap too