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  1. #1
    Veteran Member Four Rings Poodini's Avatar
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    HELP NEEDED re: Intake Manifold Flap Sensor Failure

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    So, I’ve been consistently throwing fault code P2015 (implausible signal) from the intake manifold flap sensor (2968)
    as well as the car running too lean.
    I recently changed the PCV diaphragm and is holding up fine. I tried doing a carb spray leak test but couldn’t isolate anything very well.
    Since then I’ve also discovered a rear main seal leak which SUCKS! The cost to install a new one is ridiculous given the tranny needs to be pulled off in order to access it. I just tried a bottle of ATP-G205 reseal with little effect. I just changed the oil so decided to give Blue Devil rear main resealer a shot. The amount of oil leaking has reduced somewhat but far from out of the woods.
    Regarding the IM Flap Sensor, based on its position, it looks like the only way to access one of 2 bolts is to remove the manifold!
    Question is, has anyone replaced this sensor and, is removing the manifold the only means by which to do so.

    Any/all help appreciated as always!




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  2. #2
    Veteran Member Four Rings LionKing's Avatar
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    Removing the manifold is the only way to do so. Also, during this stage, there is a flapper delete sold by ECS some people do as well. And if you're close to MD, I replaced my rear main in a night

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    "Exhaust Gases go in the turbocharger and spin it, witchcraft happens, and you go faster"

  3. #3
    Veteran Member Four Rings Poodini's Avatar
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    Quote Originally Posted by LionKing View Post
    Removing the manifold is the only way to do so. Also, during this stage, there is a flapper delete sold by ECS some people do as well. And if you're close to MD, I replaced my rear main in a night

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    I was afraid someone was gonna say that...UGHHH..

    I’m out in NorCal otherwise I’d def hit you up!

    Appreciate it bruh!


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  4. #4
    Veteran Member Four Rings
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    Removing the manifold is really not that bad. Humble Mechanic has a great how-to video on YouTube. Make sure to have some good snips for the vacuum line clamps, and some replacement vacuum line just in case.

  5. #5
    Veteran Member Four Rings bb-tt's Avatar
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    2017 TTS, 2011 Avant, 82 c3 vette, 2002 TT (sold), 2010 CC (sold), 2013 Jetta, 2018 Q7, 2019 Tiguan
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    Local Audi dealer gave me a bad manifold to make an adapter for valve cleaning, think flap motor/actuator and sensor are good, manifold just had some physical damage I can send sensor to you if you want, if you are going to try to change it instead of the whole manifold.
    Last edited by bb-tt; 09-02-2018 at 06:32 PM.
    2011 A4 Avant S-line Prestige
    Nothing to see here, keep moving!
    WPT+

  6. #6
    Veteran Member Four Rings Spawne32's Avatar
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    order the FWD manifold, fixes all these problems

  7. #7
    Veteran Member Four Rings Poodini's Avatar
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    Quote Originally Posted by Spawne32 View Post
    order the FWD manifold, fixes all these problems
    No fitment issues? Utilizes the same solenoid + Flap Position Sensor? Off hand, you know what the part number ends with? Like AA or AT for example..
    Anyone else running with this suggestion?


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  8. #8
    Veteran Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by Poodini View Post
    No fitment issues? Utilizes the same solenoid + Flap Position Sensor? Off hand, you know what the part number ends with? Like AA or AT for example..
    Anyone else running with this suggestion?


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    Literally had a guy PM me this afternoon about this very same thing, only thing different that makes a difference, is the purge solenoid mount is in the center of the manifold.... 06J133201BH


  9. #9
    Veteran Member Four Rings bb-tt's Avatar
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    Quote Originally Posted by Spawne32 View Post
    order the FWD manifold, fixes all these problems
    How does it fix these issues? Fwiw my daughter's fwd cc just had intake manifold replaced under extended warranty because it was failing the same as the quatro fails.
    2011 A4 Avant S-line Prestige
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  10. #10
    Veteran Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by bb-tt View Post
    How does it fix these issues? Fwiw my daughter's fwd cc just had intake manifold replaced under extended warranty because it was failing the same as the quatro fails.

  11. #11
    Veteran Member Four Rings Poodini's Avatar
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    HELP NEEDED re: Intake Manifold Flap Sensor Failure

    Guys, help me out with this TSI vs TSFI compatibility confusion.. I’ll use ECS as a reference everyone here knows. So, when you do a product search based on your vehicle ( ex: 2010 A4 B8 Quattro 2.0 TSFI), it then populates any further searches based on said vehicle comparability.

    It appears ECS & others have made a clear distinction that TSI parts are NOT compatible with TFSI cars. We all know that isn’t always the case. Which brings me to these intake manifolds. On the one hand, you have those designated for TSI applications (A3, Q3, VW CC, EOS, etc). The most updated version pictured below clearly states that it won’t fit with a B8 A4, both fwd & Quattro. To add insult to injury, it’s listed at only $175??!!


    On the other hand, when searched under my correct B8 A4 2.0t Quattro, here’s my option(s)..
    And can someone explain to me how is it that the version designated for our cars cost nearly 3 times as much!! This is akin to highway robbery!!

    Anyways, you get my drift. So, if any of you wish to shed some light here by outlining similarities & differences as well as comparability, I’M ALL EARS!


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    Last edited by Poodini; 09-02-2018 at 11:31 PM.

  12. #12
    Veteran Member Four Rings Poodini's Avatar
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    Quote Originally Posted by bb-tt View Post
    Local Audi dealer gave me a bad manifold to make an adapter for valve cleaning, think flap motor/actuator and sensor are good, manifold just had some physical damage I can send sensor to you if you want, if you are going to try to change it instead of the whole manifold.
    Much appreciated bro! I have the replacement sensor on-hand already. Your kind gesture duly noted.
    I’m still pissed that the only way to swap this F’ing sensor is to pull the manifold off! 🤬


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  13. #13
    Veteran Member Four Rings Poodini's Avatar
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    I mean, call me crazy but aren’t those two manifolds near identical??!!


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  14. #14
    Veteran Member Four Rings Spawne32's Avatar
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    dude i have it on my car lol the part cross reference just says it doesn't fit because its not for our car

  15. #15
    Veteran Member Four Rings Poodini's Avatar
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    Quote Originally Posted by Spawne32 View Post
    dude i have it on my car lol the part cross reference just says it doesn't fit because its not for our car
    So that latest version TSI intake for $175 WILL work then?!!!




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  16. #16
    Veteran Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by Poodini View Post
    So that latest version TSI intake for $175 WILL work then?!!!




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    Absolutely, have had it on my car for a year now. The part numbers game in this industry is disgusting. They use different PN's for the same parts all the time and just charge more depending on the brand they are sold under. Only difference with the FWD manifold is the purge solenoid location is in the center, you can see it in my pic, you zip tie the damn purge solenoid and throw your cover back on and never know the difference. You may notice the runner flap design is a little different but it doesn't impact the car any. That has something to do with how they adjust part throttle airflow to be a little different on the VW models. I saw an actual improvement in MPG in part throttle conditions because I believe it changed the amount of incoming air to be slightly less below a certain RPM.

  17. #17
    Veteran Member Four Rings Poodini's Avatar
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    HELP NEEDED re: Intake Manifold Flap Sensor Failure

    Spawne32 coming thru Big Time!

    I had a feeling that was the case but I needed confirmation from someone actually using this revised version on their B8/8.5 TFSI!

    So no other alterations or change in tune other than what you pointed out correct? Did you install it yourself? I’m assuming since the manifold was swapped that you had to do the injector kits as well no?


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  18. #18
    Veteran Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by Poodini View Post
    Spawne32 coming thru Big Time!

    I had a feeling that was the case but I needed confirmation from someone actually using this revised version on their B8/8.5 TFSI!

    So no other alterations or change in tune other than what you pointed out correct? Did you install it yourself? I’m assuming since the manifold was swapped that you had to do the injector kits as well no?


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    My injectors never came out of the head when I took my manifold off, but I have the kit and the tool to install the seals ive been trying to sell for a year now. lol No changes to the tune, my tune was already positive on the fuel trims at low rpms so it actually brought them down by 1-2% closer to 0.

  19. #19
    Veteran Member Four Rings Poodini's Avatar
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    Quote Originally Posted by Spawne32 View Post
    My injectors never came out of the head when I took my manifold off, but I have the kit and the tool to install the seals ive been trying to sell for a year now. lol No changes to the tune, my tune was already positive on the fuel trims at low rpms so it actually brought them down by 1-2% closer to 0.
    There it is..




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  20. #20
    Veteran Member Four Rings Spawne32's Avatar
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    If i can figure out this hybrid K04 turbo nonsense, I think i've found a way for us to make our own hybrid turbos sourcing parts from multiple locations for about 1000-1200 bucks.

  21. #21
    Veteran Member Four Rings
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    The Audi "TFSI" 2.0T in the B8 platform is a TSI motor. The B7 used the FSI motor.
    ECS is anymore only selling the metal manifold used on the B8.5 CPMx motors. It's stupid expensive, but it seems Audi is no longer supplying the plastic manifold for the CAEB motor.
    But you can still find the AN rev elsewhere. https://www.europaparts.com/intake-m...h133201an.html Definitely gone up since I bought mine, but it's still cheaper than the metal.
    2009 A4 Avant 2.0T quattro Prestige, 275k miles

  22. #22
    Veteran Member Four Rings Poodini's Avatar
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    Quote Originally Posted by Spawne32 View Post
    If i can figure out this hybrid K04 turbo nonsense, I think i've found a way for us to make our own hybrid turbos sourcing parts from multiple locations for about 1000-1200 bucks.
    Why go through all the trouble when you can get a JHM, HPA, or Frankenturbo for a little more?


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  23. #23
    Veteran Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by Poodini View Post
    Why go through all the trouble when you can get a JHM, HPA, or Frankenturbo for a little more?


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    I was looking for a specific wheel combination and I found what I was looking for. ;) 7+7 billet compressor wheel and 9 blade mixed flow for a S3. I just need to be able to swap the CHRA's.

  24. #24
    Veteran Member Four Rings Poodini's Avatar
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    Got it...

    Back to this P2015, it seems that conventional wisdom would be to replace the entire intake manifold vs just swapping out the flap position sensor. From online retailers to YouTube mechanics like Humble tend to echo this. I’m assuming they’re basing it on time/wear’n’tear on these plastic manifolds. Guess I’ll go ahead and order up the latest revision ...-BH as well as a new PCV breather hose as I’ve read those tend to crack and lead to vacuum leaks.

    Thanks everyone, esp Spawne32 for the knowledge!


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  25. #25
    Veteran Member Four Rings Poodini's Avatar
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    Almost forgot..

    What’s the 411 with these Flapper delete kits? I understand what it does but what are some potential negative affects doing this may have?


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  26. #26
    Veteran Member Four Rings old guy's Avatar
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    From the APR website:

    Simply removing the runner flaps can cause adverse running conditions during cold start. However through proper ECU recalibrations, APR’s able to provide RFD™ specific software for all APR software stages to eliminate this harsh running condition. This is a free upgrade for all existing APR ECU Upgrade customers with this purchase.

    Power Gains: At Stage 3 airflow levels, typical results showed a decrease in turbocharger lag, more than a 10 ft-lbs of torque gain and more than a 10 horsepower gain.

    Recommendations: This modification is recommended for APR Stage 2+ and higher modified engines.
    '03 A4 5-MT Motoza tuned Frankenturbo F21L With full supporting mods. Sold (and missed dearly).
    '13 A5 6-MT Needs more Fun Stuff: Neuspeed PM / 3.0 TDI Intercooler / H&R OE Sport Springs / Bilstein B8 Shocks / TyrolSport Brake Stiffeners / ECS Short Shifter / S5 Side Skirts / RS Grille

  27. #27
    Veteran Member Four Rings Spawne32's Avatar
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    just gotta be able to tune the codes out

  28. #28
    Veteran Member Four Rings Poodini's Avatar
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    HELP NEEDED re: Intake Manifold Flap Sensor Failure

    ..
    Since I’m running APR’s K04 file, wouldn’t it make sense to simply remove runners off the existing manifold, install the delete kit, then have my local APR dealer reflash with corrected tune?
    My understanding is, if you’re already using one of their ECU files (Stage 1 on), the flapper delete correction is free. Are they still honoring this?
    Guess I’ll call APR to find out more. Since this kit is,in essence a work-around the flapper assembly, the manifold therefore becomes little more than an air channel. So why go through the trouble of developing these flaps and associated sensor/solenoid to begin with? If it’s function is to restrict air flow, these auto engineers must have found this to be of some value, otherwise why bother?
    I’ll offer my apologies now for my naïveté regarding this concept. I’m sure I’m oversimplifying this.


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  29. #29
    Veteran Member Four Rings old guy's Avatar
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    Their purpose is to increase the turbulence of the air entering the cylinders at low engine speeds for a more complete fuel-air mix. Once the airflow is high enough the flaps fully open. In an OEM configuration, removing the restriction may make the engine run a bit rougher at low speeds.
    '03 A4 5-MT Motoza tuned Frankenturbo F21L With full supporting mods. Sold (and missed dearly).
    '13 A5 6-MT Needs more Fun Stuff: Neuspeed PM / 3.0 TDI Intercooler / H&R OE Sport Springs / Bilstein B8 Shocks / TyrolSport Brake Stiffeners / ECS Short Shifter / S5 Side Skirts / RS Grille

  30. #30
    Veteran Member Four Rings Poodini's Avatar
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    ^^
    Given this, the tune would therefore need to adjust the low end threshold of acceptable fuel to air ratio would be my guess. By negating the manifold’s ability to create more air turbulence, I’m still unclear as to how an adjustment in the tune alone can compensate for this.
    At any rate, for those of you who’ve taken the plunge and done this, your comments are definitely welcomed.
    Otherwise it may just be the safer & easier bet to go with the revised manifold and call it a day.


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  31. #31
    Veteran Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by Poodini View Post
    ^^
    Given this, the tune would therefore need to adjust the low end threshold of acceptable fuel to air ratio would be my guess. By negating the manifold’s ability to create more air turbulence, I’m still unclear as to how an adjustment in the tune alone can compensate for this.
    At any rate, for those of you who’ve taken the plunge and done this, your comments are definitely welcomed.
    Otherwise it may just be the safer & easier bet to go with the revised manifold and call it a day.


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    That's the whole reason I didn't just buy an IE manifold, because eurodyne doesn't have a tune I can use for it. It's mainly a throttle response thing at low RPM's, same reason nobody uses the Grams 70mm throttle body I posted months ago, nobody has a way to tune for it. It's a sad situation because we have plenty of mods available to us that can get us to 350 to the wheels but very few people who are able to tune for them.

  32. #32
    Veteran Member Four Rings Poodini's Avatar
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    ^^
    So, unless you’re already running an APR tune, no one else has really come up with a readily available file? It just doesn’t make sense. Why would these aftermarket guys offer these flapper delete kits but not have the supporting software needed to compensate for the cold start issue?..




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  33. #33
    Veteran Member Four Rings Spawne32's Avatar
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    If the platform didn't die immediately after the car was released, I think we probably would have seen better tuning support. Hptuners is just now starting to get into audi/vw but so far I haven't been able to get it to read an 09 yet. They are offering ZF 8 speed trans tuning as well, but no 6spd. Like I told jake over at JHM, come up with better tuning options for us poor saps here in the 09-12 range and I will gladly throw my money at you.

  34. #34
    Veteran Member Four Rings Poodini's Avatar
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    In my case I’m running APR’s K04 file with JHM’s K04-R turbo. The combo has been fine overall but their file is somewhat limiting, almost to a fault. Granted they were writing the file using JHM’s turbo but you’ld think they’re close enough that it shouldn’t be that big of a disparity.


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  35. #35
    Veteran Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by Poodini View Post
    In my case I’m running APR’s K04 file with JHM’s K04-R turbo. The combo has been fine overall but their file is somewhat limiting, almost to a fault. Granted they were writing the file using JHM’s turbo but you’ld think they’re close enough that it shouldn’t be that big of a disparity.


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    I don't think its a limitation of sorts, just that you can't do your own edits. I don't know if they will charge you extra to do the flapper delete. I still have the K03 on my car and I run the F23 eurodyne file because it provides 22psi of boost, the max that the map sensor can allow, far as I understand it. Difference is ive been able to make my own changes to get it to work better on my application, and I will continue to do so as I make more changes. If we had a more complete tuning program this wouldn't even be an issue.

  36. #36
    Veteran Member Four Rings Poodini's Avatar
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    The way I read it is, if you purchase the flapper delete kit and are currently APR tuned, regardless of Stage, that the correction file is free. Now, whether an authorized APR dealer charges you a flashing fee, that’s another enchilada. In my experience the shop still charges you for the labor to link up and upload/test the file.


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  37. #37
    Veteran Member Four Rings Spawne32's Avatar
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    Do some research on it, im curious to see what they can do for you.

  38. #38
    Veteran Member Four Rings Poodini's Avatar
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    Roger that..


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  39. #39
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    Quote Originally Posted by Poodini View Post
    Guys, help me out with this TSI vs TSFI compatibility confusion.. I’ll use ECS as a reference everyone here knows. So, when you do a product search based on your vehicle ( ex: 2010 A4 B8 Quattro 2.0 TSFI), it then populates any further searches based on said vehicle comparability.

    It appears ECS & others have made a clear distinction that TSI parts are NOT compatible with TFSI cars. We all know that isn’t always the case. Which brings me to these intake manifolds. On the one hand, you have those designated for TSI applications (A3, Q3, VW CC, EOS, etc). The most updated version pictured below clearly states that it won’t fit with a B8 A4, both fwd & Quattro. To add insult to injury, it’s listed at only $175??!!


    On the other hand, when searched under my correct B8 A4 2.0t Quattro, here’s my option(s)..
    And can someone explain to me how is it that the version designated for our cars cost nearly 3 times as much!! This is akin to highway robbery!!

    Anyways, you get my drift. So, if any of you wish to shed some light here by outlining similarities & differences as well as comparability, I’M ALL EARS!


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    I have very similar problem, but with worse price difference. I am tired of it and want opinions.

    I live in EU and have a 1.8TFSI A4 B8 2009 non-quattro. The 1.8 TFSI (mine is CDHB) is basically a spec-ed down version of the 2.0TFSI that you guys have in USA. So 1 year ago I got the Implausible signal error from the position sensor and bad fuel Trim error (because of vacuum leak) at the same time. I visited several diagnostic places plus the dealership and all said - broken intake manifold. They all showed me the Humble Mechanic video, there it is leaking around the flaps control lever. The dealership price was (converted to USD) ~900 dollars for manifold and work. They sell the entire KIT only. I decided to check by myself and the help of a friend mechanic. We disassembled the manifold and saw that it has a different lever than the one suspected for leaking (in the humble mechanic video is black mine is white). There was no play and no air leak. The manifold seemed pretty clean from oil and stuff, we cleaned it. We removed the sensor and saw that the green plastic thing with the rectangular hole for the flaps shaft is worn and decided to replace the sensor (with one new from ebay that had the audi logo and appeared that is for my car and a lot other models), so that there is no play on the sensor end. So we did that and AFAIRemeber the error disappeared but the vacuum leak error stayed. So after another long story it appeared that the vacuum leak is from the PCV. Changed the PCV and the vacuum leak error was gone and the MIL too.
    But after some time I noticed that when cold-started (was winter here) there is a slight roughness in the car and goes away after a minute. So I did a diagnostic and a new Flap Position sensor error was there - Stuck Open. So we knew the drill- removed the manifold bough a new cheaper sensor with the same number but no Audi logo (from amazon) and replaced it again. No change the error was still there. We disassembled everything again and started moving the flaps manually while monitoring the sensor readings with VAS. the flaps were moving 0-100% while the readings 43-82%. We decided to remove the sensor and see if there is a play in the rectangular hole- there wasn't. We moved the sensor manually (not the flaps) and the readings in VAS were 0-100%. Then we noticed that the sensor has about >90 degrees of travel, while the flaps shaft and the flaps have ~45 degrees of travel by design. So we decided that either the sensor had to be adapted or we got a wrong sensor both times. Unfortunately, we threw the original sensor away and I cannot compare the last letters behind the number. We might got those wrong, maybe the sensor is for the updated manifold. We found intake position flaps adaptation prompt in VAS for this sensor but it just doesn't work. It reads the Required 0% Real 42% values and says that it cannot continue. I asked the dealership and they said that there is no such adaptation- you have to replace everything. I am very skeptical that such small thing should require entire manifold. So as I live in EU some parts have different numbers and I cannot find aftermarket manifold with the same number as mine, anywhere. The dealership don't give me their numbers, but even if they did their number is for the KIT.
    The manifold looks just as the one you have on the photo and as the one all US A4 B8 TFSI ones have. I have a way to get one from USA and pay some import fees and still will be a lot cheaper than 700$ here.

    Could someone share some thoughts? I can later provide pictures and numbers. There is a video I made about the travel difference https://www.youtube.com/watch?v=Re7b...dIdv9Cqgr2Bao8 (Turn on the English subtitles )
    Can you share your 2.0TFSI manifold and sensor part numbers? I really want to risk with the 174$ TSI version, that is available everywhere in USA, just because I hate how the dealership is robbing us. According to my mechanic 2.0 and 1.8tfsi versions have the same design but different codes and part numbers.
    Last edited by kosio86; 03-20-2019 at 06:32 AM.

  40. #40
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    In the case of my replacing my OEM TFSI manifold with the updated TSI one, they’re essentially the same. Only difference is one is for longitudinal vs the other is transverse in terms of the mounting position.
    Here’s an explanation of the difference between TSI vs TFSI:

    “TSI is Turbo Stratified injection i.e direct injection in a gasoline engine(petrol) with forced induction(turbo charger). ... Volkswagen uses the TSI acronym for the engine having the concept I stated previously. while. AUDI a subsidiary of Volkswagen uses the acronym TFSI for the same concept.”

    In any event, I went ahead with the much cheaper, updated version used for VW/TSI and had my mechanic install it w/o telling him just to see if he ran into any install issues. INSTALLED W/O A HITCH OR NEED FOR ANY ALTERATION!

    I too had a PCV leak and subsequent MAF sensor shitting the bed, both replaced along with new injectors and she’s running like a champ!

    I would think in your case, the question would be, is there any structural changes between the 1.8t & 2.0t.

    Best of luck


    Sent from my iPhone using Tapatalk

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