2019+ RS3 Runner Flaps Issue (DTC P2015)

[Gmirabal]

So I recently been getting a P2015 code for the intake manifold runner flaps for some time. The car runs just fine except on every cold start it goes into limp mode and limits RPMs to 4000rpms but when the code is cleared it doesn't come back until the next cold start. There are no rough idles, engine performance is perfectly fine after clearing the codes. I finally got the sensor replace but I still get the same P2015 code pop up. Only this time it pops up more frequently (even after clearing the code) until the car fully warms up (oil temp around 160°F-180°F). Again no rough idles or engine performance loss. I tried doing the "Adaptation of load shift flap bank 1" which is for the manifold flap sensor, but it keeps stopping/not initiating because of wrong diagnostic mode or marginal conditions not met. I switched the ODB modes in OBD11 (don't hate me its the only OBD diag tool I have currently!! ) but still get the same errors. No vacuum leaks or anything and the flaps actuate just fine. Im not sure what else to do here to get the car to recognize the new values. I did the whole "disconnect the battery for 5min" and still get the same P2015 code. Has anyone with an RS3 have this issue? Or did I just end up being very unlucky to get a faulty sensor? Also, see below for the videos of the flap arms actuating I took just before writing this post, and a screen capture of the values I was monitoring during my drive 2hrs ago. Any help is appreciated!!

Intake Runner Flaps Values:


Intake Runner Flaps Actuation:

[o1turbo30v]

You will need to pull the intake manifold and see where the flaps are. Make sure they move freely, if not, see if you can fix it, if you still can’t fix it, you will need a new intake manifold.

[Gmirabal]

You will need to pull the intake manifold and see where the flaps are. Make sure they move freely, if not, see if you can fix it, if you still can’t fix it, you will need a new intake manifold.

The manifold is split into an upper and lower parts. I know the flaps are located on the lower manifold based on the diagrams. I've checked the flaps, and they move just fine. This leads me to believe that the sensor hasn't been adapted to the car. Part of the procedure whenever you remove/replace the sensor is to readapt the sensor to the ECM/ECU. In my case, the car still throws the code (albeit for frequently) while its cold and then it's fine when it warms up. If the flaps where having trouble moving freely the code will show up no matter what the conditions are. Here's what the monitors show when the DTC shows up:

[kingbrd1]

I just had this same code. I had the lower intake replaced. 2 days later this code came back but without the CEL. Come to find out the water pump was leaking into the vacuum lines and had gummed them up.

King


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[Gmirabal]

I had the whole cooling system checked out October of last year because of a leak and they replaced everything that had a leak. Since then I haven't had any sort of coolant loss. Do you happen to know if the code would come back after clearing the code? In my case, this is only after a cold start. Once I start driving a bit the flap parameters are back to normal like in the Intake Runner Flap vid. I also checked the 1 vacuum hose that goes from the lower manifold to the actuator and the hose has no signs of rot, no signs of kinks, and the hose is securely attached in both ends.

[MikTip]

From factory repair manual:

After removing or replacing the Intake Manifold Runner Position
Sensor -G336- the adaptation values must be adjusted again.