I have an O3 with the 2.0 245 engine. Done about 60k miles. Recently had the CEL come up and read off the following codes.

P2004 - Intake Manifold Runner Control Stuck Open

P2015 - Intake Manifold Runner Position Sensor/Switch Circuit Range/Performance

Now before I take the plunge and bankrupt myself on a whole new intake, has anyone had success troubleshooting on these two faults combined? I have found some stuff online about potentially the solenoid packing in, vacuum pipes for the solenoid being clogged or the sensor on the other side of the manifold being faulty. Open to ideas and experiences if anyone has any.

Have read that the plastic flaps get worn and the motor moves out with its limits hence the codes or it could be gummed up and needs cleaned. Have also read of a repair kit but not sure if its suitable for your engine. Did find this though

Darkside Developments

2.0 TDI Common Rail Swirl Flap Repair Kit (P2015) - Alumi...

Darkside Developments is a UK based diesel tuning company, specialising in VAG (VW, Audi, Seat and Skoda), BMW, MINI & Porsche Diesel Vehicles

At £26.40 Its worth a go if it fits your engine. Lot cheaper than a new unit

Alasdair

It was either the pipe going from the solenoid into the airbox (unlikely...), which I found unplugged or just something that fixed itself after a while (not the first time!).

I don't think it's possible to fit that limiter kit on the type of manifold I have in the 245. Whilst excessive play would explain the P2015 code (out of range) I don't see how this would explain P2004 (stuck open)... unless it got so far out of range that the flaps jammed open. Not come across anyone with such a problem though.

Edited 16 April16 Apr by mrodz

Maybe a dirty poor connection but if the pipe was disconnected it may have affected vacuum operation. Hope its one of those one of faults.

Alasdair

Bugger, light's come back and now doesn't want to go away :(

Maybe its needing a good clean and then reset?

Alasdair