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  1. #1
    Senior Member Four Rings Poodini's Avatar
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    Intake Manifold Replacement Questions..

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    Background: about 3-4 weeks back, was accelerating @ WOT around 105 mph when something Ďpoppedí, then was downhill fr there. Come to find the diaphragm housed in the PCV had torn, causing a significant air vacuum. Now I notice Iím leaking oil below wc is all but confirmed to be the rear main seal..🤬.
    Fixes: Tried ATP-G205 as well as Blue Devil liquid fixes and has actually slowed down the leak considerably!
    Also initially did the PCV diaphragm repair kit which seemed ok at 1st but then started to idle roughly and would throw multiple fault codes, most notably P0171 (fuel trim too lean), P2279 (leak in air intake system), & P2015 (intake manifold flapper sensor implausible)...
    Iíve replaced all 4 R8 coils, new plugs w/ correct gap for K04, cylinders look to be ok with no excessive crud or oil and replaced the PCV unit along with double checking intake hoses/connections. STILL throwing same codes.
    In terms of the IM, does P2015 typically signal its time to replace outright or can replacing the flapper sensor and installing new gaskets an option?
    Secondly, if I need to replace, whatís up with the disparity in price between a direct replacement ($550 via ECS/ OEM part # 06H-133-201-AT) vs the latest revised TSI IM ($140 via Deutsche Auto/ OEM part# 06J-133-201-BH). I realize theyíre differentiated as far as for the type of engine (TSI vs TFSI; transverse vs longitudinal). That said, visually, theyíre near identical and the BH is commonly used on VW platforms along with our A3 and TT models.

    Member Spawne32 confirmed that heís using the TSI/ BH version on his B8 with no significant modification needed.
    Has anyone else run into a similar dilemma and have any of you guys gone this alternate route?




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  2. #2
    Active Member Two Rings bb-tt's Avatar
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    Check for vacuum leak at the flapper actuator. Daughter's cc did same thing blew pvc and flapper bad at same time replaced the diaphragm in the pvc but still had vacuum leak, turned out to be leaking where the flapper actuator control arm connects to manifold. Plugged it and it was derivable until the manifold was replaced.
    Nothing to see here, keep moving!

  3. #3
    Senior Member Four Rings Poodini's Avatar
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    Quote Originally Posted by bb-tt View Post
    Check for vacuum leak at the flapper actuator. Daughter's cc did same thing blew pvc and flapper bad at same time replaced the diaphragm in the pvc but still had vacuum leak, turned out to be leaking where the flapper actuator control arm connects to manifold. Plugged it and it was derivable until the manifold was replaced.
    NOICE!
    What did you use to seal it with? Did you simply apply a layer around the juncture point?


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  4. #4
    Senior Member Four Rings Poodini's Avatar
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    I was planning to simply swap out the flapper Position Sensor. However..the brilliance of Audiís engineers are such that the way the IM/Sensor is positioned, only one of the two bolts can be readily accessed. Because the other is buttressed upright next to the alternator with zero accessibility.

    Conclusion, Iíll have to remove the 🤬 IM just to swap out that 🤬🤬 sensor❗️



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  5. #5
    Established Member Four Rings Spawne32's Avatar
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    replace it my man lol you wont have to deal with this nonsense afterwards, convert the bolts that hold it down to studs/nuts.

  6. #6
    Established Member Two Rings Quattro420's Avatar
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    It wonít be the sensor your just wasting your time, undo the vacuum line of it put gauge on it verify 30hg if you do then re-install it use ur vagcom mvb 143.3 quick throttle snap the value should go to 100% the plastic wears and the runner moves past the stop and thatís wat sets the dtc p2015, the new intake as updated arm and stops

  7. #7
    Active Member Two Rings bb-tt's Avatar
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    Quote Originally Posted by Poodini View Post
    NOICE!
    What did you use to seal it with? Did you simply apply a layer around the juncture point?


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    Used a rubber stopper
    Nothing to see here, keep moving!

  8. #8
    Senior Member Four Rings Poodini's Avatar
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    Great...
    So Iíve got a bum intake manifold AND a leaking rear main seal...

    Spawne32, I know youíve already confirmed this but, to be absolutely certain, I can use the TSI/-BH version despite all these online/EBay sellers telling me correct? If I recall, you made one minor adjustment but otherwise it bolts right up with no fitment issues correct? To clarify, my OEM IM is -AA with the vacuum system moving the flapper arm, not the previous motor type.


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  9. #9
    Senior Member Four Rings Poodini's Avatar
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    Quote Originally Posted by bb-tt View Post
    Used a rubber stopper
    You have a pic for reference?


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  10. #10
    Established Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by Poodini View Post
    Great...
    So Iíve got a bum intake manifold AND a leaking rear main seal...

    Spawne32, I know youíve already confirmed this but, to be absolutely certain, I can use the TSI/-BH version despite all these online/EBay sellers telling me correct? If I recall, you made one minor adjustment but otherwise it bolts right up with no fitment issues correct? To clarify, my OEM IM is -AA with the vacuum system moving the flapper arm, not the previous motor type.


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    Yes, you gotta understand that all TFSI engines are the same regardless of their orientation in the engine bay, the only thing that made this different physically from its longitudinal counterpart (other then the improvements in design) is the fact that on the VW's transverse layout, they move the purge solenoid (N80 valve) to the center of the manifold. Other then that, it bolts up in every way that matters identically to the OEM one for us. You won't have a single issue with it.

  11. #11
    Established Member Four Rings Spawne32's Avatar
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    I mean shit, I didn't even use a power door lock actuator from VW/Audi, I called porsche and ordered the part because it was 100 dollars cheaper from them. lol Identical part. Works exactly the same as the VW/Audi door lock actuator. You gotta play the part number game. I have one of those stepper motors for the HVAC system flap controls, its the mercedes part, identical to the VW/Audi part in every way....cheaper.

  12. #12
    Active Member Two Rings bb-tt's Avatar
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    I can check my old phone pm me an email if I can find a pic will send it. Hers was leaking right in center just plugged it like it was a bottle. Did you confirm that is where it was leaking?
    Nothing to see here, keep moving!

  13. #13
    Established Member Four Rings Spawne32's Avatar
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    Poodini I converted the intake manifold bolts to studs because two of my bolts when removed took some of the threads out of the head with it. When I saw the amount of thread that the bolt was actually catching, I saw a disaster waiting to happen. If you need the PN of the studs I used, I can find it for you.

  14. #14
    Senior Member Four Rings Poodini's Avatar
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    ^^
    Thanks Spawne32 & bb-tt for all the knowledge!
    I havenít confirmed thatís where Iím leaking although the steady droplets of oil on the ground most likely scream rear main seal so Iím betting thatís the culprit.
    And yes, the pn for the stud replacement would be great. Iím gonna attempt to do the install myself so any sage advice aside from watching Humble Mechanicís YouTube vid would def be welcomed!

    🤙🏼


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  15. #15
    Active Member Two Rings bb-tt's Avatar
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    Quote Originally Posted by Poodini View Post
    ^^
    Thanks Spawne32 & bb-tt for all the knowledge!
    I havenít confirmed thatís where Iím leaking although the steady droplets of oil on the ground most likely scream rear main seal so Iím betting thatís the culprit.


    🤙🏼


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    I was talking about the vacuum leak not the oil, initially after changing the pvc diaphragm it wasn't too bad but two days later her car was not drive-able the leak got so bad. Actually found it by accident put my hand on it while looking at something else trying to find the leak. Plugged it drove it for a day then let her take back to school in Tallahassee as the dealer there already had the intake in stock and it was covered under warranty (local dealer didn't have any appointments b4 she needed to return to school). Thank god the car broke while she was at home for once so didn't have to get ripped off by any of the shops up in Tallahassee.
    Nothing to see here, keep moving!

  16. #16
    Senior Member Four Rings Poodini's Avatar
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    Intake Manifold Replacement Questions..

    Quote Originally Posted by bb-tt View Post
    I was talking about the vacuum leak not the oil, initially after changing the pvc diaphragm it wasn't too bad but two days later her car was not drive-able the leak got so bad. Actually found it by accident put my hand on it while looking at something else trying to find the leak. Plugged it drove it for a day then let her take back to school in Tallahassee as the dealer there already had the intake in stock and it was covered under warranty (local dealer didn't have any appointments b4 she needed to return to school). Thank god the car broke while she was at home for once so didn't have to get ripped off by any of the shops up in Tallahassee.
    Apparently, the rear main seal is sort of the last stand down below as far as keeping oil/pressure at bay. Once it goes, not only will your floor and underbelly be doused in oil, it also allows pressurized air to escape, thus creating yet another source for an air leak which then can lead to all sorts of fun fault codes like P2015 and the rest of what Iím currently suffering through.
    It doesnít preclude the possibility of other air leak sources, but itís a contributor nonetheless.


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  17. #17
    Established Member Four Rings BeerBrent's Avatar
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    Quote Originally Posted by Spawne32 View Post
    I mean shit, I didn't even use a power door lock actuator from VW/Audi, I called porsche and ordered the part because it was 100 dollars cheaper from them. lol Identical part. Works exactly the same as the VW/Audi door lock actuator..
    Someone asked about this a few days ago.

    https://www.audizine.com/forum/showt...-Lock-Actuator
    I'm as cool as a cucumber in a bowl of hot sauce.

  18. #18
    Established Member Four Rings Spawne32's Avatar
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    Quote Originally Posted by BeerBrent View Post
    Someone asked about this a few days ago.

    https://www.audizine.com/forum/showt...-Lock-Actuator
    haha, ill have to find the part number

  19. #19
    Senior Member Four Rings Poodini's Avatar
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    2016 Subaru Outback 2.5 Limited
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    Decided to go with Spawne32ís suggestion and replace the OEM intake manifold with the most recently revised TSI #06J-133-201-BH. Despite our CAEB TFSIís not being included on the compatability list (transverse vs horizontal mount) itís essentially the same damn thing! As Spawne32 put it best, ďOur B8 TFSI platform got the short end of the development stick compared to that of VW/Audi TSIís... A lot more GTIís, Jettas, Passats, Tiguans, A3ís on the road compared to CAEB B8 A4/A5ís.Ē Confirmed itíll mate right up.


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