Introduction: Audi VW Porsche 2.7 3.0 Swirl Flap Delete Kit

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Symptoms of Fault

Most common error codes:

  • P1018-001, "Upper limit exceeded"
  • P2008, "Intake Manifold Runner Control [ Bank 1 ]"
  • P2011, "Intake Manifold Runner Control [ Bank 2 ]"
  • P2015, “Intake Manifold Flap Position Sensor, Bank 1 - Implausible Signal”.
  • P2020, “Intake Manifold Flap Position Sensor, Bank 2 - Implausible Signal”.
  • P3135-001, "Lower limit exceeded"

Other error codes:

18447, 7859, 008213, 18452, 008224, 012597. P2004, P2005, P2006, P2007, P2008, P2009, P2010, P2011, P2012, P2013, P2014, P2016, P2017, P2018, P2019, P2021, P2022, P2023, P3135, P1018.

Other symptoms:

  • Malfunction Indicator Lamp (MIL)(K83) active.
  • Check engine light illuminated/flashing.
  • Rough idle.
  • Decreased fuel economy.
  • Reduced acceleration.
  • Increased fuel consumption.
  • Intake Manifold Flap Motor (V157) stuck/faulty.

The Fault

The actuator motor on the intake manifold over rotates; triggering fault codes

When the Engine Control Module (ECM) detects that the intake manifold is not functioning properly it will normally illuminate the check engine light. The intake manifold control valve/position sensor (which is typically located at one end of the intake manifold) provides values which help the vehicle’s Powertrain Control Module (PCM) control the amount of air being allowed into fuel injected engines at various RPMs. Using information from the sensor, The Intake Manifold Runner Control (IMRC) determines the position of the throttle body plates (commonly called flapper valves) and adjusts them to adapt to engine load variations. This ensures a correct mixture of fuel and air by limiting the amount of air that can pass though the engine. The P2015 code means that there is out of range data from the sensor.

The P2020 code is the fault code associated with Bank 2 for the same issue.If your vehicle has a P2015 and/or P2020 error it is very likely the main dealer will look to fix this issue with one or two completely new intake manifolds at significant cost. The fault however usually lies with the actuator motor on the intake manifold(s). There are two plastic limiting stops on the large cog within the motor. These are delicate and inevitably wear, allowing the motor to over rotate which triggers the P2015/P2020 error.

Our repair brackets can be installed very easily providing a solid limit for the actuator motors - curing these faults for the life of the vehicle. There is no need to replace the complete manifolds / actuator motors which would only fail again.

The Solution

Install our swirl flap kit to rememdy this issue and prevent future faults from occuring.

Our Swirl Flap Delete Kit comprises of every component you will need to rememdy this issue. Our Bearing and Pull Rod Blanks are made from 304 Stainless Steel to provide longevity of the part. The Pull Rod Blanks have a design unique to X8R Ltd, combined with the Viton O Ring and 2 OEM design fitting clasps to guarantee most secure fit.

The X8R kit comes complete with 2 OEM Intake Manifold Gaskets, which are recommended to be changed at the same time as fitment.

We recommend to fit both manifold kits at the same time as the two manifolds work together so it is preferable for them both to have the same limit.

Vehicles Affected

Volkswagen:

  • Touareg 2004-2014
  • Phaeton 2004-2013

Audi:

  • A4 2004-2013
  • A5 2007-2013
  • A6 2004-2012
  • A7 2004-2012
  • A8 2003-2013
  • Q5 2004-2014
  • Q7 2006-2014

Porsche:

  • Cayenne 2004-2012

Engine codes: CAMA, CAMB, CANA, CANB, CANC, CAND, CAPA, CARA, CASA, CASB, CASC, CASD, CATA, CCLA, CCMA, CCWA, CCWB, CDYA, CDYB, CDYC, CEXA, CGKA, CGKB.

Associated part numbers:

Manifold part numbers: 059129711AF, 059129711AG, 059129711AL, 059129711AR, 059129711BJ, 059129711BK, 059129711BP, 059129711BQ, 059129711BR, 059129711BS, 059129711CA, 059129711CG, 059129711CH, 059129711CK, 059129711CL, 059129711DC, 059129711T, 059129712AJ, 059129712AR,059129712BA, 059129712BC, 059129712BE, 059129712BF, 059129712BG, 059129712BH, 059129712BK, 059129712BL, 059129712BM, 059129712BN, 059129712BQ, 059129712BR, 059129712BS, 059129712BT, 059129712CA, 059129712CB, 059129712CK, 059129712E, 059129712H, 059129712N, 59129712P, 059129712T.

Actuator part numbers: 059129086J, 059129086L, 059129086G, 059129086K, 059129086D, 059129086M, 059129086E.

You Will Receive

12 x Bearing Blanks

2 x Pull Rod Blanks

2 x Viton O Rings

2 x Pull Rod Blank Clasps

2 X OEM Intake Manifold Gaskets

Step 1: Remove the Pull Rod

Firstly, remove the intake manifolds from the vehicle. Then remove the pull rod located on the side of the intake manifold, this can be pulled off by hand.

Step 2: Remove the Clasp

Using a small pick, remove the clasp that holds the pull rod lever in place.

Step 3: Remove the Intake Manifold Gasket

Using the same small pick, remove the intake manifold gasket.

Step 4: Remove the Pull Rod Lever

Using a small pair of pliers, remove the pull rod lever. There will be two gaskets that hold it in (a yellow/white gasket and a red gasket), remove both of these gaskets.

Step 5: Remove the Swirl Flaps

Using pliers, remove the swirl flaps. These may be quite difficult to remove as they're most likely caked in carbon build-up. Use enough force to remove them without damaging the intake manifold.

Step 6: Clean the Intake Manifold

Be sure to cover your work station with old rags or clean the manifold in an area you don't mind getting dirty.

Spray a suitable engine degreaser or brake & clutch cleaner inside the intake manifold and leave to work into the carbon. Wipe off with old rags/tissues until it is clean. This may take some time.

There are other methods of cleaning intake manifolds however this is the method we recommend.

Step 7: Install the Swirl Flap Blanks

Slot the 6 stainless steel swirl flap blanks into the holes either side of where the swirl flaps were. They will only slot in one way.

Step 8: Install the Intake Manifold Gasket

Press the intake manifold gasket in over the top of the swirl flap blanks and the rest of the intake manifold.

Step 9: Install the Pull Rod Black

Install the pull rod blank into the hole on the side of the manifold where the pull rod lever was located. Ensure the viton o ring is fitted onto the blank.

Install the fitting clasp over the top, ensuring that it has been slot into the two grooves and is securely in place.

This completes the repair. If you need any further guidance on this install or would like to purchase the parts shown please call us on +44 01843 446643 or email us at sales@x8r.co.uk. Please also check out our instruction guide on YouTube. www.x8r.co.uk Installation is carried out at installers risk, if unsure please contact us or a professional, X8R Ltd cannot be held responsible for any adverse result of installing this product or any injuries caused by install, if in doubt ask a professional. All images and texts are copyright X8R Ltd 2022.