The Volkswagen DTC P2015 error code, often described as “Intake Manifold Flap Position Sensor: Implausible Signal,” indicates a common issue within Volkswagen vehicles related to the intake manifold flap. This article provides a comprehensive guide to understanding and resolving the P2015 fault code, ensuring your VW runs smoothly and efficiently.
The P2015 code signals a problem with the butterfly valve actuator located in your intake manifold. Over time, the stop mechanism that limits the travel of the motor and butterfly valve assembly can wear down. This wear leads to the valve assembly no longer actuating correctly. The function of this flap assembly is crucial; it introduces swirl to the air entering the intake at lower RPMs, specifically idle, to enhance emissions. It’s also known to activate above 3000rpm, potentially for both emissions and performance optimization. The linkage connecting the motor to the flap assembly can also become prone to binding.
Initially, when faced with a P2015 error, the only solution offered was a complete intake manifold replacement.
Original Solutions and Why They Fall Short:
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Full Intake Manifold Replacement: The primary, albeit costly, fix was to replace the entire intake manifold. This included the motor and linkage, costing upwards of $300 for the part alone, not including labor.
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DIY Hack Fixes (Not Recommended): Many attempted DIY or “hack” fixes, often inspired by online videos, aimed at manipulating the linkage to prevent binding. These methods, including grinding and clip insertions, are generally not effective long-term solutions. They might offer temporary relief, but the underlying wear issue persists, leading to recurrence of the P2015 code. Avoid these temporary fixes as they do not address the root cause and can lead to further complications.
The Dieselgeek Engineered Solution: A Robust and Reliable Fix
Recognizing the shortcomings of existing solutions, Jim from Dieselgeek investigated the root cause of the P2015 error. His findings revealed that the wear of the original, inadequate stop mechanism allowed the flap assembly to over-travel and bind. To combat this, Dieselgeek developed a precision-engineered aluminum bracket. This bracket acts as a secondary, robust “hard stop,” preventing the over-travel that causes the P2015 error.
http://www.dieselgeek.com/P2015_Intake_Manifold_Flap_Position_Sensor_s/1900.htm
Benefits of the Dieselgeek Bracket:
- Effective and Long-lasting: This bracket provides a genuine, durable solution to the P2015 problem by addressing the wear issue directly.
- Easy Installation: The bracket is designed for straightforward installation, making it a DIY-friendly fix for most car owners.
- Cost-Effective: Compared to a full intake manifold replacement, the Dieselgeek bracket is significantly more affordable.
- Preventative Measure: Many Volkswagen owners have proactively installed this bracket to prevent the P2015 error from occurring in the future, given the common nature of this wear issue.
- Design Refinement: Dieselgeek has continually improved the bracket design based on customer feedback, resulting in an even more robust and user-friendly product.
Installation and Post-Installation:
Notably, the Dieselgeek bracket solution requires no software adjustments (VCDS/VAG-COM). After installing the bracket, the check engine light associated with the P2015 code should automatically extinguish after a few engine start-stop cycles or within a day.
Understanding the Original DIY Hack (For Informational Purposes Only – Not Recommended for Long-Term Fix)
For historical context and to understand the initial attempts to address the P2015 issue, the original article detailed a DIY “hack” using an E-clip. This method, while not recommended as a reliable long-term solution, highlights the problem area.
Original DIY Hack Steps (Not Recommended for Long-Term Use):
This method involves modifying the existing linkage to try and prevent binding. It’s important to reiterate that this is not a recommended long-term fix, and the Dieselgeek bracket is a far superior and reliable solution. This section is for informational purposes only to understand the early attempts at addressing P2015.
Tools and Parts (For DIY Hack – NOT RECOMMENDED):
- T30 Torx bit and short ratchet extension (1/4″ drive recommended).
- Screwdrivers for prying and poking.
- Needle-nose pliers for E-clip installation.
- E-clips (originally suggested size 7/16″, thinner clips potentially better).
DIY Hack Procedure (NOT RECOMMENDED):
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Remove Engine Cover.
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Disconnect Electrical Connector: (Note: Connector not disconnected in the image). It can be helpful to push the connector inward before pulling it out.
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Move Wire Harness: Relocate the wire harness for better access. The plastic connector on top of the oil filter cap can be detached using a screwdriver and a box-end wrench.
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Remove Torx Screws: Remove the three T30 Torx screws securing the motor. Be aware of spring force as screws are loosened.
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Unhook Spring: Detach the small spring, first from the manifold end, then from the motor end.
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Pop Off Linkage: Disconnect the linkage from the motor; it’s a press-fit connection.
The engine with the motor removed:
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Create Groove (Original Hack – NOT RECOMMENDED): Using a hacksaw blade (original method used a washer as a guide, also shown), carefully cut a groove approximately 3/4 of the way around the ball joint of the motor linkage.
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Test Fit E-clip (Original Hack – NOT RECOMMENDED): Test the E-clip in the groove.
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Reassemble: Reverse the disassembly process to reinstall the motor.
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Install E-clip (Challenge in Original Hack): With the engine running and linkage in the forward position (may require manual manipulation with a screwdriver initially), attempt to install the E-clip. This step was noted to be challenging in the original DIY hack.
VCDS Output Test (For Diagnostic Purposes):
Using VCDS (VAG-COM), you can perform an output test to actuate the intake manifold valve for diagnostic purposes.
- Select Control Module
- 01 – Engine
- Output Tests
- Select ‘Intake Manifold Valve’ from the menu
- Start
This test can help verify the valve’s functionality and identify binding issues before implementing any fixes.
Conclusion: Choose the Right Solution for P2015
While initial DIY hacks were attempted, they are not recommended for a lasting solution to the Volkswagen P2015 error code. The Dieselgeek aluminum bracket offers a proven, reliable, and cost-effective fix that directly addresses the root cause of the problem – the wear of the intake manifold flap stop mechanism. For a durable and efficient repair, the Dieselgeek bracket is the superior choice, ensuring your Volkswagen’s engine performance and emissions are optimized. Visit Dieselgeek’s website for more information and to purchase the recommended P2015 fix bracket.
