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My turn for an intake manifold

cbenjes

Go Kart Newbie
Lately, I have noticed a very slight amount of hesitation/surging on acceleration when cold, so I scheduled a valve cleaning for over the holidays, figuring it was due at almost 90K miles.

Yesterday, I got my first Check Engine Light, and naturally I suspected intake manifold and/or misfires. Dead on. Fortunately, it's covered under the 120K mile/10 year extended warranty on that component. I'm having the dealer clean and scrape the valves while they are in there.

Note the intake fault logged at 102 km/hr (64 mph), most probably on I-95 at cruising speed. Interesting the misfires occurred 1052 km (653 miles) earlier than the intake fault. That's about 10 days earlier. Are they related? I assume a malfunctioning intake manifold could produce misfires.

Thursday,11,December,2014,16:24:26:24982
VCDS -- Windows Based VAG/VAS Emulator
VCDS Version: 14.10.0.0
Data version: 20141022

Mileage: 142592 km (88603 miles) Repair Order:

Address 01: Engine Labels: 06J-906-026-CCT.clb
Control Module Part Number: 1K0 907 115 AP HW: 1K0 907 115 AA
Component and/or Version: 2.0l R4/4V TFSI 0020
Software Coding: 0403010A18070160
Work Shop Code: WSC 01357 011 00200
VCID: 74EDDADF17DAB9817B3-8021
4 Faults Found:

008213 - Intake Manifold Flap Position Sensor (Bank 1)
P2015 - 000 - Implausible Signal - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100000
Fault Priority: 0
Fault Frequency: 20
Reset counter: 255
Mileage: 142384 km
Time Indication: 0
Date: 2049.14.12
Time: 05:30:30

Freeze Frame:
RPM: 2498 /min
Load: 30.2 %
Speed: 102.0 km/h
Temperature: 93.0°C
Temperature: 14.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 13.970 V

000768 - Random/Multiple Cylinder Misfire Detected
P0300 - 000 - - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 141332 km
Time Indication: 0
Date: 2049.14.00
Time: 09:46:37

Freeze Frame:
RPM: 1198 /min
Load: 33.3 %
Speed: 0.0 km/h
Temperature: 6.0°C
Temperature: 9.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 14.224 V

000772 - Cylinder 4
P0304 - 000 - Misfire Detected - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 141332 km
Time Indication: 0
Date: 2049.14.00
Time: 09:47:25

Freeze Frame:
RPM: 1212 /min
Load: 31.4 %
Speed: 0.0 km/h
Temperature: 18.0°C
Temperature: 8.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 14.478 V

000770 - Cylinder 2
P0302 - 000 - Misfire Detected - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 0
Fault Frequency: 1
Reset counter: 255
Mileage: 141332 km
Time Indication: 0
Date: 2049.14.00
Time: 09:47:25

Freeze Frame:
RPM: 1212 /min
Load: 31.4 %
Speed: 0.0 km/h
Temperature: 18.0°C
Temperature: 8.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 14.478 V


Readiness: 0000 0000
 

nvturbo

Go Kart Champion
Buy the manifold and replace it yourself. Plus, you can clean valve chambers.
 

vwgti2.0t

Go Kart Champion
Buy the manifold and replace it yourself. Plus, you can clean valve chambers.

The manifold is covered under warranty for 10 years/120k miles. The extra cost for the dealer to clean the valves is probably less than what it would cost to buy the manifold + the tools to clean the valves.

OP, yes, the manifold failing could cause misfires and so can carbon buildup. Let them replace the manifold and go from there if you still notice any misfires.
 
HPA holiday sale 2400 for Manifold and K04, HPA manifold + K04 + clean valves = happy driver.
 

sijray21

Go Kart Newbie
The manifold is covered under warranty for 10 years/120k miles. The extra cost for the dealer to clean the valves is probably less than what it would cost to buy the manifold + the tools to clean the valves.

OP, yes, the manifold failing could cause misfires and so can carbon buildup. Let them replace the manifold and go from there if you still notice any misfires.

this.

I ended up cleaning my ports, put it all back together, ran great, but then I got the p2015 error... talked to the dealer and my car was covered under warranty for the manifold replacement. they offered to clean it for $250 or something like that, but since I JUST did it, I opted not to have them clean them again. the tools and time to pull the manifold (if you've never done it before) are worth much more than $250. hell, the kit to properly remove and install the fuel injectors & seals is $200 by itself (if you're doing it properly, that is).
 

vwgti2.0t

Go Kart Champion
HPA holiday sale 2400 for Manifold and K04, HPA manifold + K04 + clean valves = happy driver.

For a manifold that looks like crap inside, doesn't gain any power over OEM, and that nobody has a tune for to code out the flappers? Yea..pass.

this.

I ended up cleaning my ports, put it all back together, ran great, but then I got the p2015 error... talked to the dealer and my car was covered under warranty for the manifold replacement. they offered to clean it for $250 or something like that, but since I JUST did it, I opted not to have them clean them again. the tools and time to pull the manifold (if you've never done it before) are worth much more than $250. hell, the kit to properly remove and install the fuel injectors & seals is $200 by itself (if you're doing it properly, that is).

Oh yea, removing the manifold is cake. I've done it more than a handful of times. I was just saying the manifold (~150) plus cleaner and brushes and all of that.

The first time I did mine, I replaced the seals on the injectors that came out without using the VW tool and everything was fine. I just used some picks and things. I've done it twice by just sticking the injector right back in the hole without replacing any seals and have had no issues that way either. I really don't think it's nessesary to replace them. Well, actually, I've proved that you don't have to. :thumbsup:
 
For a manifold that looks like crap inside, doesn't gain any power over OEM, and that nobody has a tune for to code out the flappers? Yea..pass.



Oh yea, removing the manifold is cake. I've done it more than a handful of times. I was just saying the manifold (~150) plus cleaner and brushes and all of that.

The first time I did mine, I replaced the seals on the injectors that came out without using the VW tool and everything was fine. I just used some picks and things. I've done it twice by just sticking the injector right back in the hole without replacing any seals and have had no issues that way either. I really don't think it's nessesary to replace them. Well, actually, I've proved that you don't have to. :thumbsup:

I believe HPA has a tune for it.
At the price of 2400, its still cheaper than the APR kit.
 

vwgti2.0t

Go Kart Champion
I believe HPA has a tune for it.
At the price of 2400, its still cheaper than the APR kit.
They said they were working on a tune for it, but to my knowledge it isn't complete. It may be cheaper, but it includes no tune. And nobody makes a tune for the manifold so it's pretty much a paperweight.

If you wanted cheap, I believe the CTS kit is at or under 2 grand before the tune.
 

cbenjes

Go Kart Newbie
HPA holiday sale 2400 for Manifold and K04, HPA manifold + K04 + clean valves = happy driver.

Yeah, but I'd also need a stronger clutch, too, so add another grand. Then I'd probably spin the tread off the tires every 6 months. I think I'll stick with Stage 1 and have the dealer replace the manifold and clean the valves.

I'll report if there is a noticeable difference in power when I get it back....
 

cbenjes

Go Kart Newbie
Cook VW did an excellent job replacing the intake manifold and cleaning the valves. Acceleration is much smoother. The car runs like new again!

At 89,000 miles, mostly run at highway speeds using primarily BP or Shell V-Power 93 octane, here's what the valves looked like before and after:

dirty valves 1.jpg

dirty valves 2.jpg

dirty valves 3.jpg

clean vavles.jpg
 

SmokeyGTI

Ready to race!
Having my intake manifold replaced as we speak. Also having the valves cleaned per dealer suggestion since there's likely a lot of carbon build up. Only thing I'll have to pay for is valve cleaning fortunately. Hope it helps as the cars felt a little sluggish especially with the colder New England temperatures setting in!


Sent from my Sprint iPhone using Tapatalk
 

rasetsu

Ready to race!
I'm already on my second intake manifold. First one was replaced under warranty at about 15K miles after I mentioned a few rough starts and idles. No CEL code then. Got the code several weeks ago at 35K miles and I cleared it with my P3 gauge to see if it comes back and it came back yesterday. Will be calling the dealer in a couple of weeks when I have time. Car feels the same but I do notice that my boost pressure is down one PSI at idle every now and then. Usually sits at 21 or so in park and now fluctuates down to 20 psi occasionally with AC off. Hopefully the dealer won't give me push back since I'm stage 1 with Carbonio intake now.

UPDATE:
Autonation VW in Richardson, TX performed the manifold replacement under extended warranty. They did not say anything about my tune or intake. I asked them to perform the carbon cleaning while they had the manifold off. Tech said it was worth cleaning, but not horribly bad yet. My out of pocket was around $300 for the carbon cleaning.
 
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