Vehicle

Volkswagon Golf 1KZ 2008, TSI BLG engine

Symptom:

Engine light on, and vehicle responsiveness a little slow

The Vehicle had been bought to the workshop to find out why the engine light is coming on, a quick scan revealed a 08213 error also known as p2105 fault intake manifold flap position sensor fault improbable.

Diagnostics:

Scanning the vehicle With The Bosch KTS system showed the p2105 fault and the location, the location of the unit is on the right hand side [picture 1] of the motor and the manifold flap is vacuum controlled via a vsv solenoid that moves the vacuum diaphragm to the desired position, if you remove the vacuum lines and test the vacuum with vac gauge to confirm vac diaphragm works, will save a lot of wasted time.

the VSV solenoid can be actuated by a scan tool and with the vacuum line installed you will see the flay move, it is common for the flap arm to vac diaphragm rod breaks off so check that too.

After that check the flap position sensor, you can back probe the sensor and check for 5v reference and earth, also check the potentiometer the same as a TPS switch, once you have found the sensor to be faulty, replace with a new unit. once you have done this you are not all in the clear the sensor now has to be a basic setting carried out so the computer knows the start position. other wise you may get another fault code, the procedure is listed below.

Diagnostics stage 2:

As the fault codes suggested that the intake flap position sensor was faulty, we changed the unit, we could not get it to fail in the workshop, and after a few test drives we identified that you can operate the intake flap system when you rev the engine to just over 3000 rpm (even when in Park/neutral), then the flap will go to 0%. so we tried this a few times with a vacuum gauge attached to the vacuum line (IN) just in case if boost pressure was forcing the diagram to push out. we this wasn’t the case but we did find that when the vacuum actuator rod didn’t move field 4 in basic setting now read ADP FAIL, this time the rod didn’t move we had the right vacuum and we heard a click from the vac solenoid but no vacuum to the diaphragm, we said BINGO, we found it we tapped the vacuum solenoid and then it operated. Clearly we had a sticking vacuum solenoid.
We ordered a new unit and test drove the vehicle again and again to confirm that the vehicle was now free from errors

Basic Settings:

NOTE: you cannot find live/current data for intake flap system but you can when you call up group 142 in basic setting to see what the sensor and actuator is doing during testing before carry out the basic setting adaptation.

Intake Manifold Runner
0%= off/down,  98% = on/up (refer to picture 1)

Prerequisites:

• Ignition ON
• Engine OFF
• System voltage at least 11.0 V.

[Select]
[01 – Engine]
[Basic Settings – 04]
Group 142
[Go!]
Activate the Basic Setting.
[ON/OFF/Next]
Wait until Field 4 shows “ADP. O.K.”.
[Done, Go Back]
[Close Controller, Go Back – 06]

• Switch Ignition OFF for at least 60 seconds.

Notes:

• The newer timing chain driven engines which were phased in during model year 2009 the engine may need to be running at idle. Common examples of these engine codes include CCTA, CBFA and CCTA.
• Never run Basic Settings with the IMRC motor linkage disconnected from the intake manifold. It may damage the new part.

Final Checks & Summary:

After carrying out basic setting and fault codes are cleared it is best to test drive the vehicle to confirm the issue is now gone it may take more that a small test drive to confirm the fault is eradicated.

Images

2008 VW golf intake flap sensor location PICTURE 1

2008 VW golf intake flap sensor removed

2008 VW golf intake flap VSV solenoid