Intake valve stuck open/closed CEL. HELP?

A6 All/ S6 All
#1

Hey guys.
My 08 S6 just had the carbon cleaning done and while in there, the mechanic noticed my flaps on the intake were failing. One actually fell off and was sitting on the valves. Thank God it was caught!!!

Anyhow, I bought a new intake from ECS, got a good deal on a brand new one complete with new motors and bolt on ready. Had my repair Indy install the new intake and within 30 mi, the code pops up on the dash, showing intake valve stuck open and another code saying stuck closed.
The shop hooked up computer and verified that motors work as they should. No issues. Even went so far as swapping back to old valve motors and it did the same thing, but code back on the dash.

I did do research on here and most people who had issues, had them bc it was vacuum line related. On the 08, it is fully electronic. And of course, all electrical connections are solid.

I’ve spent nearly $1000 trying to diagnose what the hell is going on and why that light shows the dash. Am I missing something here??? Two shops have looked at it, no prevail. My last stop is the dealership where I fully expect to get raped.

Anyone had a similar issue? Can anyone help me?

#2

Ask ECS why/how they sold you an intake manifold when Audi corporate won’t send any out until the redesigned model/part is released (and shipped). A large number of us are currently waiting on orders as they’re on back order. They may give you your money back or a credit towards the redesigned part whenever it’s released.

#3

Also, in case I didn’t mention, you’re probably stuck with the CEL problem until the redesigned manifold comes out. Any of the originals will eventually have the same problem. With mine, I’m pretty much just stuck with the CEL coming on every other day or so until the new one comes.

#4

does the revised version have white or red plastic flaps, I can’t remember.

Also, I’m having the same issue; intake flap stuck closed. Although my issue is definitely a bad lower actuator. Upper still works fine.

Word has it the JHM tune disables the lower intake flaps (not the plastic changeover/upper flaps). Couldn’t get confirmation if it disables them completely or just cycles them open all the time. I’ll post the observed behavior once I load the tune and mount my catback.

#5

Well, I called ECS and they pretty much blew me off. I pushed a lil harder and the lady said she will have a manager get a hold of me. So… that sucks. And they have no idea that there is a redesign happening.

What I don’t understand is why did the damn thing work prior to the new intake? I mean, it’s gotta be something simple. But both shops have installed/uninstalled and show everything is proper.

My last stop will be the dealer. Unfortunately not til the beginnging of next month can I attack this again. If they fail, I might just have to suck it up and enjoy the lil CEL icon on the dash. Yay…

Thanks all. Stay tuned.

#6

Well the good news is your on the right forum.

ECS isnt going to be much help they are just a parts warehouse they dont have lots of inside information on specific cars and parts they history of doing the same thing to others as your experiencing. Sounds like they had the old intake manifold and luckly for them they were able to pawn it off on you.

Before you get too worried get the exact code that your car is getting and post it here. Not just the P code get the full code. If they have a vag com it should give them freeze frame data.

If you cant get the codes you can consider getting a vag com for yourself. I think you can get a personal version for like 250

With vag com you can get clear and log all the code data along with doing vag com mods to the car.

If you can at least get the codes we can help put you in the right direction

#7

The code that I can grab off my scanner shows P2006 and P2007. Which is valve stuck open/closed.

Right, ECS prolly just blowing out old inventory and found a good sucker to buy it. :frowning:
Oh well. Moving on, figure out how to solve this problem… Appreciate all the help guys!

Aj

#8

This might sound stupid but when my inlet manifold was refitted the connectors for the flap motors were refitted the wrong way round ::slight_smile:

#9

First thing I thought about as well. But after having both shops install/uninstall the manifold, no way both can screw t up. Not to mention, using the Audi Technician software, the tech can manipulate each motor. When it tells motor 1 to move, it moved. Same with 2. If wiring was switched, wrong motors would turn. So it’s def not that as well.

Appreciate the thoughts! Thanks!

#10

You can do a few things.

You can unplug the sensors to make sure the P code changes. That would be the first trick.

Then make sure that the flaps are actually moving. Its un likely but there is the chance that the flaps were put into the closed spot when the sensors were installed.

If you have the motor thats moving you can pull off the intake but keep the wires connected or just use jumper wires and actuate the motor to make sure that the flaps are moving and not just stuck as the code suggests. That has actually happened in the past where the flaps were damaged and they got stuck in the open position. The motor arms might still move but the flap arm is stripped