2008/9 S5 "p2004 intake runner stuck open" ERROR

[stefdds]

As one of my previous posts mentioned, I'm going to be changing one of intake runner sensors G336 (potentiometer) ; upper and lower actuators are functioning ok per (Output tests - 03). The Audi manual mentions a Adaptation once renewed via a audi diagnostic tool. I noticed on the Adaptations -10 tab , under Advanced functions, it opens a window that looks like measuring blocks and it asks for a group number in the first block.
Will I be able to adapt this sensor? If so, what info will I need to enter into that block. ?
Please note , the "short to ground" on the interlock is created by me ; it is not part of the p2004 fault. Thank you.


my apologies for the incorrect format of the scan, I'll change / edit soon. Thanks.

 

[stefdds]

Monday,14,December,2020,10:41:08:19210
VCDS -- Windows Based VAG/VAS Emulator Running on Windows 7 x64
VCDS Version: 20.12.0.1 (x64)  HEX-NET CB: 0.4529.4
Data version: 20201125 DS322.1
www.Ross-Tech.com

Dealer/Shop Name: Stefan Czechorski DDS
Workshop Code: 123 12345 123456

VIN: WAURV78T99A015469   License Plate: SFN***
Mileage: 199580km-124013mi   Repair Order: 12142020



--------------------------------------------------------------------------------
--------------------------------------------------------------------------------


Chassis Type: 8T-AU48 (8T0)
Scan: 01 03 05 06 07 08 09 0E 0F 15 16 17 19 1E 36 37 42 46 47 52
          53 55 56 65 67 77

VIN: WAURV78T99A015469   Mileage: 199580km-124013miles

01-Engine -- Status: Malfunction 1010
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
05-Acc/Start Auth. -- Status: Malfunction 0010
06-Seat Mem. Pass -- Status: Malfunction 0010
07-Control Head -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: Malfunction 0010
0E-Media Player 1 -- Status: OK 0000
0F-Digital Radio -- Status: OK 0000
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: Malfunction 0010
1E-Media Player 2 -- Status: OK 0000
36-Seat Mem. Drvr -- Status: Malfunction 0010
37-Navigation -- Status: OK 0000
42-Door Elect, Driver -- Status: Malfunction 0010
46-Central Conv. -- Status: Malfunction 0010
47-Sound System -- Status: OK 0000
52-Door Elect, Pass. -- Status: Malfunction 0010
53-Parking Brake -- Status: OK 0000
55-Headlight Range -- Status: OK 0000
56-Radio -- Status: OK 0000
65-Tire Pressure -- Status: OK 0000
67-Voice Control -- Status: OK 0000
77-Telephone -- Status: OK 0000
-------------------------------------------------------------------------------
Address 01: Engine (J623-CAUB)       Labels: None
   Part No SW: 8T0 907 560 UM    HW: 8T0 907 560
   Component: V.6  JHM      H10 0003 
   Revision: 76H10---   
   Coding: 01140009180F0120
   Shop #: WSC 02621 444 176472
   VCID: 997AB2A690D2384C65-80CC

3 Faults Found:
005924 - Starter Interlock Signal
               P1724 - 002 - Short to Ground
             Freeze Frame:
                    Fault Status: 01100010
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 199464 km
                    Time Indication: 0
                    Date: 2020.12.10
                    Time: 20:00:07

             Freeze Frame:
                    RPM: 628 /min
                    Load: 30.2 %
                    Speed: 0.0 km/h
                    Temperature: 76.0°C
                    Temperature: 50.0°C
                    Absolute Pres.: 980.0 mbar
                    Voltage: 14.605 V

008196 - Intake Manifold Flap; Bank 1
               P2004 - 004 - Stuck Open
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 199464 km
                    Time Indication: 0
                    Date: 2020.12.10
                    Time: 20:00:10

             Freeze Frame:
                    RPM: 643 /min
                    Load: 26.7 %
                    Speed: 0.0 km/h
                    Temperature: 76.0°C
                    Temperature: 50.0°C
                    Absolute Pres.: 980.0 mbar
                    Voltage: 14.732 V

008196 - Intake Manifold Flap; Bank 1
               P2004 - 002 - Stuck Open - MIL ON
             Freeze Frame:
                    Fault Status: 11100010
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 199464 km
                    Time Indication: 0
                    Date: 2020.12.11
                    Time: 06:52:16

             Freeze Frame:
                    RPM: 1339 /min
                    Load: 20.4 %
                    Speed: 0.0 km/h
                    Temperature: 18.0°C
                    Temperature: 18.0°C
                    Absolute Pres.: 980.0 mbar
                    Voltage: 13.589 V

Readiness: 0100 0000

-------------------------------------------------------------------------------
Address 03: ABS Brakes (J104)       Labels:. 8K0-907-379-V1.clb
   Part No SW: 8K0 907 379 AB    HW: 8K0 907 379 AB
   Component: ESP8 quattro  H04 0060 
   Revision: --------    Serial number: --------------
   Coding: 110500
   Shop #: WSC 06325 000 00000
   VCID: F9BA92267092D84CC5-80AC

No fault code found.

-------------------------------------------------------------------------------
Address 05: Acc/Start Auth. (J393)       Labels:. 8K0-907-064-05.clb
   Part No SW: 8K0 907 064 F    HW: 8K0 907 064 F
   Component: BCM2 1.1      H80 0141 
   Revision: 00002001   
   Coding: 0B0000
   Shop #: WSC 06325 000 00000
   VCID: B326600E127EE21C4F-80E6

   Subsystem 1 - Part No SW: 8T0 959 754 M    HW: 8T0 959 754 M
   Component: FBSAUDIB8 IDG  H34 0050
   Serial number: 0107000112192005   

   Subsystem 2 - Part No SW: 8K0 905 852 D    HW: 8K0 905 852 D
   Component: ELVAUDIB8  H36 0041
   Serial number: 0208000043444011   

1 Fault Found:
00955 - Key 1
            002 - Lower Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100010
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 95
                    Mileage: 199153 km
                    Time Indication: 0
                    Date: 2020.12.03
                    Time: 14:48:42


-------------------------------------------------------------------------------
Address 06: Seat Mem. Pass (J521)       Labels:. 8T0-959-760.clb
   Part No SW: 8T0 959 760 B    HW: 8T0 959 760 B
   Component: MEM-BFS       H09 0043 
   Revision: AA000000    Serial number: 00001001124746
   Coding: 00017025002C00000000
   Shop #: WSC 06325 000 00000
   VCID: C2C835CA5DC45B94D4-8096

2 Faults Found:
03337 - Switch for Back Rest Locking
            008 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 4
                    Fault Frequency: 1
                    Reset counter: 73
                    Mileage: 170098 km
                    Time Indication: 0
                    Date: 2018.11.19
                    Time: 19:32:33

02095 - Component Protection Active
            000 - - - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 255
                    Mileage: 188461 km
                    Time Indication: 0
                    Date: 2019.12.25
                    Time: 09:36:48


-------------------------------------------------------------------------------
Address 07: Control Head        Labels: 8T0-035-7xx-07-H.clb
   Part No SW: 8T0 035 729 L    HW: 4E0 035 729
   Component: Interfacebox    H43 4610 
   Revision: 00000000    Serial number: 339HT087504055
   Coding: 0025003
   Shop #: WSC 06325 000 00000
   VCID: C2C835CA9DC45B94D4-8096

   Subsystem 1 - Part No: 8T0 919 609 A
   Component: E0380 BedienteilH08 0100

   Subsystem 2 - Serial number: 00000000128574

   Subsystem 3 - Serial number: 0106.08.080000000100010063ÿ

   Subsystem 4 - Serial number: 010063ÿ

No fault code found.

-------------------------------------------------------------------------------
Address 08: Auto HVAC (J255)       Labels:. 8Tx-820-043-3Z.clb
   Part No SW: 8T1 820 043 AC    HW: 8T1 820 043 AC
   Component: KLIMA 3 ZONEN H06 0140 
   Revision: C1000000    Serial number: 0109.08.080922
   Coding: 48022000
   Shop #: WSC 06325 000 00000
   VCID: F2A8A50A2DE4AB1484-80A6

No fault code found.

-------------------------------------------------------------------------------
Address 09: Cent. Elect. (J519)       Labels:. 8K0-907-063.clb
   Part No SW: 8K0 907 063 D    HW: 8K0 907 063 D
   Component: BCM1 1.0      H22 0253 
   Revision: 05022001    Serial number: 00000000205657
   Coding: 26001091063CAF010000000300003D3D0F1C138800010161000000
   Shop #: WSC 12345 123 123456
   VCID: B02C6F02E368D90432-80E4

   Subsystem 1 - Part No SW: 8T1 955 119 C    HW: 8J1 955 119   Labels: 1KX-955-119.CLB
   Component: WWS 110808  H13 0040
   Serial number: SWFBIE 0000094     
   Coding: 00FD11

   Subsystem 2 - Part No SW: 8K0 955 559     HW: 8K0 955 559   Labels: 8K0-955-559.CLB
   Component: RLS  H04 0003
   Serial number: 10224813           
   Coding: 02532C

   Subsystem 3 - Part No SW: 8K0 941 531 BA    HW: 8K0 941 531 BA
   Component: E1 - LDS  H03 0031
   Serial number: 00000000002210113891

   Subsystem 4 - Part No SW: 8K0 907 410 A    HW: 8K0 907 410 A
   Component: UGDO HL US  H04 0060

2 Faults Found:
00576 - Terminal 15
            008 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 73
                    Mileage: 170098 km
                    Time Indication: 0
                    Date: 2018.11.19
                    Time: 19:32:00

02258 - Door Opener Transmitter
            004 - No Signal/Communication - Intermittent
             Freeze Frame:
                    Fault Status: 00100100
                    Fault Priority: 3
                    Fault Frequency: 247
                    Reset counter: 102
                    Mileage: 170679 km
                    Time Indication: 0
                    Date: 2018.12.04
                    Time: 13:54:00


-------------------------------------------------------------------------------
Address 0E: Media Player 1        Labels: 4E0-910-111.lbl
   Part No SW: 8T1 035 110 C    HW: 8T1 035 110 C
   Component: MP3-Changer     H43 0390 
   Revision: 00043003    Serial number: AUZ5ZBH8547276
   Shop #: WSC 00000 000 00000
   VCID: AA187D6A05B4A3D4FC-80FE

No fault code found.

-------------------------------------------------------------------------------
Address 0F: Digital Radio        Labels: 4E0-910-593-SIR.lbl
   Part No SW: 4E0 910 593 M    HW: 4E0 035 593 F
   Component: SDAR SIRIUS     H07 0160 
   Revision: 00000000    Serial number: AUZ4Z7H0383037
   Coding: 0000100
   Shop #: WSC 06325 000 00000
   VCID: B12A6A062862D00C3D-80E4

No fault code found.

-------------------------------------------------------------------------------
Address 15: Airbags (J234)       Labels:| 8K0-959-655.clb
   Part No SW: 8K0 959 655 F    HW: 8K0 959 655 F
   Component: AirbagVW-AU10 H27 0410 
   Serial number: 0039KD1410Y% 
   Coding: 303333334330303030304A55304C38543053
   Shop #: WSC 06325 000 00000
   ASAM Dataset: EV_AirbaECUVWAUDI010 A02007
   ROD: EV_AirbaECUVWAUDI010_A02.rod
   VCID: C0CC3FC25BC84984C2-8094

   Seat occupied recognition:
   Subsystem 1 - Part No SW: 8K0 959 339     HW: 8K0 959 339
   Component: BF-Gewichtss.  H01 0050
   Serial number: 5810000R08000018BT

   Crash sensor for side airbag: driver side:
   Serial number: 6334MSME35006D79G

   Front Passenger's Side Airbag Crash Sensor:
   Serial number: 6344MSME3F20417CI

   Rear Side Airbag Crash Sensor (on driver's side):
   Serial number: 6352QSME540033361

   Passenger side rear thorax airbag crash sensor:
   Serial number: 6362QSME53000B3AA

   Crash sensor for front airbag: driver side:
   Serial number: 63732SME4B043F30$

   Crash sensor for front airbag: front passenger side:
   Serial number: 63832SME61002F0AY

No fault code found.

-------------------------------------------------------------------------------
Address 16: Steering wheel (J527)       Labels:. 8K0-953-568.clb
   Part No SW: 8K0 953 568 M    HW: 8K0 953 568 M
   Component: Lenks.Modul   H05 0005 
   Revision: --------    Serial number: 90372RBQ00047
   Coding: 000016
   Shop #: WSC 12345 123 123456
   VCID: C4C433D247D055A4E6-8090

   Component: E221 - MFL  H02 0003

No fault code found.

-------------------------------------------------------------------------------
Address 17: Instruments (J285)       Labels:. 8T0-920-xxx-17.clb
   Part No SW: 8T0 920 981 E    HW: 8T0 920 981 E
   Component: KOMBIINSTR.   H30 0224 
   Revision: 00000000    Serial number: 9D9622A88    
   Coding: 831501000300D705020000
   Shop #: WSC 02621 444 17647
   VCID: BE30413A293C3F74B0-80EA

No fault code found.

-------------------------------------------------------------------------------
Address 19: CAN Gateway (J533)       Labels:. 8T0-907-468.clb
   Part No SW: 8T0 907 468 K    HW: 8T0 907 468 K
   Component: GW-BEM 4CAN-M H09 0092 
   Revision: EB302042    Serial number: 4200E088048079
   Coding: 000303
   Shop #: WSC 06325 000 00000
   VCID: C9DA22E660F288CC15-809C

   Subsystem 1 - Part No SW: 8K0 915 181 B    HW: 8K0 915 181 B
   Component: J367-BDM  H04 0150
   Serial number: 1803724F010808     

4 Faults Found:
02256 - Quiescent Current
            001 - Upper Limit Exceeded - Intermittent
             Freeze Frame:
                    Fault Status: 00100001
                    Fault Priority: 7
                    Fault Frequency: 254
                    Reset counter: 102
                    Mileage: 170133 km
                    Time Indication: 0
                    Date: 2018.11.20
                    Time: 09:41:00

01312 - Powertrain Data Bus
            004 - No Signal/Communication - Intermittent
             Freeze Frame:
                    Fault Status: 00100100
                    Fault Priority: 1
                    Fault Frequency: 1
                    Reset counter: 82
                    Mileage: 198739 km
                    Time Indication: 0
                    Date: 2020.11.17
                    Time: 11:38:41

01314 - Engine Control Module
            004 - No Signal/Communication - Intermittent
             Freeze Frame:
                    Fault Status: 00100100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 82
                    Mileage: 198739 km
                    Time Indication: 0
                    Date: 2020.11.17
                    Time: 11:38:41

03041 - Energy Management Active
            000 - - - Intermittent
             Freeze Frame:
                    Fault Status: 00100000
                    Fault Priority: 7
                    Fault Frequency: 39
                    Reset counter: 86
                    Mileage: 189358 km
                    Time Indication: 0
                    Date: 2020.01.15
                    Time: 17:14:00


-------------------------------------------------------------------------------
Address 1E: Media Player 2 (R199)       Labels:. 4E0-035-785.lbl
   Part No SW: 4E0 035 785 F    HW: 4E0 035 785 C
   Component: SG ext.Player H15 0850 
   Revision: 00000000   
   Coding: 020000
   Shop #: WSC 06325 000 00000
   VCID: AB16786ECA4EBADC07-80FE

No fault code found.

-------------------------------------------------------------------------------
Address 36: Seat Mem. Drvr (J136)       Labels:. 8T0-959-760.clb
   Part No SW: 8T0 959 760 B    HW: 8T0 959 760 B
   Component: MEM-FS        H09 0043 
   Revision: AA000000    Serial number: 00001001129050
   Coding: 00197325002C00000000
   Shop #: WSC 06325 000 00000
   VCID: C2C835CA5DC45B94D4-8096

1 Fault Found:
03337 - Switch for Back Rest Locking
            008 - Implausible Signal
             Freeze Frame:
                    Fault Status: 01101000
                    Fault Priority: 4
                    Fault Frequency: 1
                    Reset counter: 73
                    Mileage: 170098 km
                    Time Indication: 0
                    Date: 2018.11.19
                    Time: 19:32:33


-------------------------------------------------------------------------------
Address 37: Navigation        Labels: 4E0-910-88x-37.lbl
   Part No SW: 4E0 910 888 M    HW: 4E0 919 887 M
   Component: MNS US          H51 1100 
   Revision: 00000000    Serial number: 341HO087511923
   Shop #: WSC 06342 000 00000
   VCID: B83C5722CB1801447A-80EC

No fault code found.

-------------------------------------------------------------------------------
Address 42: Door Elect, Driver (J386)       Labels:. 8K0-959-793.clb
   Part No SW: 8K0 959 793     HW: 8K0 959 793
   Component: TSG FA        H09 0149 
   Revision:             Serial number: AX
   Coding: 011C03225E002201
   Shop #: WSC 12345 123 123456
   VCID: FDB2863664BAE46CE9-80A8

1 Fault Found:
02123 - Door Warning Light / Entry Light
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 3
                    Fault Frequency: 15
                    Reset counter: 105
                    Mileage: 198468 km
                    Time Indication: 0
                    Date: 2020.11.11
                    Time: 18:25:57


-------------------------------------------------------------------------------
Address 46: Central Conv. (J393)       Labels:. 8K0-907-064-46.clb
   Part No SW: 8K0 907 064 F    HW: 8K0 907 064 F
   Component: BCM2 1.1      H80 0141 
   Revision: 00002001    Serial number: 0113745169   
   Coding: 0102069A007AC4C400B000
   Shop #: WSC 12345 123 123456
   VCID: B326600E127EE21C4F-80E6

   Subsystem 1 - Part No SW: 8K0 959 719     HW: 8K0 959 719
   Component: GTO BF  H06 0040
   Serial number: 00000000000000055750

   Subsystem 2 - Part No: 1K0 951 605 C
   Component: LIN BACKUP HO  H03 1301

   Subsystem 3 - Part No SW: 8R0 959 591     HW: 8R0 959 591
   Component: J245EE16SKB10  H01 0180
   Serial number: 0123456789ABCDEFGHIJ

1 Fault Found:
00198 - Automatic Day/Night Interior Mirror (Y7)
            004 - No Signal/Communication
             Freeze Frame:
                    Fault Status: 01100100
                    Fault Priority: 2
                    Fault Frequency: 1
                    Reset counter: 73
                    Mileage: 170098 km
                    Time Indication: 0
                    Date: 2018.11.19
                    Time: 19:32:37


-------------------------------------------------------------------------------
Address 47: Sound System (J525)       Labels:. 8T0-035-223-ASM.clb
   Part No SW: 8T0 035 223 AD    HW: 8T0 035 223 G
   Component: DSP STD       H08 0300 
   Revision: S2600000   
   Coding: 020101
   Shop #: WSC 02621 444 176472
   VCID: F0ACAF0223E8990472-80A4

No fault code found.

-------------------------------------------------------------------------------
Address 52: Door Elect, Pass. (J387)       Labels:. 8K0-959-792.clb
   Part No SW: 8K0 959 792     HW: 8K0 959 792
   Component: TSG BF        H09 0149 
   Revision:             Serial number: eU
   Coding: 011C03225E002201
   Shop #: WSC 12345 123 123456
   VCID: FCB48B327FA0ED64DE-80A8

1 Fault Found:
02123 - Door Warning Light / Entry Light
            012 - Electrical Fault in Circuit - Intermittent
             Freeze Frame:
                    Fault Status: 00101100
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 98
                    Mileage: 199345 km
                    Time Indication: 0
                    Date: 2020.12.09
                    Time: 13:39:13


-------------------------------------------------------------------------------
Address 53: Parking Brake (J540)       Labels: 8K0-907-801-V1.clb
   Part No SW: 8K0 907 801 E    HW: 8K0 907 801 E
   Component: EPB Audi B8   H05 0060 
   Revision: 00000003    Serial number: 10000000078316
   Shop #: WSC 00000 000 00000
   VCID: B12A6A06E862D00C3D-80E4

No fault code found.

-------------------------------------------------------------------------------
Address 55: Headlight Range        Labels: 8K0-907-357.clb
   Part No: 8K0 907 357 B
   Component: Dynamische LWR  H01 0030 
   Revision: 00000001    Serial number:              
   Coding: 0000002
   Shop #: WSC 06324 000 00000
   VCID: B4246312D770E52456-80E0

No fault code found.

-------------------------------------------------------------------------------
Address 56: Radio        Labels: 4E0-910-541.lbl
   Part No SW: 4E0 910 541 T    HW: 4F0 035 541 N
   Component: TUNER EU/US/RDW H42 0630 
   Revision: 00000000    Serial number: 357H 087507682
   Coding: 0000002
   Shop #: WSC 06325 000 00000
   VCID: B12A6A062862D00C3D-80E4

No fault code found.

-------------------------------------------------------------------------------
Address 65: Tire Pressure (J502)       Labels: 8K0-907-273.clb
   Part No SW: 8K0 907 273 A    HW: 8K0 907 273 A
   Component: J502-RDK      H03 0250 
   Revision: 00001001    Serial number: 13140781525422
   Coding: 0CD154
   Shop #: WSC 06324 000 00000
   VCID: B02C6F02E368D90432-80E4

No fault code found.

-------------------------------------------------------------------------------
Address 67: Voice Control        Labels: 4E0-910-75x-67.lbl
   Part No SW: 4E0 910 754 Q    HW: 4E0 035 753 A
   Component: SDS 3501 US     H46 0630 
   Revision: 00000000    Serial number: 00000807290057
   Shop #: WSC 12336 024 394758
   VCID: B4246312D770E52456-80E0

No fault code found.

-------------------------------------------------------------------------------
Address 77: Telephone        Labels: 4E0-910-336.lbl
   Part No SW: 4F0 910 336 H    HW: 4E0 862 335
   Component: Handyvorb2      H20 1130 
   Revision: 00000000    Serial number: 00000005054612
   Coding: 0010900
   Shop #: WSC 06325 000 00000
   VCID: A81C87621BB891C4EA-80FC

No fault code found.

End----------(Elapsed Time: 02:01, VBatt start/end: 12.1V/12.0V)-----------
	
	



	
	

		

	

 

[NEtech]

Is Basic Settings. for Bank 1
Engine in idle
Group 142
[Basic Settings-04]
[ON/OFF/Next]
Wait until Field 4 show "ADP Ok"

For Bank 2, same procedure, with Group 144

 

[stefdds]

Greetings from the US NEtech ; many, many thanks!!!!
I will do a update once I install the sensor and the adaptation ; about a week from today.
All the best NEtech!

 

[stefdds]

Good Morning!
I decided to order some brand new genuine Audi sensors PN 03C907386E (latest revision). So, while waiting for those to arrive, I thought I'd get a used genuine sensor from ebay ($15.00) and see if I could do some Bench Testing with it.

With the car still in the unrepaired state, I did follow NEtech's procedure above with the VCDS and Bank 1 did show "ERROR" in the "on/off" box. Bank 2, I think showed On or OK. So that is certainly a valid test (thanks again NEtech).

I made some notes and the used sensor tested seemed to be ok, that is while moving the sweeper dial on the back side of the sensor, the voltage changed. I also discovered that not all potentiometers are the same: automotive style vs. volume control etc. The automotive sensor needs to be supplied with some power , where as the volume control type you can test with a ohm meter. Perhaps you can test both with a ohm meter, it just happened that I figured out later that the sensor has a polarity and during testing with the ohm meter, I wasn't having much luck. I'll do a Update on the install , probably in the how to section, once I do the new part install and adaptation. Also, I discovered a much easier way to install and un-plug the sensor ; no need to remove facia cover and move core support! I'll get some pics once I do the exchange.

Someone may discover this post who doesn't have VCDS (although I can't imaging that ) and wants to test / verify a used part or a existing part on the car.

 

[stefdds]

Well, the challenge continues: I did the (genuine audi used , but tested) sensor install on Bank 1 (pass. side here in the US) and , I erased the fault p2004 , with the car idling Group number 142 it only shows the "ERROR" in the fourth field / box.

Group 142: Voltage in the 3rd box is 1.980v ; I clicked on the "ON/OFF/NEXT" button several times and I can hear a slight dull click on the car when I do this ; I waited a few minutes and nothing changed on the screen. Also, the fault returns right away. Box 1 and 2 show 99.6% . And in red font below the VCDS shows Basic Settings ON.

Group 144 (Bank 2) engine idling , shows field 1 and 2........ 99.6% , field 3 shows 3.94v , and field 4 "ADP OK" .

I then erased the fault again, with only the power/key "ON" engine not running : and grp. #142 field 1 shows 99.6% field 2 was blank , and field 3 was around 0.6 volts and field
four showed "ADP Run" ; when I started the car, the "ERROR" showed in field four once again. And the fault was stored.

I also bench tested the original sensor that I removed and per the diagram above it seemed to test OK, that is, as I moved the sweeper on the back of the sensor, the voltage changed (from 0.4v to 4.1v).


Could the intake runner be stuck (I didn't try to turn it with the sensor off of the car) ? When I did the Output test in VCDS for the lower actuator, the lower motor cycled fine. Wouldn't the linkage bind or jam if the runner was stuck / jammed ? I did notice the lower voltage in grp. 142 , 3rd. field 1.980v ? vs. grp. 144 3rd.field 3.94volts.

I do have some brand new genuine Audi sensors coming, but it doesn't appear to be a sensor problem.

Thanks , and all advice welcome!

 

[stefdds]

Also, I removed the sensor so I could observe the shaft , I then went back into VCDS "Output Tests" and activated the one for the intake runners (lower actuator motor) as I wanted to directly observe the shaft clocking back and forth while the actuator motor was running (ie activated). And It was rotating back and forth just fine.
It looks like I have a "false - positive" on my hands . I'll have to check the WD and see what else is on that circuit. I wasn't doing anything else with or to the car lately, so I don't think it is anything like that. It just appeared (CEL). I will let you know as I make discoveries! And, I'll be sure to check the fuses!!!!!!!!!!!!!!! Thanks again!

I checked my WD's and found the Potentiometer(s) page ; very helpful as there is one wire from the ECU , one 5V prewiring harness wire , and a ground. I'm going to check the ground as I mentioned above, the voltage on the basic settings is really low compared to Bank 2. There is a black corrugated loom protector (very small diameter , less than 1/4") and it has a melted flat spot on it as it is resting against the front of the cylinder head ; it contains three wires from the sensor plug and the electric actuator motor. It is really difficult to see in that front of the engine (I'm using magnification and a mirror!!) ! The core support horizontal structure is right there. I may go up-stream and tap into the wires to do a diagnostic . I think that low voltage may be a clue. ??? I'm focusing on the Left side of the WD page.

 

[stefdds]

Well regarding sensor G336 , I did some testing with the DVOM: (engine running and / or Ignition ON , that is , I did both) Testing was probed at the sensor plug terminals with the sensor removed.

The Black / White wire (which I think is 5V reference) showed 4.9V D141
The Purple / White wire (form the ECU J623) showed 0.00v
The Brown wire showed continuity (ohm meter test) wire 220

It appears not to be getting a ECU signal . Any thoughts . Thanks !


12/22
This may be "ok" as I thought about this and with the sensor/potentiometer being disconnected and only reading the plug terminals, the purple/white wire is the "sweeper" which I think measures the voltage and sends it back to the ECU. With the senor not present, there is no voltage to send back. I think this terminal should be zero volts under these conditions/test.

I think I will test the other side (benefits of a V8!) I will also check the continuity of the ECU wire (purple and White) ; perhaps the signal can't get back to the ECU when the sensor is plugged in and installed ???????????

 

[stefdds]

Good Evening, I did a continuity check: I knew ground wire and 5v reference were ok, but I checked all three anyway and the purple and white wire going to the ECU had continuity , so It appears the circuit is OK. ; very glad to see that! VCDS also showed voltage , although it was about half of the other side (Bank 2). 1.9v (Bank 1) with "ERROR" in field 4 vs. 3.98v Bank 2 . with "ADP OK" in field 4. There are no vacuum lines involved with this "early" 2008 Magnesium intake manifold system. They later went to composite / plastic and vacuum actuated linkage.

I'm starting to think the that the intake manifold flaps are indeed worn or out of spec. $2700.00 for the complete assembly: manifold, actuators, sensors .
https://www.ecstuning.com/b-genuine-volkswagen-audi-parts/intake-manifold/079133185bm/

 

[stefdds]

I thought this was a good post regarding the explanation of a "stuck open" and a "stuck closed" intake runner. NOTE, this is only for insights as to some of the functions of these runners. This owner has the vacuum actuated plastic manifold, but I believe the fault codes and the functions are the same. Here is the link to the post on Audizine. (especially the second paragraph ; go to top of the page , post by Bailey).

P2004/5 P2006/7 Intake Flaps Stuck Open/Closed (Vacuum Actuated Flaps)-Adaption ERROR

Hi I'm new to the forum and VW/Audis and I hope I can find some information/help from other members. I will keep this post updated until the issue is resolved and can share with the community. I have done multiple searches and haven't found anyone with the vacuum actuated flaps, with my specific...

www.audizine.com

This is beginning to remind me of the "press clutch pedal to start" fault: briefly, it turns out that the tolerances are so close and minimal with the throw out bearing linkage / fork and slave cylinder travel that even minimal wear to the clutch disc or linkage will eventually prevent the car from starting. The clutch switch (buried deep in the cowl plenum) has some sort of sensor set tolerance and if the system doesn't travel far enough, the sensor will not satisfy the interlock, thus the car will not turn over/start. The Dealers answer is to install a new clutch, throw out bearing, and all necessary linkage. (even though there is 50-70% clutch material left on the disc !! ; that is, the clutch is not worn out) It was such a prevalent problem that countless threads and two main repairs were devised: one was a modified slave cylinder rod (about 2-3mm longer) , the other is to cut the interlock wire and ground the ecu end. Both solved the problem.

This Electrical intake manifold flap / runner system seems to be quite sophisticated both in design and tolerance spec and is a "consumable" item .

 

[stefdds]

Uwe, perhaps you could consider editing the title of this Thread as it has evolved beyond what I had anticipated ( naive me!) . As I think it would be more searchable and helpful. ???
Some thing like 2008/9 S5 "p2004 intake runner stuck open" ERROR (electric mechanical actuators) Aluminum ,its actually Magnesium, manifold.

What ever you think would be most beneficial , The electric mechanical actuators are unique to this year / prod. date S5

 

[Uwe]

Uwe, perhaps you could consider editing the title of this Thread

Done.

-Uwe-

 

[Uwe]

This Electrical intake manifold flap / runner system seems to be quite sophisticated both in design and tolerance spec and is a "consumable" item .

Has nobody devised a method of repair? I know on some other engines, simply adding mechanical stops fixes similar problems.

-Uwe-

 

[stefdds]

Thank you Uwe, I appreciate that gesture.

I thought of two more tests I wanted to do before I apply the "nuclear option" (ie replace the entire intake manifold assembly). One was to see if I could turn the Bank 1 runners by hand; I wanted to feel the movement and see if I could perceive any interference ; unfortunately, I could not isolate just the shaft from the linkage mechanism . The ring lever arm on the shaft is some sort of a press fit and as you lightly pry on the arm the shaft moves with it . The other way to do this would be to remove the main arm from the shaft lever arm, as it is fastened on the pivot point with a pin and a "C" clip - a very small C clip facing backwards! I could get it off, but not controllably and I could not use a magnet to capture it as I pry as all of the hardware is Stainless Steel . So , while the sensor was off of the shaft, but still electrically connected I did my second test ; mostly out of curiosity. UPDATE: (edit), I was able to get the C clip off ok, the shaft moved freely with no interference felt through its entire travel; it was very smooth.

With the car running and VCDS open in basic settings and the sensor disconnected from the shaft, bur electrically plugged in I wanted to see what grp. 142 would show when I manipulated the sweeper on the potentiometer. I did have to click on the "ON / OFF tab" each time I moved the sweeper. Field one block percentages did change and the actuator did cycle one time with each change and also the Voltage field block did change (from 0.5v to 4.6v. , but the ERROR in block four never changed or showed any other population. So, there must be some other intake air input to the ecu, besides the potentiometer ( actuator motor ?????) which then triggers the hard fault code that returns immediately upon clearing. I did try to get the voltage the same as Bank 2 grp. 144, but I couldn't match it.

It will be interesting to see what those bank 1 runners look like. I will watch this post for any suggestions. I will update when I do the install, but it will most likely be 3-4 weeks. I would expect two weeks alone just to get the part to my door. Thanks again to the forum as I'm getting much more comfortable with checking basic parameters with VCDS as well as a DVOM for obvious problems.

 

[stefdds]

When I was putting the flap arm (with sensor) back into position to reattach it to the actuator arm (electric motor) I did notice that the arm is loaded ; meaning in order to get the two points back together in order to get the pin on the long arm through the flap arm hole, I did have to push down with a bit of force to line them up ; it is not a passive fit. I'm thinking this loaded condition , over time, would cause some wear, especially in the closed position (Bank 1 at 2:00 o'clock position and Bank 2 at 10:00 o'clock position). When you shut the car engine off, the flaps close and the arms Are loaded. When you start the car , when its cold, the flaps stay closed and as it warms up, the flaps open: both banks at 12:00 o'clock position. All appears to function as designed! (edit) I think I may have discovered something: as I mentioned Bank 1 sensor is loaded and under tension and requires some pressure/force in order to move the pin arm in and out of the sensor arm , when its attached ..................Bank 2 on the other hand requires no force or pressure to move the pin arm in the sensor arm ; it is passive and freely moves . I think that is Significant considering the very tight tolerances that this system functions under. And may also be why the replacement intake manifold comes as such a complete package/assembly. All the components are probably synchronized and matched together. (end of Edit) .

My theory is that with time that rest position under load creates some wear and the actuator motor senses that and registers a fault. Only my opinion for this specific situation.

 

[Jack@European_Parts]

Has nobody devised a method of repair? I know on some other engines, simply adding mechanical stops fixes similar problems.

-Uwe-

Indeed over 10 years ago with two pins installed or even a third for center with rubber inside motor or a T bolt externally with adjustable rubber bumps on lower servo to address each runner to linearize!
Additionally the sensors can have the holes hogged out to gain an offset adjustment and some quick work with file.

It is best before doing one to take measurements of a proper NEW intake flap, to determine mechanicals not addressed in RTFB!

 

[stefdds]

Thank you Jack , I was also trying to think of some way to make a adjustment. (until I viewed this video!!!!).

More information / insight found! Although this YT video is a V10 S8 ; The year and the manifold material and configuration is the same for a V8. I think I now know what is going on!
There is a ton of plastic hardware moving around in there ; I'm sure it gets hot and brittle with time. That manifold is not "just a empty casting" I'll bet there is a broken piece jammed or floating around in the upper center section and it is interfering with Bank 1 runners.

It is really highly detailed, but the sections of interest to me start @ 45:33 , 48:32 my favorite! 49:20, 49:56 , 50:50, 53:10
IF, the flaps are not broken, I think this is the wear problem: note if you look closely how the triangle pattern with the three holes at 56:25 and 57:11 the three holes toward the front are worn larger, much larger than the other three holes toward the middle and the rear. And thus xs movement begins!

 

[Jack@European_Parts]

God loves bushing's!

I'm not a fan of deleted components!

I have rebuilt some intakes with real sealed roller bearing's and proper seal compounds + O-rings.

Never to fail again!

 

[stefdds]

Thanks Jack, and I know you are not a fan of mods. I don't want to delete anything either! It is a very elegant system!! I just thought it was a great video to show "what was behind the curtain!" It really adds alot of insight as to what is probably happening with my, as well as many others, situation(s). These magnesium manifolds had a short run (in this configuration) on the S5's so it is really hard to find them in a broken state ; especially on video. I'm much more confident now in ordering the assembly. Actually, I'm a bit surprised that it is still available! And, thanks for looking over my post/problem. Stefan

 

[stefdds]

Here is my prediction : as shown in the video and the Audi literature, the upper or center manifold flaps make this manifold a VARIABLE length runner manifold. Below 4000 rpm, the flaps open and you are utilizing Long runners (channeled path) within the manifold; good for torque and drivability and smooth idle. Above 4K rpm, the flaps close and you have short runner path within the manifold for extra power and a more aggressive throttle response . As stated in the Audi literature, the "upper" runner flaps are plastic with..........silicone seals around them ...........to create a good seal.

My prediction is that one of those silicone seals or part of it has broken off and traveled down inside the casting runner / path and is caught between the lower potentiometer flaps and the manifold casting, thus not letting the flaps on Bank 1 close completely in their rest position. And that is why I feel that pressure and load and must apply force (see post #15 ; which does feel spongey !!!!!) in order to connect or reconnect the actuator linkage on the bank 1 side!

I will certainly update , with pictures, once I get the brand new replacement installed (and the original intake manifold off and disassembled - "split" the castings etc. ).

here is a link to the parts source and it also has a great (expandable) exploded diagram: https://www.jimellisaudiparts.com/p...oupe/Intake-manifold/5508420/079133185BM.html

Here is Audi's service manual on this / my motor 4.2L V8 (NOTE: pg. 6 cut-away diagram of upper flaps in situ / manifold) and pg.24 cut-away diagram

http://www.vaglinks.com/vaglinks_com/Docs/SSP/VWUSA.COM_SSP_377_4.2L_FSI_Engine.pdf