Volkswagen Intake Manifold Failure and Removal Code P2015

2010 Volkswagen Tiguan with a 2.0 TSI engine. Fault code number is P2015 or 08213.

Trouble Code: “Intake Manifold Runner Position Sensor/Switch Circuit,Range/Performance.”

Volkswagen Intake Manifold Failure:

Code indicates failure of intake manifold, therefore manifold will have to be replaced. It might be mistaken sometimes as sensor failure but actually sensor is seeing something wrong with flap positioning, not that sensor itself is broken.

Below are new and old flap positioning sensors. For all the bad looks old sensor has, is still working properly. There is nothing wrong with it.

Problem lies elsewhere, on opposite side of intake manifold. That vacuum operating controller you see circled in red? That’s the problem in this case. Usually control arm is snapped or gets lose. However, whole intake has to be changed either way.

On this unit is most likely internal failure of the valve. Valve is not holding vacuum or not responding properly to it. Post will not be as detailed as it should. Not enough pictures were taken but will leave few basic things here, maybe it helps.

Volkswagen New Intake Manifold

New intake manifold comes complete with sensors and valves included. Only fuel rail need to be removed from old manifold and installed to new one. Instead of paying dealership prices which are sometimes more than car is worth, intake manifold was bought online (Ecstuning.com). Total was less than Cad $300 including shipping and an extra vent hose. 

Is recommended buying a vent line for new redesigned intake manifold, cost about $15. Installation is simple. Install one side on the vent hose to vacuum valve and hang the rest somewhere (red circle).

Removal Of Intake Manifold

Disconnect battery ground terminal, just in case.

Remove engine cover, remove oil filter and unplug anything you see might get in your way. Remove fuel return line (Red Circle in the picture) and vacuum lines located on right side of manifold. Make sure you remember what goes where for installation. Taking pictures of removal helps with installation.

All was done from the top, vehicle was not lifted. Inter-cooler plastic air hose stayed in place. As per image below, yellow arrows show what needs to be disconnected (probably forgot some things there but easy to figure it out). 

Red arrows show visible intake bolts and blue arrows show hidden ones. Remove screws holding coolant metallic pipes on the left and front of intake manifold (2 locations).

Volkswagen Intake manifold has 7 T30 bolts. Five of intake manifold bolts are on top (red arrows) and easy to access. Two other bolts are hidden underneath (blue arrows) but still accessible after throttle body is removed.

Remove fuel line. Its located on right side of intake manifold (see picture/white arrow). Use a 17mm open wrench to remove fuel line.

Remove throttle body. This thing is not easy. Start with rubber boot. Release both clamps holding intake boot and pull it out. It will require some force but eventually will come out. Below is an image of boot while pulling it out.

Volkswagen Intake Manifold Failure

Remove 4 T30 (same screws as intake manifold) throttle body screws. Two screws are not visible therefore will take some time to get them out. Here is a picture after removal of both intakes (old and new) to give you an idea where screws are.

Volkswagen Intake Manifold Failure: Once throttle body is out, remove intake manifold support bracket. Its a M10 bolt and is quite difficult to get to it. Remove all intake manifold bolts and maneuver intake manifold out of place, a couple of electrical plugs to undo from underneath. Unplug oil sensor.

When removing intake manifold injectors might be stuck to intake manifold. It’s not a problem just remove them and push them back in on engine block.

Remove everything from old intake manifold and install them to new manifold. Fuel rail has two screws only. Exchange fuel rail from old intake manifold to new one. When installing new manifold be careful to not over-tighten screws or guaranteed you will break stuff, that thing is cheap plastic.

Installation is reversal of removal, make sure you take pictures and document your removal steps to make installation easier.

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