Intake manifold flap issue Passat B6 58 plate 2.0 tdi CR DPF 140PS

[Majorlook]

Hi, i've had my Emissions light on for a couple of months now and finally got round to getting VCDS, previously i have taken off the anti-shudder valve and the egr and given them a good clean which made no difference to the Emissions light, i plugged my VCDS cable in and heres the fault that it threw up:
1 Fault Found:
008201 - Intake Manifold Flap; Bank 1
P2009 - 000 - Short to Ground - MIL ON
Freeze Frame:
Fault Status: 11100000
Fault Priority: 2
Fault Frequency: 12
Reset counter: 255
Mileage: 157603 km
Time Indication: 0
Date: 2010.11.06
Time: 00:03:18

Freeze Frame:
RPM: 0 /min
Speed: 0.0 km/h
Load: 0.0 %
Load: 100.0 %
Lambda: 99.4 %
Mass Air / Rev.: 0.0 mg/str
Temperature: 77.4°C

Readiness: 1 1 0 0 0

I've had a look round on the forums and some people are saying the whole intake manifold has to be replaced along with the actuator and others are saying it can be that the swirl flaps are blocked up or the fuse has gone, can anyone enlighten me as to which fuse this is on the B6 CR passat? and also if anyone has any other advice before i go out and buy a new intake manifold?

thanks in advance!

[niall campbell]

have you changed the sensor ?

Scrapyard a good place to go as well .............

Try reading this and checking your wiring 008213 - Intake Manifold Flap Position Sensor (Bank 1) My Solution.

you could also try youtube

[martin1810]

Have you checked the wiring in case the code is correct and you have a short to ground

[Majorlook]

I've not changed the sensor as the fault is with the motor itself by the looks of things and I've seen other people who have posted the fault that specifically states the position sensor.

[martin1810]

The error says short to ground so you have a "short to ground" Fix the short

[Majorlook]

I had a quick look last night and of the 5 pins in the connector, 4 of them had continuity to ground, does anyone have a wiring diagram? Ive checked my haynes manual but there isnt one for the intake system.

[Majorlook]

OK so I found the short, the motor inside the intake manifold flap actuator has a direct short to its casing, by the looks of it its sealed for life too so I can't check the internals.

The motor has the following on the side:
12v
A2C53241415
3J2502

and the part number for the actuator is:
03L 129 086 v120

Anyone know if I can just buy the Motor from somewhere or will I have to buy the full actuator?

[Majorlook]

To follow up, as a temporary fix I have put a thin layer of high temperature resistant flame retardant electricians tape around the motor to prevent it from touching the actuator housing and then tested for shorts to the casing which there weren't, I then applied a 12v DC source each way to the terminals on the motor and it rotated fine each way.

Fitted the whole thing back in the car and cleared the fault codes and then used VCDS to adapt the intake manifold flap/runner and it worked fine. Took the car for a drive and no more emissions warning light.

Again, this is only a temporary fix to carry me over until I can get round to going to a scrapyard or buying a new actuator.

[Radek]

There are some manifold repair kits avilaible from this website manifoldskitsuk.co.uk
I have purchased repair kit for 2.7 tdi from them but they also have kits for 2.0tdi.

[Jaffar83]

To follow up, as a temporary fix I have put a thin layer of high temperature resistant flame retardant electricians tape around the motor to prevent it from touching the actuator housing and then tested for shorts to the casing which there weren't, I then applied a 12v DC source each way to the terminals on the motor and it rotated fine each way.

Fitted the whole thing back in the car and cleared the fault codes and then used VCDS to adapt the intake manifold flap/runner and it worked fine. Took the car for a drive and no more emissions warning light.

Again, this is only a temporary fix to carry me over until I can get round to going to a scrapyard or buying a new actuator.

Hi I have the same issue as you with the 2009 short circuit fault mine even sparked today when it made contact!
Can you tell me did a new motor fix the issue?
Thanks