Manifold error P2015 on 2.0 TDI CAGB

[Novica]

Hi,

I have fixed error P2015. The error was connected to flaps position reading. Flaps in rest position are going over limit ans ecu reads unusual values and gives error and triger check engine light.

I have cleaned manifold, EGR and flaps on February 2018 and passed 16000km.

I have ordered this bracket:





Started with dismantling:




Throtle body after 16000km from cleaning:



EGR valve after 16000km from last cleaning:








Exaust gas entrance on EGR valve:



Inlet valves entrance on head:













After cleaning:

















Cleaning manifold flaps motor inside:





Bracket inserted and flap motor connected to manifold:









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[Novica]

EGR valve motor opened and cleaned, valve moved to open position in order to clean valve and seat:









On the end opened throttle body motor:











On the end everything put together and replaced manifold gasket with new one:



Used torque wrench for manifold and high pressure fuel pipes:



Marked position of bracket, as you can see, manifold must be removed in order to insert it:



Tools that I have used:



Fuel system pressurized and refilled with fuel, P2015 error deleted, throttle body, EGR and manifold flaps adapted (performed basic settings):









I have performed test drive on city, checked memory for any error and everything was fine, no more check engine light :



I have plan to do next cleaning after summer as I am using car more then 50% in city.

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[dan2485]

good work,

the build up of crud in the intake manifold normally causes the error as a flap does not seat correctly.

Did you strip and clean the manifold?

[Novica]

Yes, I have, twice this year. On the end of february and now again due to this error.
As I am driving mostly in town, I will cleaned it again after summer (warmer period).

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[Scafandru1]

How did you clean the intake holes in the engine block (where you can see the valves)?
What is the procedure to pressurise the fuel system and refilling with fuel?
Thanks