intake manifold flaps stuck open

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Mar 22, 2014 | 05:17 PM

xboltss

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intake manifold flaps stuck open

check engine lit last week on my 08 Q7 4.2L, i scanned with VCDS & it gave 2 Faults Found:
008196 - Intake Manifold Flap; Bank 1
P2004 - 002 - Stuck Open - MIL ON

008197 - Intake Manifold Flap; Bank 2
P2005 - 002 - Stuck Open - Intermittent
i opened the hood & found 1 of intake manifold runner control linkages came out of it place
everything good after i popped it back in & clear the code

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Mar 24, 2014 | 06:52 AM

ATL2.8Qmmm

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Quote:

Originally Posted by xboltss

That one came loose on my 08 4.2L the same day I bought it CPO from the dealer. Since I bought it out of state, I was not going back. I went to a hardware store and got a 4mm e-clip and used some pliers to get it back on. They make E-clip tools which would have made it easier. I found just sticking the post of the linkage back in the hole would lead to eventually popping back out. I'm going by memory on the 4mm part, so YMMV.

Google "4mm e-clip" and this tool helps install http://www.duratrax.com/accessories/tools/dtxr1107.html

It's the only metric e-clip tool I've found.

I didn't have the tool but it sure would have saved me from using some four letter words.

Mar 24, 2014 | 01:45 PM

xboltss

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i just popped it back in, it hasn't come off again for a week or so.
is there a groove for a 4mm E clip at the end of the post?
when i popped it in, i didn't look at it.
thanks for good advise

Mar 25, 2014 | 05:15 AM

ATL2.8Qmmm

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Quote:

Originally Posted by xboltss

i just popped it back in, it hasn't come off again for a week or so.
is there a groove for a 4mm E clip at the end of the post?
when i popped it in, i didn't look at it.
thanks for good advise

Yeah. There's a little groove. Look at the other ones and you'll see it. I went to the dealer and they didn't show it as an individual part. Basically you had to buy the entire assembly. They offered me some e-clips from a kit they have but their kit was SAE and not metric. Not sure how that works on European cars. Found it at a Do-it-best hardware store since Home Depot and Lowes didn't have metric either.

Mar 26, 2014 | 06:11 PM

xboltss

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thanks ATL
i installed a SAE E clip, not perfect fit but i plied it in a bit with a pair of pliers. hope it won't come out easily

Mar 27, 2014 | 05:56 AM

TypeRod

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I love happy, cheap endings to vehicle troubleshooting!

Oct 10, 2018 | 03:23 PM

George Trudeau

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From: Woodinville, WA

Sorry to resurrect an old post!! But, I have this same issue on my 07' Q7 S-Line (4.2). I have some questions for anyone willing to humor me! But first, the codes, below:

3 Faults Found:
008196 - Intake Manifold Flap; Bank 1
P2004 - 002 - Stuck Open - Intermittent

008197 - Intake Manifold Flap; Bank 2
P2005 - 002 - Stuck Open - Intermittent

008569 - Bank 2; System Too Lean off Idle
P2179 - 001 - - Intermittent

"Intermittent". I haven't pulled the car apart yet (wife is away with it)…. but would "Intermittent" indicate something different? Also, that 3rd lean code has been plaguing me since I bought the car. Haven't been able to track it down. It triggers an engine light every 4-6 weeks. Sometimes it goes out on it's own, sometimes I have to clear it. Hasn't caused any big issues.

Also- That picture above is the MONEY SHOT. Thank you for providing! All of those arms that connect to... that 'mechanism' (I have no idea what it is), is it possible that it could have failed?

~George