If your VW TDi is suffering from the P2015 error, caused by wear of the plastic stoppers of the throttle valves in the intake manifold, and if you are having an engine version with plastic manifold (VAG 03L129711AG), here is an instruction video for a quick and very low cost solution to your problem.
DISCLAIMER : This solution is maybe not suitable to be used permanently, it is only a quick and very efficient method to avoid the P2015 problem, e.g. in order to pass the technical vehicle inspection, with your car. If you decide to follow these instructions, you are definitely doing this on your own risk ! I can by no means be hold responsible if there should be any kind of damage to your engine or car from using this fix, or if you are violating any laws in your country this way !!
Here again the dimensions of the self made part :
- rubber tube, 20 mm outer diameter, 8 mm inner diameter, 50 mm long. Preferably silicone rubber, because of temperature resistance. Don't use a plastic tube (PE, PP), it will melt !
- steel tube, 8 mm outer diam. 5 mm inner diam. , appr. 110 mm long.
- distance from one side of the tube to the rubber tube appr. 16 mm.
- distance from rubber tube to the upper side of the steel tube, with M6 thread is appr. 36 mm (measured from lower end of steel tube)
- press one end of the steel tube as flat as you can.
- drill 5,5 mm hole in the upper end of the bended steel tube, and cut a M6 thread.
ATTENTION : by mistake the camera was turned by 180° when the position of the fix was filmed at the end of the video, being quite confusing. The upper end of the video is then pointing to the front of the car, the lower end towards the rear. This is the right position of the fix, it is BEHIND the actuator, between actuator and cylinder head, seen from your position (standing in front of the car). Apologies for that, this happened when the camera was handed over.
Mounting instructions :
There is an unsued ear with a 6 mm hole on the right side of the cylinder head, behind the actuator motor (seen from your position). This ear is used to hold the fix in the correct position, using the M6 bolt/screw.
To bring the rubber behind the lever of the actuator motor, so that it can provide a stopper function to it, you may need to move the lever out of the way first. This is a bit tricky, use a screwdriver or similar to push the lever forward, while you are inserting the fix into the right position. It may be necessary to do this a number of times and bend your part into the right form, before it will fit in there and can be fixed with the M6 bolt. The flat end of the steel tube is going into a gap between the plastic manifold and the cylinder head. It is not absolutely necessary, but will give additional position stability to the rubber.
Resetting the error / Deleting the MIL :
After mounting of the part it is advisable to delete the P2015 error with a suitable OBD device (e.g. bluetooth dongle and Android smartphone). Alternatively you can also disconnect the battery of the car for 30 minutes, this should also reset the error, the MIL (Malfunctioning Indicator Light) should be deleted and the actuator work fine again.
Material cost are less than 10,- €, time to make it appr. 30 mins, mounting in 10 mins.
Hope you found this useful !!
DEUTSCH : Ich bin Deutscher, habe aber keine Zeit den Text oben komplett zu übersetzen. Wenn einer von Euch sich die Mühe machen möchte das zu tun und die Übersetzung bei den Kommentaren postet, füge ich diesen gerne hier ein, selbstverständlich mit Verweis auf Deine Hilfe.