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my W212 E500 2009 with M273 Engine, shows a failure in SD.
0522 - The Tumble flap (Bank 1) has a Malfunction
This failure is the only one shown in SD
The Air intake Manifold was replaced 1 year ago.
All connectors are plugged in, all hoses are in place.
The levers are movable and pressure test via SD is good.
Engine idle is also good, I can't recognize anything.
The failure comes again after a while (after deleting)
The attached file is in German, but maybe someone has an idea...?
That's interesting... intake plenum replaced but same issue with flapped flagged bad on one side only, right?
There is no position sensor for these flaps. They get opened or closed based on vacuum solenoid being On/Off.
The odd part is that its on one side only. We can guess vacuum supply is ok or perhaps available vacuum is barely enough for both actuators... Check your vacuum source on M273 (pump check valve or intake?)
What data is the ECU sensing to report flap issue... intake MAP/MAF difference in level??
Can dirty intake valves on Bank1 (passenger side) where PCV dumps oil be responsible for lower vacuum level.
I think intake failure used to be commun in M272/3 era with aluminum intake box but no longer in M276/8 with plastic intake plenum. Here M273 intake was replaced... new or used unit??
Last edited by CaliBenzDriver; Apr 26, 2025 at 03:47 PM.
Thank you for reply.
It's a new one "Original Pierburg" and, yes just the one side.
That is strange, because it's a new part.
So the 2 sensors are for the inside flaps, not the tumble flaps down to the head?
I thought could be the sensor maybe.
I would give it a try to check with an external vacuum pump and to clean the PCV
The tumble flaps are just in idle closed, right?
Can they be monitored?
Thank you for reply.
It's a new one "Original Pierburg" and, yes just the one side.
That is strange, because it's a new part.
So the 2 sensors are for the inside flaps, not the tumble flaps down to the head?
I thought could be the sensor maybe.
I would give it a try to check with an external vacuum pump and to clean the PCV
The tumble flaps are just in idle closed, right?
Can they be monitored?
We both get down to the same question:
how does ECU monitor the intake plenum flap position ?
to understand what makes a new flap appear bad.
Last edited by CaliBenzDriver; Apr 26, 2025 at 06:32 PM.
That's a lot of reading stuff.
To understand it I may have to read it twice.
How is it possible from a new part, something to be broken so fast.....
I hope, I don't have to remove the Manifold
That's a lot of reading stuff.
To understand it I may have to read it twice.
How is it possible from a new part, something to be broken so fast.....
I hope, I don't have to remove the Manifold
Start with OLD parts which were never replaced.
This Intake Manifold is powered by vacuum. The vacuum hoses + check valves are on the car and not part of the new Pierburg Intake manifold assy you bought new.
The one in green, inspect them
Your DTC : 0522 - The Tumble flap (Bank 1) has a Malfunction
This tumble flap has 3 names : So the Y22/9 has now 3 names : CHARGE MOVEMENT FLAP, SWIRL FLAP and TUMBLE FLAP ...lol
Here is the bad news for you. First Lets use the component ID name as Y22/9 in this discussion.
Y22/9 is a single unit driving both Left and Right bank "tumble flap".
Thus if you have DTC of 0522 - The Tumble flap (Bank 1) has a Malfunction it can only meant 2 things.
AA - First is indeed there is a broken link or
BB1 - the position sensor does not read that Bank 1 tumble flap actually has positioned itself properly. BB2 - simple bad connection or loose connection at sensor connector.B28/9 or B28/10, if bank 1, supposedly it will be B28/10 sensor.
01.Try to clean the contacts of both .B28/9 or B28/10 wired connector and the sensor side ( male and female ) with electrical contat cleaner.
See how it goes.
02. The sensors both are the same : A2721530232, if test 01 still produce no cure, you then swap these two sensos position, see if the DTC then shift to Bank 2 or not ?
If DTC shifted to Bank 2, its only the sensor being bad.
If DTC still stay the same for Bank 1, final check with swapped sensor so that we use a known good sensor .....is to read the sensor signal at sensor itself by backprobing.
Why you may ask ? This can tell if the connector + its wire to ECM is not the bad one or indeed there is a broken plastic link internally
This time no need to run the engine, use vacuum hand pump and suck and play with that middle actuator Y22/9 with Ignition ON engine off.
When we suck vacuum actuator Y22/9 using vacuum pump, it will move both tumble flaps.
It should then trigger both B28/9 or B28/10 sensors to send signal to ECM.
So, I changed the Tumbleflap sensor Bank 1, I installed the sensor from the used manifold and until now the failure doesn't come back.
I also changed the hoses, on the M273 there is just 1 coming out from the Manifold and 1 from the vacuum valve. The hose that - comes from the Manifold - has been changed was not the size like the original, so I don't know if it was the sensor or the hose. The hose was also porous. To identify the issue I think I will install the new "issued" sensor to bank 2 to see if the problem comes back....
I'll check that all.
Before I also checked the wires from the sensor plug to the ECU plug with continiuty.
It was all good.
I'll clean them up and we'll see....
Feedback will come
Also do wire harness shake, push,pull, squuze test, while doing continuity test.
Actually load test is better than continuity, but more DIY wiring work as you can't load 5V driver circuit feeding a sensor........
Also do wire harness shake, push,pull, squuze test, while doing continuity test.
Actually load test is better than continuity, but more DIY wiring work as you can't load 5V driver circuit feeding a sensor........
I tested again.
Did continiuty test (from sensor to ecu) with shake, push,pull, squuze...
That's all fine.
Sensor is working from 0V to 5V by manual movement from the tumble flap lever.
Test your female terminal pin tension at the connector plastic body ( containing female terminals ) for the ECU/ECM, wire side.
Your terminals woud be MLK 1.2 for the small one and SLK2.8 for the big one
If you can measure the MALE terminal at the ECU side. Below is MLK 1.2 spec.
size in millimeters
BOSCH ECM also uses Kostal terminals, MLK 1.2 and SLK 2.8
Test your female terminal pin tension at the connector plastic body ( containing female terminals ) for the ECU/ECM, wire side.
Your terminals woud be MLK 1.2 for the small one and SLK2.8 for the big one
If you can measure the MALE terminal at the ECU side. Below is MLK 1.2 spec.
size in millimeters
BOSCH ECM also uses Kostal terminals, MLK 1.2 and SLK 2.8
Tested again
No loose pin connection.
Both valves have a resistance of 30ohms, also good.
Deleted fault code with DAS and Xentry.
The fault comes again.
I wonder why it shows less km in the ECM than it really is.
Odometer 197.490km
ECM. 97.490km
Maybe your Engine computer is rather new of been fixed before and ECM mileage deleted?
If say 200is KH difference, it is normal, I have some modules with less mileage than Instrument Cluster A1.
-----------------
Back to your intake manifold issue :
The only way now is to measure, no need scope the command towards the flap and the sensor value from the said flap, while looking at Xentry.
Two DMM should be enough, but scope is better for sure as it can record glitch.
You need to measure the other sensor, what is the voltage value.
If you DMM has logging feature, even better albeit at 1 data point per second.
But only scope can show us the real high speed command of ECM to flap and response from sensor when the flap move.
I own the car for one year now, so don't know what happened to the car before...
I just own a normal multimeter, no scope for now.
But I keep looking.
Also changed a second time the other sensor from the old manifold to test.
I have to wait some weeks until the fault comes back, can't provocate it.
I experience similar thing before, it turns out my vacuum hose are leaking... and not only that, my vacuum pump also pumping oils. After replacing the vacuum pump and the hose, no more tumble flap issue anymore.
I experience similar thing before, it turns out my vacuum hose are leaking... and not only that, my vacuum pump also pumping oils. After replacing the vacuum pump and the hose, no more tumble flap issue anymore.
That is interesting.
I renew 2 hoses that comes from the Manifold to the valve and one that goes to the pressure sensor. The big hoses from the vacuum pump looked good and I didn't see any oil in it....
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