Loss of Power Due to Oil and Carbon Build Up in Intake Manifold on Volkswagen Jetta TDI

Problem Description and Possible Solution

Oil and carbon tend to build up, creating restrictions in the intake manifold. Symptoms will be loss of power (sometimes severe) and poor fuel economy.

Problem Data
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Average mileage: 132,252 (60,000–300,000)
Engines affected: 1.9L 4 Cylinder Diesel Turbo, 2.0L 4 Cylinder Turbo
14 model years affected: 1996, 1997, 1998, 2000, more2001, 2002, 2003, 2004, 2005, 2006, 2009, 2010, 2012, 2013
51 people reported this problem
Viewing 1 - 20 of 23 comments
Loss of power on acceleration, black smoke out of the tail pipe if I try to accelerate hard.
sounds like air sucking when shifting, lots of exhaust smoke,fuel use.
loss of power- check engine light comes. Problem happende in 2009 and has reoccured at end of 2011. Mechanic found carbon build-up in intake manifold.
Intake was almost completely closed off!
Glow plug light came on and engine lost power. Sucked it ups took to VW dealership for diagnostic and they said I had a loose air hose on my 2013 TDI Passat. John told me the repair cost would be $3,600.00 to replace exhaust filter, Exhaust Heat Sensor, and other parts because there is no warning until something gets clogged up from the excess diesel causing excessive build up in the exhaust system.
Million dollar question is could this be true or am I being scammed to cover up some of the fraudulent software on the VW TDI's???
Classic example of carbon and oil buildup in intake manifold which triggered engine light and sticking intake flap.
Slight loss of power. Mechanic recommended clean-up before things got worse. $600 repair but now I have the peppy TDI that I fell in love with and approx 3mpg better.
Accelerates slow, after car is warm and then restarted it Rev up to 2,000 rpm the back to normal idle, has code p0605
Loss of power due to carbon build up in the intake manifold,also cat
EGR valve had an electrical short within the EGR valve. Needed engineers from home office to locate the problem. The fix replace valve. Now at 80000 miles service, vaccuume hose leak causing power loss and possible intake manifold replacement.
engine refused to start at 74000, and 140,00 miles dealer said clogged egr and intake manifold, required cleaning on first one, required replacement of egr and intake on second job and several thousand dollars later and 5000 miles it is going again.

Avoid vw diesels!!!!!
When turbo is kicking in sounds like a whistle going up in pitch. Black smoke when stepping on it. Terrible mpg about half normal.
Engine light came on. Dealer diagnosed that the Intake Flap Motor needs to be replaced, and they want $690 for the part! There was a recall (actually a "Required Vehicle Update") that replaces this part free of charge for regular gas vehicles, but not for the TDI (diesel vehicles). Doesn't make sense to me. Obviously, they have the same problem with the diesel cars.
intake clogged causing lack of power and excessive black smoke.
My car is a 2001 VW beetle diesel 1.9L 4 Cylinder 5 speed.
taking car in now for expensive repair. even mechanic said poor design. manifold intake valve needs replacing. only warning was warning light came on. ridiculous if woll be continuing issue.
The car seems to run great but the check engine light is on. The dealership said it retrieved the fault codes P2015 & P2016 & the car needs to have the intake manifold assay replaced….$1,100. Do I have other options? this has been 300 miles ago & the car is still running great but for how long? thx joel
just been told that the turbo went out and they will replace the manifold along with it. Almost $5000
Deb
Lost all power while driving on highway. Dealer tech diagnosed: "throttle body failed/stuck due to carbon build up." The failed throttle body was replaced. Tech removed and cleaned carbon build up from EGR valve. I was charged over $1,000 for the repair (dealer applied coupon of $100, so total out of pocket was $956.07).
Car was hard to start and would cut off 3 or 4 times before it would run. Rough idle even when warm. Replaced injectors and EGR cooling tubes several times. Cleaned intake and now all is good. Also replacing tandem pump for good measure as it is leaking oil significantly.