Jetta TDI

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
RepairPal Verified
Average mileage: 133,703 (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
57 people reported this problem
Viewing 1 - 20 of 26 comments
Loss of power on acceleration, black smoke out of the tail pipe if I try to accelerate hard.
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???
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!
Classic example of carbon and oil buildup in intake manifold which triggered engine light and sticking intake flap.
Loss of power due to carbon build up in the intake manifold,also cat
When turbo is kicking in sounds like a whistle going up in pitch. Black smoke when stepping on it. Terrible mpg about half normal.
Accelerates slow, after car is warm and then restarted it Rev up to 2,000 rpm the back to normal idle, has code p0605
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.
intake clogged causing lack of power and excessive black smoke.
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 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.
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!!!!!
My car is a 2001 VW beetle diesel 1.9L 4 Cylinder 5 speed.
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
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.
Vehicle runs for 3 or more hours the looses substantial power and can hardly make it up small hills.. shut car off for about 5 minutes, seems to be fine for another 2-3 hours, then same problem...loss of mileage appx 10-12%...56 mpg to 46 mpg...engine bucks like its missing...
very slow acceleration; took it to VW they changed exhaust manifold and EGR cooler. Solved problem. Cost $1500.
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).