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

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.

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Average mileage: 125,260 (60,000–251,873)
Engines affected: 1.9L 4 Cylinder Diesel Turbo, 2.0L 4 Cylinder Turbo
10 model years affected: 1996, 2001, 2002, 2003, more2004, 2005, 2006, 2009, 2010, 2012
32 people reported this problem
15 people shared problem details
2003 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo145,000
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!!!!!
2005 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo100,003
sounds like air sucking when shifting, lots of exhaust smoke,fuel use.
2003 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo
Intake was almost completely closed off!
2005 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo75,000
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.
2001 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo60,000
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.
2009 Volkswagen Jetta TDI- 2.0L 4 Cylinder Turbo65,000
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.
1996 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo153,000
Loss of power on acceleration, black smoke out of the tail pipe if I try to accelerate hard.
2010 Volkswagen Jetta TDI- 2.0L 4 Cylinder Turbo104,000
Classic example of carbon and oil buildup in intake manifold which triggered engine light and sticking intake flap.
2001 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo106,328
My car is a 2001 VW beetle diesel 1.9L 4 Cylinder 5 speed.
2006 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo109,000
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.
2004 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo251,873
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.
2006 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo222,000
I have EGR issues. This is the fourth time. The VW shop said that the carbon build up in the manifold is what causing the smell in the interior of the car and also the reduced feul milage as well as power reduction.
2004 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo125,000
Build up of carbon was so great that when starting the engine, the noise mimiked a bag of rocks being moved around. After a week in the shop, the mechanic said there was just build up and there was no way to prevent this from happening again.
2004 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo124,000
Lost power after accerlating at signal light...pistons blew.aaaaarrrggghh 4,000 to put in old but same mileage engine.Jetta diesel wagon 2003/04
2002 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo175,000
intake clogged causing lack of power and excessive black smoke.
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