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.

RepairPal Verified
Average mileage: 132,699 (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
45 people reported this problem
22 people shared problem details
2005 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo100,003
sounds like air sucking when shifting, lots of exhaust smoke,fuel use.
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.
2003 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo
Intake was almost completely closed off!
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.
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!!!!!
2009 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo99,000
Loss of power due to carbon build up in the intake manifold,also cat
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.
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.
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.
2002 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo175,000
intake clogged causing lack of power and excessive black smoke.
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.
2009 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo128,000
just been told that the turbo went out and they will replace the manifold along with it. Almost $5000 Deb
2010 Volkswagen Jetta TDI- 2.0L 4 Cylinder Turbo82,877
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).
2013 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo96,000
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???
2006 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo205,000
When turbo is kicking in sounds like a whistle going up in pitch. Black smoke when stepping on it. Terrible mpg about half normal.
1998 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo300,000
Accelerates slow, after car is warm and then restarted it Rev up to 2,000 rpm the back to normal idle, has code p0605
2010 Volkswagen Jetta TDI- 1.9L 4 Cylinder Diesel Turbo113,400
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.
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.
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