VW Caddy Diesel: Power Loss and Intake Manifold Fix

Last month, my VW Golf 2.0 TDI (2012) showed the same symptoms. The intake manifold flap control system was failing, causing inconsistent airflow control during acceleration. Despite no engine light, the power loss and fuel consumption increase were clear signs. The manifold flap actuator had carbon buildup preventing proper movement. The flap itself was stuck, disrupting proper air distribution. This affected engine performance significantly, especially during acceleration. The hissing sound came from air leaking around the compromised flap seal. The repair required: Complete intake manifold removal, Cleaning of flap control mechanism, Replacement of actuator and worn seals, System recalibration This was a serious issue requiring immediate attention. Leaving it unfixed risks further engine damage and continued poor performance. Recommend finding a workshop specializing in VAG diesel engines, as they frequently handle intake manifold flap issues. Key diagnostic steps they performed: Vacuum system testing, Flap movement verification, Intake pressure sensor check, Complete manifold inspection The repair eliminated all symptoms, smooth acceleration returned, fuel efficiency improved, and the hissing disappeared.

Thanks for sharing those repair details. Sounds exactly like what my Caddy experienced, even the bit about no engine light despite the reduced power and hissing. The mechanics also found carbon buildup affecting the manifold flap on mine. Just curious, what did the full repair end up costing you? And has everything been running smoothly since the fix? My intake manifold repair was completed about 6 months ago, but recently noticed some minor flap control issues again, though nothing as bad as before. Would be really helpful to know if any follow-up maintenance was needed in your case. The carbon buildup seems to be a common problem with these intake systems.

Good to hear you had similar issues fixed. Since seeing the mechanic about my Golf TDI intake manifold flap control problem, everything has worked perfectly. The total repair came to 465€, which covered replacing the defective switch intake manifold control and thorough cleaning of the system. After 8 months, engine performance remains strong with no signs of the previous reduced power or hissing. The intake system now works as intended, and fuel consumption has stayed normal. No follow-up repairs have been needed. To prevent future carbon buildup in the intake manifold, I now use a high-quality fuel additive every 10000km. This helps keep the flap control mechanism clean and moving freely. Also running the engine at higher RPMs occasionally seems to help prevent deposits from forming. If youre noticing minor flap control issues again, might be worth getting the intake system checked soon before it develops into a bigger problem.

Thanks for the advice. After dealing with the issues described, I finally took my Caddy to a specialist diesel workshop last week. They confirmed the manifold flap was sticking due to carbon deposits, leading to poor airflow control and the engine performance problems I mentioned. The total repair came to 520€ including: Manifold removal and cleaning, New flap control actuator, Fresh seals, System testing The mechanic showed me the gummed-up parts and explained how carbon buildup affects the intake system over time. He recommended using fuel system cleaner every 5000km to help prevent future issues. After a week of driving, the engine runs much smoother. No more jerking during acceleration or hissing sounds. Fuel consumption is back to normal too. The mechanic even gave me his direct number in case any flap control problems come back, though he expects the fix to last with proper maintenance. Glad I found a reliable workshop that knew exactly what to check. The whole experience was much better than my previous repair attempts elsewhere.