VW Crafter Stalling Issues, Common Air Valve Problem

As a hobby mechanic with some repair experience, I had a similar issue with my 2004 VW Transporter TDI. The symptoms were nearly identical, unstable idle speed and stalling, especially after the engine reached operating temperature. The idle control problems turned out to be caused by heavy carbon buildup in the intake manifold. The workshop did a thorough cleaning of the intake system and replaced the air valve since it was also contaminated. Total repair cost was 425€, which included diagnostics, cleaning, and parts. After the repair, the idle speed remained stable and the stalling completely stopped. The check engine light also cleared and never came back. For your Crafter, would you mind sharing: Current mileage, Any previous intake or air valve repairs, Whether you notice any black smoke when accelerating, If the stalling happens more frequently in certain conditions This information would help determine if you are dealing with the same intake contamination issue. These symptoms are common on diesel engines from that era, but proper diagnosis is important before replacing parts.

Thanks for sharing your experience. My Crafter has 120095KM on the clock with the last service done 3 months ago. The engine idle problems started about 2 weeks ago. No black smoke during acceleration, but the engine stalling happens most frequently right after stopping at traffic lights when the engine is fully warm. The idle speed becomes very erratic, dropping from normal to almost zero. Your intake manifold cleaning suggestion makes sense, since our symptoms match closely. Have not had any previous air valve or intake repairs done yet. Did your mechanic need any special tools for the intake cleaning procedure? Also wondering if there are any preventive measures to avoid this buildup from happening again once fixed.

The intake cleaning on my Transporter was done with specialized carbon cleaning equipment, but any qualified workshop should have these tools. The process took about 2-3 hours for a complete cleaning. Based on your mileage and symptoms, it sounds exactly like the idle control issues I experienced. The erratic idle speed and stalling at traffic lights are classic signs of carbon buildup affecting the IAC valve function. Since your last service was recent, ask if they checked the air intake system. In my case, regular maintenance helped prevent the issue from returning. I now: Use high-quality fuel, Replace the air filter more frequently (every 15000km), Run the engine at higher RPMs occasionally to help clear deposits, Get the intake system checked during each service The total cost for preventive maintenance is much lower than waiting for complete system failure. The IAC valve and intake cleaning should resolve your idle problems completely, just as it did on my van. Make sure they check all intake components while the system is apart.

Appreciate the detailed feedback and maintenance tips. Will get the car booked in next week for the intake system cleaning and IAC valve check. The regular idle speed drops and engine stalling are becoming really frustrating, especially in traffic. Since the symptoms match your experience so closely and we have similar vehicles, I feel more confident about the likely cause now. The lack of black smoke in my case also suggests carbon buildup rather than a fuel system problem. Your preventive maintenance schedule makes a lot of sense. Never realized the air filter should be changed that frequently, but it seems worth it to avoid these idle control issues returning. Will definitely implement your suggestions about using better fuel and occasional higher RPM running once the repair is complete. Thanks for confirming the repair time and explaining the cleaning process. Good to know it needs special equipment, will make sure to find a workshop that has the proper tools for carbon cleaning. Really hoping this fixes the engine stalling issue once and for all.