Rough Audi A4 TDI: Intake/Manifold Warning Signs Alert

Had similar symptoms with my 2016 Audi A6 3.0 TDI. The check engine light triggered due to an intake manifold leak, causing engine misfire and rough idle. The manifold pressure sensor readings were inconsistent, indicating a serious vacuum leak. The intake manifold had developed hairline cracks from heat stress, allowing unmetered air to enter. This caused the air-fuel mixture to run lean, resulting in poor performance and the strong exhaust odor. Initially thought it was just a simple gasket issue, but the problem was more severe. The repair required complete intake manifold replacement since the scorching had warped the original unit. The job included: New intake manifold assembly, Replacement of all related gaskets, New manifold pressure sensor, Full system diagnostic check, Air intake system cleaning This was not a minor repair, the intake manifold is a critical component affecting engine performance. Driving with this issue risks further engine damage. The symptoms match exactly what you describe, and based on your mileage, its a common failure point for this engine series. Recommend finding a certified Audi specialist who can properly diagnose and document the manifold pressure readings before starting repairs.

Thanks for sharing your experience. My car had nearly identical symptoms and it turned out to be a split intake manifold too. Very annoying issue that really hurt engine performance until fixed. Just curious, do you remember the total repair cost for the manifold replacement and gasket leak repairs? Also wondering if youve had any other related issues pop up since getting it fixed? My check engine light came on again last week and Im worried its connected to the original problem.

After getting it properly repaired by a certified shop, I can confirm the total cost came to 1180 Euro for fixing the intake manifold that was damaged from scorching. This included replacing all compromised gaskets and installing a new manifold pressure sensor. Since the repair, my engine has run perfectly smooth with no check engine warnings or vacuum leaks. The fresh manifold installation completely resolved the rough running and power loss issues. If your check engine light has returned, I would suggest having it scanned right away. While its unlikely to be related to the previous manifold repair if it was done correctly, its best to catch any potential issues early before they cause additional engine damage. A properly repaired intake manifold system should provide years of reliable service. The key is using quality parts and ensuring all gasket seals are correctly installed during reassembly. A vacuum leak test after repair can confirm everything is sealed properly.

Thanks everyone for the replies and advice. Finally got the car back from the shop yesterday after getting the manifold issues fixed. Total bill was 1350 Euro, a bit more than expected but worth it to have the car running properly again. The mechanic showed me the cracked intake manifold and worn gaskets they removed. Pretty obvious why the engine was running so rough. They replaced the entire manifold assembly, all gaskets, and installed a new manifold pressure sensor since the old one was giving false readings. Car runs like new now, no more jerking during acceleration or exhaust smell. The air intake system is properly sealed and the engine pulls strong again. Really glad I got it addressed before causing more damage. Will definitely keep monitoring for any warning lights, but the shop did thorough testing after the repair and everything checks out normal now. Lesson learned about not ignoring these symptoms when they first appear.