VW Lupo Diesel Intake Manifold Failure & Performance Drop

Had a similar manifold pressure issue on my 2007 VW Polo TDI. The engine misfire symptoms matched exactly, rough idle, stalling, and heavy exhaust fumes. The gasket leak between the intake manifold and cylinder head was causing significant air intake problems. The repair required complete manifold removal, cleaning of carbon deposits, and replacement of the gasket set. Found scorched areas where exhaust gases had been escaping. The manifold pressure sensor also needed replacement since it was providing faulty readings to the ECU. This is definitely a serious issue that needs immediate attention. Continuing to drive with these symptoms can lead to further engine damage and increased fuel consumption. The root cause in my case was carbon buildup combined with age-related gasket deterioration. Recommend getting it properly diagnosed with manifold pressure testing. The air intake system should be thoroughly inspected, particularly around gasket contact points. Would suggest checking the EGR valve too, as it often contributes to carbon accumulation in these diesel engines. In your case, given the age and mileage, its likely a combination of worn gaskets and carbon deposits affecting proper manifold sealing. Best to have it fixed by a shop specializing in VW diesel engines.

Thanks for sharing your experience with the manifold pressure problems. The symptoms you described match what I experienced. Just curious, do you remember roughly how much you paid for the full repair? My local shop quoted quite high. Also, has everything been running smoothly since the gasket leak was fixed? No more engine misfire or air intake issues? Just want to make sure I know what to expect after the repair.

Since having the intake manifold repaired last month, my VW Polo has been running perfectly, no more engine misfire issues or vacuum leaks at all. The complete fix cost 1180€, which included replacing the scorched manifold sections and installing new gaskets. The car manifold pressure readings are now stable, and those worrying symptoms like rough running and stalling have completely disappeared. Fuel economy has actually improved now that the air intake system is properly sealed again. Looking back, even though the repair cost was significant, it was worth addressing the manifold sensor and sealing problems properly rather than risk more extensive engine damage. These intake manifold issues tend to get worse if left unchecked, so getting it fixed by a qualified shop was the right call. The repair resolved all the vacuum leak symptoms, no more excessive exhaust fumes or performance issues. The engine now runs smoothly and maintains proper manifold pressure like it should.

I finally got my manifold issues sorted after dealing with all those problems. Took it to a certified VW shop last week and got everything properly diagnosed and repaired. Total bill came to 990€, which was actually lower than expected given the work needed. The mechanic found multiple issues, worn gaskets causing a major air intake leak, carbon buildup around the manifold sensor, and some damaged sealing surfaces. They did a complete manifold removal, cleaned everything thoroughly, replaced all gaskets, and installed a new pressure sensor. After picking up the car yesterday, the difference is incredible. No more stalling, rough running is completely gone, and engine performance is back to normal. The exhaust fumes have cleared up too. Really glad I got it properly fixed instead of trying cheaper temporary solutions. Just wish I hadnt waited so long or trusted that previous questionable repair job. Lesson learned about finding a qualified shop that actually knows these engines. At least now I know everything is sealed up right and working like it should.