VW Polo Diesel's Rough Running & Stalling Crisis Revealed

Had similar symptoms on a 2015 VW Golf TDI at 160000km. The engine misfire and rough running turned out to be a significant intake manifold pressure leak. The scorching around the gasket created a vacuum leak, causing unstable manifold pressure and poor engine performance. The repair required replacing the entire intake manifold assembly and gaskets. The damage was extensive since the leak had been occurring for some time, affecting multiple engine components. The check engine light triggered due to the system detecting irregular air-fuel mixtures. This is typically a serious issue requiring immediate attention. Continuing to drive with these symptoms risks further engine damage. The repair involves: Complete manifold removal, Inspection of surrounding components, Replacement of damaged gaskets, Testing for proper manifold pressure, ECU reset and system diagnostics The job took 2 full days at the shop. Would recommend finding a specialist familiar with VW TDI engines, as proper diagnostic equipment is essential for this repair.

Exact same issue on my 2017 Polo last winter. The check engine light came on and the engine misfire symptoms matched yours perfectly, rough idle, jerking, and that unmistakable exhaust smell. My gasket leak turned out to be worse than initially thought, affecting both the intake manifold and surrounding components. The repair sorted out the problem completely and my car runs like new now. No issues since the fix, which is a relief given how worrying those symptoms were. Did you end up getting yours fixed? Curious about what you paid since repair costs seem to vary quite a bit. Have you noticed any other problems popping up after the repair?

Glad to update on my repair experience. After taking my Golf to a VW specialist, they confirmed the intake manifold was severely compromised. The manifold pressure readings were way off due to the scorching damage around the gasket area. The repair cost came to 1180€, which included replacing the entire intake manifold assembly and associated components. Since the fix, the engine performance has returned to normal. No more check engine warnings, rough running, or exhaust smell issues. The manifold sensor readings are now stable, and the air intake system is working as intended. It was definitely worth addressing promptly to prevent additional engine damage. The repair has held up perfectly for the past 8 months. No related issues have emerged since, and the engine maintains steady power delivery without any hesitation or misfires. The air-fuel mixture is properly regulated now that the manifold pressure is correct. You made the right call getting yours repaired too. These intake manifold problems tend to worsen quickly if left unchecked.

I finally got mine fixed after finding a reputable VW specialist. The diagnostic confirmed what I suspected, a failing intake manifold causing those nasty performance issues. The gasket leak had gotten pretty bad, allowing excess air into the system and throwing off the engine performance. The total repair came to 950€, which included: New intake manifold assembly, Replacement gaskets, Labor for removal and installation, System diagnostics and ECU reset The repair took about a day and a half, but the results were worth it. The engine runs smoothly now with no more jerking or stalling. The exhaust smell is completely gone and the check engine light hasn't come back. Been driving for about 2 months since the fix without any issues. Huge difference from my previous mechanic who just kept resetting the check engine light without addressing the actual vacuum leak. Really glad I found someone who properly diagnosed and fixed the underlying problem.