Intake manifold replaced and loss of power

[Delj1983]

Intake manifold replaced, now loss of power.

Hi all, I’ve had the intake manifold replaced due to the engine warning light and fault codes. I’ve now noticed a considerable power loss compared to before the replacement. There isn’t any warning lights or codes ( the van was remapped by the previous owner).

Has anyone else had this problem? Thanks

 

[e82_rk]

I have this same issue replaced the intake manifold today car is running smooth just not much power it also had been remapped by last owner

 

[Delj1983]

I’m going to do a smoke leak check on the manifold this week to rule out an air leak. Failing that I’m thinking it needs to be remapped for the new runner actuator?

 

[e82_rk]

Let me know how it goes i can see my actuator does move when the engine is running but not sure if its doing it correctly for example with the engine on without revving it it was opening and closing slowly then stopped so maybe it does need to be reset? I will also try get a smoke test done Monday.

 

[FWhite]

Let me know how it goes i can see my actuator does move when the engine is running but not sure if its doing it correctly for example with the engine on without revving it it was opening and closing slowly then stopped so maybe it does need to be reset? I will also try get a smoke test done Monday.

I heard about the complete intake flaps / actuator being removed when remapping.
It seems it is there for pollution improvement only but in the long run some plastic parts can get sucked in causing engine damage, so some tuner diligently remove them.
Are you sure you had it installed and connected before?

 

[indy4x]

Not sure of the purpose on a VW but my previous drive was an 09 Jeep Grand Cherokee with the Mercedes OM642 V6 diesel engine.

The flaps in the intake manifold (called swirl flaps by MB) were there to improve low down torque

 

[FWhite]

Not sure of the purpose on a VW but my previous drive was an 09 Jeep Grand Cherokee with the Mercedes OM642 V6 diesel engine.

The flaps in the intake manifold (called swirl flaps by MB) were there to improve low down torque

Well, like it had not enough torque...

I still have a big Merz Diesel and sure it doesn't miss torque.

But yes, you're right. That low rpm torque would probably translate in lower rpm utilization and then less pollution too.
But that may have taken care of during the mapping in your TDI.
The problem with the VW is that the flaps are made of somehow weak plastic and in the long run they may get sucked in, so some workshops decide to just remove them.

 

[e82_rk]

I heard about the complete intake flaps / actuator being removed when remapping.
It seems it is there for pollution improvement only but in the long run some plastic parts can get sucked in causing engine damage, so some tuner diligently remove them.
Are you sure you had it installed and connected before?

Yes I remove the old intake manifold and actuator myself and was changing it due to the rod shaking and causing an air leak but it had a lot more power before replacing and only issue was going in limp mode every now and then

 

[Delj1983]

Same as above, the removed intake and the new intake both look the exact same. The reason I replaced it (genuine VW parts) was due to engine management light and runner code which cleared after the replacement. The only thing I can think of is that the remap does not recognise the new actuator? There’s no codes using Carista and the van runs really well but a loss of power at top end and garages can’t run their diagnostics due to the remapping software