In Sept I had to have the entire intake manifold replaced (covered by warranty) because the "intake runner has broken from the adjustment lever". The way the dealer explained what that means sounds just like what you explained. It took them like 3 months to track down the problem and my symptoms just kept getting worse and worse (rough idle, misfires, bad engine "hiccup" at 2500 rpms). I also had all injectors replaced at the same time and had carbon build up hand cleaned. Car ran great for a while and now I can feel the "hiccup" starting again at 2500 rpms. Dealer explained about how VW has redesigned the intake manifold for 2010's due to this issue. I have to say, reading your post is depressing as I have this sinking feeling that this is not the last time I will have to replace the intake manifold.
Reviews of OEM Volkswagen intake manifold
40 votes
I had my intake manifold replaced at 30k miles now I have 107k miles and they are telling me it needs to be replaced again due to some faulty vacuum flap....never hear problems like this with Japanese cars....
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