VW Passat

Early BKP engines tend to crack in the cylinder head, allowing exhaust gases into the cooling system. Typical symptom is intermittent coolant loss. VW sometimes offered 50% goodwill on parts costs.

Symptoms: Coolant warning flashes after long journeys, heater occasionally blows cold air, coolant loss without visible external leak

The hexagonal oil pump drive shaft spins round and loses its positive drive to the oil pump. The pump delivers no oil pressure, causing catastrophic engine failure. Affects all 2.0 TDI 140PS up to build date 03.11.2009.

Symptoms: Oil pressure light illuminates, engine noise suddenly increases, engine dies — often without warning

The undersized hex driver of the oil pump in the balance shaft module wears away; oil pressure collapses. No audible warning — the first indication is the oil pressure warning light just before engine failure.

Symptoms: Oil pressure warning illuminates abruptly, engine dies under full load, turbo bearing damage immediately

The unit injectors wear at high mileage and cause hesitation and power loss between 2,000 and 3,000 rpm. A single defective element costs around €600; four elements cost around €2,400.

Symptoms: Hesitation and power loss in the mid-rpm range, rough running, fault code stored in the engine ECU

The variable turbine geometry turbocharger seizes due to oil additive deposits. The deposits form from burned engine oil and are nearly impossible to remove with conventional means.

Symptoms: Fluctuating engine power, turbocharger fails to build boost, boost pressure regulation fault codes, power loss under load

The Passat B6 rusts on the bonnet, boot lid, doors, wheel arches and A-pillars. Inadequate cavity protection at the rear and sharp drill holes in sheet metal joints promote zinc blisters and widespread corrosion from about 2–3 years.

Suspension springs on the Passat B6 break, causing dangerous listing of the vehicle. Particularly affected are vehicles with many kilometres of city driving. Suspension springs are a known weakness of this model.

Wheel bearings on the Passat B6 wear earlier than usual — both front and rear. Damage to front wheel bearings is documented from as early as 100,000–150,000 km; on the Passat Variant the rear axle is also affected.

The steering rack on the Passat B6 develops knocking and clunking noises at full lock and shows increased steering play. A new steering rack including fitting costs over €2,000.

The electric parking brake on the Passat B6 fails due to defective actuator motors at the rear brake callipers. When defective, the brake can neither be applied nor released, requiring recovery.

On 4Motion variants of the Passat B6, the Haldex clutch fails through blocked oil filters or pump failures when the oil change interval (60,000 km) is not maintained. The vehicle then runs on front-wheel drive only.

Rust around the rear number plate lights is typical on the Passat B6, caused by inadequate sealing at the mounting holes of the lighting unit. VW revised the design from October 2007.

On the 2.0 TDI BMP/BMR, the cooling system loses fluid via the water pump or EGR cooler. Coolant evaporates during operation without visible drops. Cylinder head at risk if neglected.