KNOWN FAULTS · Volkswagen

Volkswagen Passat B5 / B5.5 common problems.

2000–2005 · Petrol / Diesel

Sources are not verified in real time and no entry confirms that your car is affected.

4 known faults with sources

Engines: 1.6 / 2.0 (atmosférico) (Petrol) · 1.8 T (Petrol) · 1.9 TDI (Diesel) · 2.5 TDI V6 (Diesel)

Applies if: Weak points of this model from inspections, breakdown statistics and recalls; anything specific to one engine is stated in the sheet.

Water in the brake servo and engine from blocked drains (Passat B5)Known weak points

Engine / equipment: Volkswagen Passat B5 and B5.5 (petrol and diesel)
Period mentioned: 1996–2005
Symptoms: Water building up below the windscreen (ventilation plenum) that rusts the brake servo from inside: a hard brake pedal, less braking or failure; if the diaphragm perforates, the engine sucks in water (emulsion under the oil cap) and can hydrolock. Also damp carpets from blocked air-conditioning or sunroof drains.
Possible cause described: Uncleared ventilation-plenum drains. In 2007 the VAG group issued a bulletin (TSB 51B8) to check the drains; replacing the servo, pipes and vacuum pump cost about £980.
Check for the garage: Clear the drains below the windscreen; look for water there and emulsion under the oil cap; feel the carpets.
Cost cited in the source: No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.

Engines: 1.8 T (Petrol)

Applies if: Only the 1.8 T.

Ignition coils on the 20-valve 1.8 TEngine

Engine / equipment: 20-valve 1.8 T: Golf IV, Bora, Passat B5, Audi A3 8L and A4 B5, Seat León
Period mentioned: Approx. 2001–2003
Symptoms: Misfires, hesitation and the engine light; the engine runs on one cylinder fewer.
Possible cause described: The individual coils on 1.8 T engines from those years failed frequently. The German guide quotes about €100–200 for coils and leads.
Check for the garage: Read the per-cylinder misfire codes and replace the affected coil (preferably with a revised one).
Cost cited in the source: Approx. €100–200 for coils and leads (German guide).A rough figure from the original database, not an up-to-date quote.

Engines: 1.9 TDI (Diesel)

PD TDI camshaft, injectors and cylinder headInjection / cylinder head

Engine / equipment: 1.2, 1.4, 1.9 and 2.0 TDI unit-injector (PD) engines, including the VW-sourced 2.0 CRD in Chrysler, Dodge and Jeep
Period mentioned: 2000–2010
Symptoms: Growing noise from the cylinder head, power loss and rough running (cams and lifters); unstable idle, smoke or hesitation (injectors); on the 16-valve 2.0 TDI, coolant loss with no visible leak from a cracked head.
Possible cause described: The camshaft also drives the unit injectors and carries a heavy load: without VW 505.01 oil the lobes and lifters wear. 2.0 TDI PD injectors fail frequently. Some 16-valve 2.0 TDI heads (part number ending in A) crack; VW considered it fixed by the end of 2006.
Check for the garage: Check the oil history (VW 505.01), listen to the head, check injector balance rates with a diagnostic tool and, on the 16-valve 2.0 TDI, read the head part number (03G 103 351) and look for coolant loss.
Cost cited in the source: Camshaft and lifters: approx. €400–800; 2.0 TDI PD injectors: €900–2,000A rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: 120,000–200,000 km. This is not a maintenance interval and does not predict a failure.

Engines: 2.5 TDI V6 (Diesel)

Applies if: Same 2.5 TDI V6; the sources cover the A4 and the A6.

Worn camshafts, air mass meter and injection pump on the 2.5 TDI V6Engine

Engine / equipment: 2.5 TDI V6 with distributor pump: Audi A4 (B5 and B6), A6 (C5) and VW Passat B5
Period mentioned: 1997–2005
Symptoms: An engine that runs rough, loss of power or hesitation; now and then the injection pump fails; oil leaks from the engine or gearbox.
Possible cause described: AUTO BILD (March 2008) reports more and more complaints about the A4's 2.5 V6 because of worn camshafts (Audi did not issue a recall) and adds that the Multitronic gearbox fails mainly with this engine, because of its high torque. On the A6 (1997–2004), AUTO BILD lists faulty air mass meters causing loss of power or hesitation, injection pumps that fail now and then and oil leaks from the engine and gearbox, mainly on the TDI. The Passat B5 has the same engine.
Check for the garage: If the engine gets noisier or runs worse with the miles, have the garage check the camshafts by removing the cam covers. Read the codes and test the air mass meter before touching the pump. With the Multitronic gearbox, ask for its history and check that it does not jerk or slip.
Cost cited in the source: No verified estimate; ask the garage for a quote.A rough figure from the original database, not an up-to-date quote.