Volkswagen Passat B6 1.9 / 2.0 TDI PD common problems.

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.

Sources from the original database

Engine / equipment

DQ250 6-speed wet-clutch DSG (2.0 TDI, 2.0 TSI and other powerful engines in the Golf, Passat, Tiguan, A3, TT, Octavia, Superb, Leon…)

Period mentioned

2003–2020

Symptoms

Jerking or shudder when pulling away and at low speed, harsh shifts, gearbox warning or limp mode; codes P17BF, P189C, P0841, P0871 or P0717.

Possible cause described

In most cases the cause is the mechatronic unit (the electro-hydraulic control unit), not the clutches. The oil shares a circuit with the clutches and degrades, carrying debris that damages the valves; the pan can also rust and leak. Volkswagen specifies an oil and filter change every 60,000 km.

Check for the garage

Read codes with ODIS or VCDS, check the oil change history, inspect the pan for rust or leaks and the clutch adaptation values. Replacing the mechatronic control board is often enough.

Cost cited in the source

Oil and filter change: maintenance every 60,000 km; control board or mechatronic: expensive repairA rough figure from the original database, not an up-to-date quote.

Mileage cited in the database: from 60,000 km. This is not a maintenance interval and does not predict a failure.

Sources from the original database

Engine / equipment

Air conditioning with clutchless compressor and N280 regulating valve (combustion VW, Audi, Seat, Cupra and Skoda from 2006)

Period mentioned

2006–2026

Symptoms

The air does not cool or cools intermittently (for example only at motorway speed), and sometimes the compressor rattles with the A/C on. Codes 01232 (N280 valve), P2612 or 00898.

Possible cause described

The compressor regulates its output with the N280 solenoid valve, its most common failure point. Audi issued technical bulletins over a manufacturing fault in this valve on Sanden compressors. Its connector can also become brittle and corrode (especially without the engine undertray), or the wiring fails.

Check for the garage

Read the codes and N280 control current with VCDS or ODIS, measure its resistance (about 10 ohms) and check the connector and wiring before replacing parts. If the valve or compressor is replaced, the whole circuit must be flushed.

Cost cited in the source

N280 valve: a cheap part (about 30 dollars) where sold separately; new compressor with circuit flush: considerably moreA rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

2.0 TDI pump-injector: VW Passat and Sharan, Audi A4 and A6, Škoda Superb and Seat Alhambra from 2005–2009

Period mentioned

2005–2009

Symptoms

The oil pump stops working all at once, nearly always at high revs. The red oil pressure warning light comes on when the damage is already done.

Possible cause described

AUTO BILD (May 2013): the hexagonal shaft that drives the oil pump wears and can end up spinning freely; VW puts it down to “tolerance deviations”. Without oil at least the turbo is ruined, and often the whole engine. VW and Škoda confirmed cases “in the three-digit range” and review each case for a goodwill contribution. The group's other 2.0 TDI engines have a different pump drive.

Check for the garage

If the oil pressure warning light comes on, stop the engine as soon as you can and do not drive on. VW does not recommend a preventive repair; if you want one, the balance shaft module, which holds the shaft, is replaced. If the engine has already failed, ask the brand for a goodwill contribution.

Cost cited in the source

€1,300 to €1,700 for the balance shaft module at the dealer; an independent workshop replaced just the shaft and its seat from €650 (AUTO BILD, 2013).A rough figure from the original database, not an up-to-date quote.

Sources from the original database

Engine / equipment

VW Passat B6 1.6 FSI and 2.0 FSI; the 140 PS 2.0 TDI has the same symptoms

Period mentioned

2005–2009

Symptoms

It is hard to start and the electronic engine management plays up.

Possible cause described

According to L'argus (February 2009), on the Passat 1.6 FSI and 2.0 FSI a faulty earth point in the engine bay causes hard starting and electronic management glitches; the 140 PS 2.0 TDI has the same starting and electronic problems. Some of these Passat faults were the subject of recalls.

Check for the garage

Have the garage check and clean the earth points in the engine bay before replacing sensors or control units, and ask VW by VIN whether any recall is still open.

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.

Sources from the original database

Engine / equipment

VW Passat B6 2.0 TDI 140 PS from 2006 and 2007

Period mentioned

2006–2007

Symptoms

The coolant level drops a lot and has to be topped up often.

Possible cause described

According to L'argus (February 2009), Passat 2.0 TDI 140 PS cars from 2006 and 2007 showed excessive coolant consumption because of a porous cylinder head gasket. VW set up a scale of contributions towards the repair.

Check for the garage

Check the coolant level with the engine cold and do not drive on if the temperature warning comes on. To confirm the head gasket, the garage can pressure-test the system and look for combustion gases in the coolant.

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.

Sources from the original database

Engine / equipment

VW Passat B6 2.0 TDI 170 PS (pump-injector)

Period mentioned

2005–2009

Symptoms

The glow plug preheating fails, which on a diesel usually shows when starting from cold.

Possible cause described

According to L'argus (February 2009), the preheating problems on the Passat 2.0 TDI 170 PS came from the Wehrle preheating control unit, which was replaced with a Beru or Bosch one.

Check for the garage

Have the garage read the preheating fault codes and check the make of the control unit: if it is a Wehrle, the fix is to replace it with a Beru or Bosch one. Check the glow plugs too.

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.

Sources from the original database