Popular mid-size family car with solid build quality and spacious interior. The B7 is essentially a facelifted B6 with improved reliability. The 2.0 TDI EA189 engine is proven and can easily reach 200,000+ km with proper maintenance, though it has well-documented DPF, EGR, and dual-mass flywheel issues. Manual transmission is more reliable than the DSG. Main concerns: DPF clogging from short trips, timing belt service every 5 years/130,000 km, and clutch/flywheel wear around 100,000 km. Watch for rust on estate models in regions with road salt. Pre-2012 TSI petrol engines should be avoided due to timing chain issues.
Blocked filter from short trips causes power loss and warning light · more· less
The DPF clogs when the car is driven primarily on short trips or at low speeds, preventing proper regeneration. Symptoms include loss of power, increased fuel consumption, and the DPF warning light illuminating. Some owners report the car attempting to regen every couple of weeks without completing successfully. Professional cleaning costs €200-400, while replacement runs €1,500-2,500. To prevent this, regularly drive at highway speeds (100+ km/h for 20+ minutes) to allow proper regeneration. The DPF material can swell and contract causing fractures which lead to fragmentation, reducing catalyst efficiency.
Dual-mass flywheel failure€800 - €1,600
Typically fails around 100,000-150,000 km causing vibration and noise · more· less
The dual-mass flywheel on 2.0 TDI models typically fails between 100,000-150,000 km. Symptoms include vibration through the pedals, rough running, and rattling at idle or during gear changes. Parts cost €250-500 (OEM brands like LuK or Sachs), with 3-6 hours labor (€400-900). Total cost ranges from €800-1,600. When replacing the flywheel, it's strongly recommended to replace the clutch simultaneously since the labor overlaps. Combined clutch and flywheel replacement runs €1,000-2,000. The crankshaft needle bearing and bolts must be renewed when replacing the DMF as the bolts are stretch-type.
EGR (Exhaust Gas Recirculation) valve failure€500 - €1,200
Carbon buildup causes sticking valve, rough idle, and EPC light · more· less
Contamination of the EGR valve and swirl flaps is a common fault on EA189 engines. Carbon soot buildup from short trips causes the valve to stick, resulting in rough idle, poor starting, and the EPC warning light. On the Passat B7, the EGR is difficult to access, which increases labor costs. Professional replacement costs €700-1,200 at Volkswagen dealers, or €500-800 at independent specialists. Some owners clean the EGR and throttle valve themselves every 40,000-50,000 km as preventive maintenance (takes about 1 hour). Vehicles driven primarily on short trips around town are more prone to EGR valve problems.
Timing belt and water pump€600 - €1,100
Scheduled replacement every 5 years or 130,000 km - essential maintenance · more· less
The 2.0 TDI engine requires timing belt replacement every 5 years or 130,000 km, whichever comes first. This is critical maintenance - if the belt fails, it will cause catastrophic engine damage (bent valves, damaged pistons). At independent garages in the Netherlands/Germany, expect to pay €500-800 for timing belt replacement, or €700-1,100 at Volkswagen dealers. It's strongly recommended to replace the water pump simultaneously (adds €100-250), as it's driven by the timing belt and has a similar lifespan. If the water pump fails 6-12 months later, you'll pay another €300-600 in labor to redo the job. The kit including belt, tensioners, and water pump costs €150-250 for quality aftermarket parts.
Turbocharger failure€1,200 - €2,500
Oil contamination causes sudden power loss and black smoke · more· less
Turbo failure on the 2.0 TDI EA189 is often caused by oil contamination or failure to maintain proper oil change intervals. Symptoms include sudden loss of power, black smoke from exhaust, and difficulty accelerating. Some 2012-2014 Passat TDI models experienced turbo failures at relatively low mileage (under 100,000 km) due to manufacturing defects - there was a recall with extended warranty coverage (10 years/120,000 miles) for affected turbos. Replacement cost ranges from €1,200-2,500 depending on whether you use remanufactured or new OEM turbos. To prevent failures: use VW-approved synthetic oil, change oil every 10,000-15,000 km, and avoid excessive idling.
Fuel injector failure€600 - €2,500
Failed injectors cause rough running, smoke, and poor starting · more· less
Fuel injector issues are relatively common in the 2.0 TDI, especially on high-mileage cars. Injectors can fail from the factory, become clogged from poor fuel quality, or start leaking. In many cases injectors become noisy even at low mileage. Symptoms include rough running, black smoke, poor cold starting, and reduced power. A single injector replacement costs €600-900 (parts €250-350 + coding + labor). If multiple injectors fail, costs can reach €2,000-2,500 for all four. Important: replacement injectors need coding to the ECU. Injector 3 is more expensive as it contains an in-cylinder pressure sensor. Use premium diesel fuel and replace fuel filter every 30,000-40,000 km to minimize risk.
DSG DQ250 mechatronics (if equipped)€300 - €1,800
6-speed wet clutch DSG is reliable but requires service every 60,000 km · more· less
The 6-speed DSG DQ250 fitted to 2.0 TDI models is the wet-clutch variant, which is more reliable than the 7-speed DQ200 dry-clutch version. This gearbox has proven reliable when properly maintained. DSG service (oil and filter change) is required every 60,000 km and costs €250-350 at independent specialists, or €350-450 at Volkswagen dealers. If neglected, mechatronics unit failures can occur, costing €1,200-1,800 to repair/replace. The manual transmission is even more reliable and has lower maintenance costs, making it the preferred choice for high-mileage drivers.
PCV valve failure€150 - €350
Plastic valve fails from heat exposure causing oil consumption · more· less
The PCV (Positive Crankcase Ventilation) valve fails due to normal wear from extreme heat. It's a plastic component transporting very hot gases, so eventual failure is expected. Symptoms typically appear between 60,000-80,000 km and include increased oil consumption, rough idle, and whistling sounds from the engine bay. The OEM PCV valve (oil separator) costs €140-180, while aftermarket options run €80-120. Labor is approximately 1 hour (€80-120), bringing total cost to €150-350. This is a straightforward DIY job with basic tools. Most VW/Audi vehicles will need one or two PCV valve replacements in their lifecycle. Should be checked every 50,000 km as preventive maintenance.
Rear suspension bushings€250 - €500
Worn hydro bushings cause rumbling and clunking at low speeds · more· less
Some Passat B7 models experience rear suspension rumbling or clunking at low speeds over bumps. The cause is typically faulty lower-arm hydro bushings, which need to be replaced. Bushings may wear out and need replacement as a vehicle approaches 100,000 km, though aggressive driving or rough roads can decrease lifespan. Parts cost €80-150 for quality bushings (brands like Lemförder, Meyle HD), with 2-3 hours labor (€150-300). Total replacement cost is €250-500. It's common to replace ball joints and other suspension components simultaneously. Wheel alignment (€50-80) is also recommended after suspension work.
Excessive oil consumption€50 - €3,000
EA189 engines can consume 1L per 1,000-2,000 km - design issue · more· less
Excessive oil consumption is frequently reported by EA189 owners. Volkswagen's official allowance is 0.5L per 1,000 km (1L per 2,000 km), which many consider excessive for a modern engine. Some owners report using 1L per 1,600 km, while others experience 300-500ml every 4,000 km. The root cause is piston ring design - the oil ring has no drain holes and relies on free-flow oil return, which at higher engine speeds forces oil into the combustion chamber. DPF regeneration exacerbates this as extra fuel dilutes the oil, allowing it to leak past rings. A faulty crankcase ventilation diaphragm (part 2000003231) is also common and replacing it (€50-120) can reduce oil consumption. Severe cases may require piston ring replacement (€2,000-3,000).
Reliable diesel workhorse with manageable maintenance needs
The Passat B7 2.0 TDI is a proven, reliable family car that can easily exceed 200,000 km with proper maintenance. The EA189 engine is robust, though it requires regular attention to DPF health (avoid short trips), timely timing belt replacement, and monitoring of oil consumption. Most issues are well-documented and predictable. Budget for major services every 2-3 years (timing belt, flywheel/clutch, DSG service if applicable). Manual transmission models are more reliable and cheaper to maintain than DSG versions.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Volkswagen dealer or specialist records essential. Verify timing belt replacement if over 5 years or 130,000 km.
Tires
Check tread depth, age (date codes), uneven wear patterns. Common sizes: 205/55R16, 215/55R16, 235/45R18.
Cold start
Must start engine completely cold. Listen for unusual sounds, rattles, or smoke.
Body condition
Check for rust especially on estate models - door sills, wheel arches, tailgate around license plate.
Test drive
Minimum 20 minutes including highway speeds to check DPF regeneration and transmission operation.
Specific for this vehicle
Check for DPF warning light
During test drive, watch for DPF light. Ask owner about regeneration frequency. Avoid cars used only for short trips.
Timing belt service history
Must be replaced every 5 years or 130,000 km. Verify proof with receipts. Budget €700-1,100 if due.
Clutch and flywheel operation (manual)
Test clutch engagement point. Listen for rattles at idle with clutch engaged. Feel for vibration through pedals.
DSG gearbox operation (if equipped)
Drive for 15+ minutes. Feel for jerky shifts, hesitation, clunking. Verify DSG service history (every 60,000 km).
Check oil level and consumption
Check dipstick - oil should not be overfilled. Ask owner about oil consumption between changes. 1L per 2,000 km is Volkswagen's limit.
Scan for fault codes
Use VCDS or OBD scanner to check for stored codes, especially EGR, turbo, DPF, and injector faults.
Rust inspection on estate models
Carefully check wheel arches, door bottoms, sills under plastic covers, tailgate, and front hood lip.
Listen for rear suspension noise
Drive over bumps at low speed. Listen for rumbling or clunking from rear - indicates worn bushings.
Verify high-pressure fuel pipe recall completed
For 2011-2012 models with 2.0 TDI - contact Volkswagen dealer with VIN to verify anti-vibration weights were added.
Camshaft lobe/brake vacuum pump (2015)Check if applicable
The Passat B7 has been recalled 51 times across all model years. Contact a Volkswagen dealer with the VIN to verify all recalls have been completed. The high-pressure fuel pipe recall (2011-2012 2.0 TDI) and Takata airbag recalls are particularly important.
Warranty Status
Factory warranty (2 years)Expired on all B7 models
Diesel emissions equipment warranty (EU)Extended due to dieselgate
Turbocharger extended warranty (2012-2014)10 years / 193,000 km (if applicable)
All Passat B7 models (2011-2015) are outside their original factory warranty. Due to the dieselgate scandal, Volkswagen extended warranty coverage on certain emissions-related components in affected markets - check with your local Volkswagen dealer. Some 2012-2014 models have extended turbocharger warranty coverage (10 years/193,000 km) - verify applicability with VIN.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.