Popular first car and city runabout with excellent fuel economy on long runs (60+ mpg possible). However, the 1.2 TDI is NOT suitable for repeated short journeys - Volkswagen admits this themselves. The EA189 engine suffers from DPF clogging, EGR valve failures (especially after dieselgate emissions fix), and fuel filter cracking (recall for 2010-2014 models). Parts are affordable and widely available, but repair costs add up due to design flaws. Avoid if you do mostly urban driving - choose the petrol instead.
DPF clogs from short journeys, causing limp mode and power loss · more· less
This is the single biggest issue with the Polo 1.2 TDI. Volkswagen now admits that the 1.2 TDI is not suitable for repeated short runs from cold. The DPF cannot reach operating temperature (600°C+) on short trips, preventing regeneration. Symptoms include juddering at 20-30 mph, delayed throttle response, DPF warning light appearing every 7-10 days, and eventually limp mode with max 3000 rpm. Professional DPF cleaning costs €400-800, while dealers may quote €2,000+ for replacement. Some owners find the actual cause is a faulty N75 turbo actuator valve (€150-300 fix) rather than the DPF itself. Prevention: Regular motorway drives of 20+ minutes at 2500+ rpm.
EGR valve failure and cooler cracking€700 - €1,200
Design flaw causes EGR cooler to crack internally, worsened by dieselgate fix · more· less
The EA189 engine has a fundamental design flaw in the EGR cooler that causes internal cracking and coolant-soot sludge buildup. The dieselgate emissions software update increased EGR operation frequency, making failures more common. Symptoms include yellow coil light, limp mode, and fault codes P0403/P0405. Cleaning is ineffective - replacement is required. Parts cost €330-400 plus €300-600 labor (6-8 hours work). Some owners report Volkswagen covered this under a "Trust Building Measure" - contact Volkswagen UK with your VIN. Early 1.2 TDI models were most affected, and many have already been repaired by Volkswagen at their expense.
Fuel filter cracking (recall issue)€0 - €200
Fuel filter cover cracks due to vibration, causing diesel leaks and fire risk · more· less
All 1.2 TDI engines built between 1 April 2010 and 1 April 2014 were recalled for cracked fuel filters. Pressure pulsations and engine vibrations cause fatigue cracks in the filter cover at the inlet fitting, leading to diesel leaks and potential fire risk. If you're buying a Polo 1.2 TDI, verify with Volkswagen using the VIN that this recall work has been completed (should be free). If not done, insist the seller completes it before purchase. Affects Polo, Skoda Fabia/Roomster, and some Seat models with the same engine.
Turbo actuator failure (N75 valve)€150 - €2,500
Actuator sticks from gentle driving, causes EPC light and limp mode · more· less
The turbo actuator tends to stick if the car is driven too gently or only for short trips, as carbon builds up. Symptoms include EPC (Electronic Power Control) light, limp mode, and fault code P00AF (turbocharger module stuck). Volkswagen will not sell the actuator separately. Actuator-only repair at a specialist costs €150-300, but if turbo internals are damaged from prolonged running in limp mode, full turbo replacement runs €1,200-2,500. Prevention: Use premium fuel and regular spirited driving (occasional acceleration to higher RPM). Check vacuum lines to and from turbo for leaks, as these can cause similar symptoms.
Dual-mass flywheel (DMF) failure€600 - €1,500
DMF fails prematurely, especially with start-stop system use · more· less
The dual-mass flywheel on the 1.2 TDI is known to fail prematurely, particularly due to start-stop system usage. Volkswagen technical document TPI 2039968 acknowledges this issue. Symptoms start with intermittent noise on idle, progressing to rough grinding on startup, then loud rattling/banging from the bellhousing. Typical failure occurs around 100,000 km. Volkswagen no longer supplies the original DMF and offers a single-mass conversion kit instead. Replacement cost: €350-450 for parts (DMF, bolts, needle bearing) plus €400-600 labor (4-6 hours, requires gearbox removal and subframe alignment). Some owners report €1,350-1,500 total when done with clutch replacement. Use LUK or Sachs parts.
Timing belt replacement€400 - €800
Scheduled maintenance item at 140,000 miles or 10 years · more· less
Unlike the 1.2 TSI petrol which uses a timing chain, the 1.2 TDI uses a timing belt. Volkswagen's official interval is 140,000 miles (225,000 km) or visual inspection at 100,000 miles. However, many mechanics recommend replacement at 100,000 km as a precaution, given that belt failure causes catastrophic valve/piston contact. Independent garage cost: €250-400 parts plus €150-400 labor. Volkswagen dealer: €600-800 total. Always replace the water pump at the same time (adds €100-200 to parts cost) to avoid repeating the labor later, and ensure the belt isn't contaminated by coolant leaks.
Water pump and thermostat failure€600 - €1,400
Plastic housing cracks, typically fails between 70,000-100,000 km · more· less
The Polo 6R water pump uses a plastic housing design that's prone to cracking and leaking. Volkswagen has released multiple revisions (8+) but the fundamental plastic design remains problematic. Symptoms include coolant warning light, engine overheating, poor cabin heating, or visible coolant leaks. Replacement parts: €400-500 (water pump, thermostat housing, coolant, seals). Labor: €400-900 (4-6.5 hours) depending on workshop. Total at Volkswagen dealer: €1,200-1,400. Independent garage: €600-900. Some owners supply their own INA parts and pay €150 for labor only. Always replace water pump and thermostat together. Consider aftermarket all-metal water pump for improved durability.
Injector failure€500 - €2,000
Delphi injectors fail causing misfires, rough idle, and starting issues · more· less
The 1.2 TDI uses Delphi common-rail injectors that can fail, typically causing idling misfires and jerking during low-speed acceleration in first gear. Symptoms also include delayed starting and slight engine misfires even after cam sensor replacement. Each new genuine injector costs €300-550 depending on market. Labor adds €200-400 as injectors must be coded to the ECU using diagnostic equipment (IMA value entry required). Total for one injector: €500-950. If multiple injectors fail (common), cost rises to €1,500-2,000. Never buy used injectors - they rarely fix the problem. Always use new Delphi or Bosch injectors and have them properly coded.
Glow plug replacement€150 - €450
Glow plugs fail causing hard starting in cold weather · more· less
Failed glow plugs are one of the most common causes of starting problems on Volkswagen TDI engines. Symptoms include extended cranking before starting (worse below 10°C), multiple start attempts needed, and flashing coil light. One failed plug causes slight delay; multiple failures can prevent starting entirely. Each glow plug costs €25-40 (newer models with integrated pressure sensors cost €100+ each but the 1.2 TDI uses standard plugs). Labor: €100-200 for all 3 cylinders. Total: €150-300 for parts and labor. Volkswagen recommends replacing all plugs together when one fails, as they age as a set. Diagnosis requires VCDS/VAG-COM scanning for fault codes.
Alternator failure€300 - €1,000
Voltage regulator fails, causing battery drain and electrical issues · more· less
Alternator failures manifest as slow cranking, dim lights, flickering battery warning light, voltage dropping below 13V at idle, and fault code P0622. A healthy alternator should maintain 13.5-14.4V. Common cause is voltage regulator failure within the alternator. Parts: €160-250 for alternator unit. Labor: €100-250 (1.5-3 hours). Total: €300-500 at independent garage, €600-1,000 at Volkswagen dealer. Often replaced together with battery (adds €100-180). Battery sensor failures can mimic alternator issues - costs €150-300 to diagnose and replace if faulty. Alternators typically last 100,000+ km but can fail earlier with harsh driving or added electrical accessories.
Air conditioning compressor failure€100 - €2,500
Condenser stone damage and evaporator leaks common in 6R models · more· less
AC issues are common on the Polo 6R. Most frequent: stone chips causing condenser holes (€100 regas if caught early), evaporator gas leaks (described as "normal" on 6R/6C - detectable by sniffing air outlets), and compressor mechanical failure. Compressor failure symptoms: loud rattling for 2-3 seconds when engaging, then shutdown; squealing or grinding noises; metal particles in system. Simple regas service: €100-150. Evaporator replacement or valve/pressure switch repair: €600-1,000. Full compressor replacement with system flush, new receiver drier, and refrigerant: €1,800-2,500. AC should be serviced every 2 years to maintain efficiency and prevent failures.
Oil leaks (valve cover, turbo lines)€150 - €600
Common leak points include valve cover gasket and turbo oil lines · more· less
TDI engines are notorious for oil leaks, especially on the backside where they're hard to see. Most common: valve cover gasket (oil appears to come from nowhere, travels down engine), turbo oil feed/return line gaskets (very common on EA189 engines), oil filter housing, and crankcase breather (if clogged, causes high pressure leading to seal failures). Valve cover gasket: €50-100 parts, €150-300 labor. Turbo line gaskets: €30-60 parts, €100-200 labor. Oil filter housing: €80-150 total. If oil leaks are caught early, repairs are affordable. Ignoring them leads to larger leaks and potential turbo damage from oil starvation.
Only suitable for regular long-distance driving
The Polo 1.2 TDI can be reliable if driven appropriately - regular motorway trips are essential. However, for city use or short journeys, this diesel is unsuitable and will cause repeated expensive repairs (DPF, EGR). Volkswagen themselves admit this. The EA189 engine also has design flaws (EGR cooler cracking) that affect all examples regardless of driving style. Budget €350-750/year for repairs on top of regular maintenance.
Pre-Purchase Inspection Checklist
General checks
Service history
Complete Volkswagen dealer or specialist records essential. Verify oil changes every 15,000 km / 12 months.
Cold start - CRITICAL
Must start engine completely cold. Listen for rattling noises. Check for excessive smoke (small black puff is normal, white/blue is not).
Body condition
Check sills and rear wheel arch lips for rust bubbling. Inspect under plastic covers at mud flap mounting points.
Test drive (minimum 30 minutes)
Include varied speeds, especially motorway driving to check DPF regeneration capability. Feel for steering pull, brake vibration, unusual noises.
Specific for this vehicle
Ask about driving pattern and verify with seller
If the car has been used primarily for short urban trips (under 10 km), walk away. DPF and EGR issues will be inevitable. Look for cars that have done regular longer journeys.
Check for DPF warning light and regeneration issues
During test drive, watch dashboard for DPF light. Ask seller when it last appeared. If they say "every week" or "often", the DPF is already problematic. Feel for juddering at 20-30 mph or delayed throttle response.
Verify fuel filter recall completed (2010-2014 models)
Contact Volkswagen dealer with VIN before purchase. This is critical - fuel leaks are a fire risk. Insist seller completes recall if not done.
Verify dieselgate emissions fix completed
Check with Volkswagen using VIN. All EA189 1.2 TDI engines were affected. The fix increases EGR stress but is legally required in most countries.
Scan for fault codes with VCDS/OBD scanner
Look for codes: P0403/P0405 (EGR), P00AF (turbo actuator), P0622 (alternator), DPF-related codes. Any stored codes indicate existing or recent problems.
Check for EPC warning light during test drive
Drive for 15+ minutes and watch for yellow EPC light. If it appears with power loss, turbo actuator or boost control issues are present.
Listen for DMF noise on cold start and at idle
Loud rattling, grinding, or banging from the bellhousing indicates DMF failure. This is expensive (€600-1,500).
Check coolant level and condition carefully
Low coolant or brown/milky appearance indicates water pump, thermostat, or head gasket issues. Look for dried coolant residue around water pump area.
Inspect for oil leaks on engine backside
Use a torch to check the rear of the engine from underneath. Valve cover gasket and turbo oil lines commonly leak but are hard to see.
Test air conditioning thoroughly
Run AC for 10+ minutes. Should blow cold (under 10°C). Listen for rattling from compressor when engaging. Smell vents for unusual odors (evaporator leak).
Check all electrical functions
Test all electric windows (common failures), parking sensors (corrosion), trunk lock operation, all lights, infotainment system.
Inspect rear wheel arches for corrosion
The lip on rear wheel arches collects mud and salt. Look for bubbling paint - this is the most rust-prone area on Polo 6R.
EGR valve "Trust Building Measure" (early models)Contact Volkswagen UK for eligibility
Takata airbag inflator (various production dates)Check with Volkswagen using VIN
Contact a Volkswagen dealer with the VIN to verify all recalls completed. The fuel filter recall is critical (fire risk). The dieselgate fix is legally required in most European countries. Some early-model EGR failures may be covered under Volkswagen's Trust Building Measure - worth calling Volkswagen UK customer service.
Warranty Status
Factory warranty (2 years / 100,000 km)Expired on all 2009-2014 models
Anti-corrosion warranty (12 years)May still apply - check with VW
Extended warranty availabilityThird-party options available
All Polo 6R 1.2 TDI models are outside their original factory warranty. The 12-year anti-corrosion warranty may still apply to newer examples (2012-2014), but Volkswagen has refused some claims citing "edge and fold corrosion" exclusions - inspect carefully. Third-party extended warranties are available but often exclude DPF, EGR, and injector issues on high-mileage diesels.
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.