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2009 Volkswagen Passat repairs by problem area

Engine (59%)

Transmission and Drivetrain (7%)

Brakes and Traction Control (3%)

Suspension and Steering (3%)

Electrical and Air Conditioning (17%)

Paint, Rust, Leaks, Rattles, and Trim (8%)

Other (3%)

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Chart based on 175 repairs.

See TSBs and recalls for the 2009 Volkswagen Passat.

2009 Volkswagen Passat engine repair cost distribution

$2500+ (0%)

$1000 - $2499 (11%)

$500 - $999 (27%)

$100 - $499 (20%)

< $100 (42%)

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Chart based on 95 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

34300 mi

Check engine light, not reproducible.

71000 mi US $415	Evidence of very slight engine oil leak at turbo bypass vale and timing belt cover. Valve replaced, timing belt cover gasket replaced.
77000 mi US $100	Rear main engine seal leaking. Replaced under extened warranty. Total bill $950, owner's share was $100 due to warranty.
94000 mi US $1100	Rough idle. Engine code indicated bad intake manifold, a known issue with the 2.0 turbos of this era Leaking water pump, replaced
96000 mi US $300	Replaced throttle sensor relays. Car went into limp mode, had to be towed.
96000 mi US $1500	Car in limp mode again a few weeks later, replaced throttle body.

49000 mi

Turbo needed a new valve or something as it had a small leak that was under warranty. Also arbon build up started at 37K miles. It was out of warranty and was 1000 dollars plus then usually what happen they screw up the injectors.

115000 mi US $414	will need de carbonizing of fuel injection manifold
123100 mi US $1053	Car would not start after sitting in parking lot after dinner, replaced bad fuel pump and module assembly
130000 mi US $39	ignition coil replaced
131000 mi	Valve spring broke and repaired, Stuck fuel injector
138000 mi US $175	oil pressure sensor
155000 mi US $369	replaced breather valve, vehicle has multiple air leaks

100000 mi US $670	Engine running rough - spark plugs changed Engine leaking oil - Oil gasket changed
109700 mi US $850	Water pump.

38000 mi

US $50

Turbo recirculating valve (diverter valve) was leaking oil. Upper timing belt cover was leaking oil. All replaced under VW CPO warranty with $50 deductible.

55800 mi

C $560

Manifold flap stuck

58000 mi

Vehicle needed to have the Intake Manifold replaced. Included replacement of the Intake Manifold Gasket and Throttle Body Gasket.

81000 mi US $800	1) cleaned carbon off intake valves (was getting misfires & getting worse by week) 2) replaced intake valve stem seals
100000 mi US $921	Engine using 3 Qts oil in 10K miles. Replace rear main seal. Replace transmission input shaft seal.
110000 mi US $737	Replaced intake manifold Fuel pump died and was replaced.
111000 mi	Fuel Pump Control Module died and was replaced.
129200 mi US $540	Radiator fan electrical caused constant battery draw, causing battery to be depleted.
130000 mi	PCV Valve Oil Separator failed; part replaced

46000 mi	Check engine light was on though the car operated normally. Intake manifold and fuel injector o-rings were replaced under warranty and that resolved the problem.
76700 mi US $688	Check engine light was on. Carbon build up on intake valves. Cleaned carbon from valves and intake ports. Replaced injector origns and cleaned injector bores.
93000 mi US $662	Turbo bypass valve replaced. It was leaking oil into engine. Breather valve failed. It was replaced.
116500 mi US $407	Check engine light on. Replaced high fuel pressure sensor in injector rail
128000 mi	Fuel pump needed to be replaced.

32240 mi	engine, parking brake and emissions warning lights have all come on recently - adjusted and repl as required.
42780 mi	check engine light, check gas cap light and check parking brake light (+ABS warning) came on in the space of a week. Some are related - parts ordered. Annoying!
45880 mi	recurring dash warning lights for check engine and gas cap - apparently all related to emissions control. VW says that their warning systems are too sensitive!
46500 mi	second failure of intake manifold. Old manifold flapper valve had a plastic tab - these almost all fail. My 1st failed at 15,000km, and now again. New part has metal tab. See service manager more often than my good friends! aux cooling fan - had an intermittent fault - which meant occasionally main cooling fan running longer than it should. Warning light was automatically assumed to be faulty (of course - VW) but this time it was showing as an emmision fault.
82540 mi C $700	Heavy carbon buildup mostly due to DI design - off warranty so no help from VW. 2 full handfulls of carbon where removed! Told that this is normal for 2.0T and many other DI motors. s1 injector and 1 coil also needed replacement.
83080 mi C $720	Fuel system - throttle body replaced. Seems premature, as are most component failures. No non proprietary parts available.
93580 mi	dashboard warning light indicated engine overheating and guage showed maximum temperature. Car was towed to service center, no overheating observed, not recorded in vehicle computer and could not be replicated. Problem has not recurred.
108380 mi C $1	main front crankshaft seal - leaking. Seal is a very flimsy single filament model that replaces earlier more robust units - mechanic reports common early KM replacements required. Expensive!!
108780 mi C $550	main engine cooling fan failed to start till temp at 130, auxiliary fan burned out.

38000 mi

Entire intake manifold was replaced

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23560 mi	Intake flap sensor replaced
26040 mi	Intake manifold replaced
71600 mi	Engine Light On, Intake manifold replaced a second time.
109740 mi C $1200	Water pump replacement. (Check engine light on)

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101000 mi

US $109

Cam chain tensioner failure resulted in engine locking up. Repair would cost more than car value. Sold to different mechanic for very little who said he would replace engine and then sell. Bought Camry as replacement. No more VWs.

106500 mi

¤500

Fuel pump replacement

79000 mi US $430	breather valve clogged
84300 mi US $1048	water pump leaking
88000 mi	Timing Cover - Upper: UPPER TIMING CHAIN COVER AND GASKET Oil pan & gasket Inner CV Boot on right After returned home from dealer Replacing UPPER TIMING CHAIN COVER AND GASKET, low coolant warning light came on. Coolant was on floor of my garage. Returned to dealer. They said water pump was out. Cars back at shop that replaced 6 mos ago
92750 mi	VAG Action CODE 20AE, NHTSA recall 17V509--Fuel pump continuously running causing battery to drain, intermittent stalling. I have had hesitation while driving and sometimes surging. Received recall notice in September. Last month I have been dealing with a drained battery directly caused by fuel pump continuously running after car's ignition is turned off. Called VAG advised no fix. I called Dealer nearest to me, VW of Fairfield, Ca who also advised there still is no fix, VAG does not provide road side assistance, battery charge or anything else. I again called VAG advising I would file complaint with state's attorney general office as battery charger was toast, cannot continue to disconnect and reconnect battery to use car, fuel pump can be heard running when ignition is turned off and will not continue to use AAA. They finally agreed to let dealer change out fuel pump's control module. They then wanted me to buy a new battery which I refused as battery was only about a year old that had replaced a 2 year old battery. I was able to exchange battery under warranty and so far am not hearing fuel pump running when drove home. I am not convinced repair is successful as dealer emphasized temporary and could not guarantee. I am driving my other car and have listed this one for sale. VAG has no idea when an "official" fix will be available.

95700 mi	Rear main seal oil leak. Oil leak and OBDII code P12a2 P2181. Reset the code and keeping an eye to water temp. Water temp = ~80C. CEL remains off after 35 miles.
955000 mi	P2181 in about 10 minutes from cold start. Reset the OBD II.
97000 mi	fuel pump controller recall

8281 mi	Check Engine Light On, hose replaced
11206 mi	Engine Light On, hose replaced

125000 mi

US $50

Failed coil pack, was able to diagnose with P-code

5051 mi	Gas Cap light followed by check engine light. Dealer performed "P4 cluster adaptation recall." Check engine light / gas cap light (evap leak warning)
8195 mi	Cap light followed by check engine light; Dealer found evap leak fault when they pulled the code, so they ran an evap leak test, but the evap system passed their test so they just cleared the code. Check engine light /gas cap light (evap leak warning)
12228 mi	Gas cap loose light followed by check engine light, indicating an evap system leak; 3rd time this problem occurred in one year. Dealer really dug in to troubleshoot and finally replaced "most likely" part, which was the purge valve. Check engine light/gas cap light (evap leak warning). Dealer replaced N80 purge valve.
18800 mi	Check Engine light diagnosed as bad flap/motor in intake manifold. Parts replaced, but check engine light came back. Car immediately returned, dealer performed some adaptation procedures, but check engine light again illuminated. Car returned to shop after a new intake manifold that was ordered, arrived; however, the dealer could not finish the installation because dealer failed to order a few bolts that were also needed. Faulty intake manifold replaced along with two seals for injectors that came out when original manifold was taken out. Check engine light no longer comes on and driveabiliy improved, so I think this fixed the problem

103000 mi US $800	Needed to "decarbonize" the valves - also about $800.
104000 mi US $600	Then needed new water pump - about $600
115400 mi US $1109	Water pump - intake manifold studs - injector seal
143000 mi US $825	Needed a new fuel pump

50500 mi

US $470

Intake manifold replaced under warranty. $470 charged to clean deposits from intake.

73000 mi US $414	CEL on due to misfire in 2 cylinders. Replaced spark plugs performed engine wash
74700 mi US $700	Intake manifold carbon buildup. Dealer performed a manual engine cleaning (soda blasting).

42700 mi

US $200

Fuel injector stopped working

27000 mi	Intake was replaced under extended warranty for problems with intake flap valve and actuator
28000 mi US $50	Radiator had a seam leak. Replaced with new
47000 mi	Intake was replaced under warranty. Intake runner valve stuck open.
51000 mi	Fuel injector failed (open). Hydro-locked engine with fuel. Replaced injector, changed oil
138000 mi US $300	Fuel Injector was beginning to fail. Intake valves required cleaning

46700 mi US $675	Warning light on. Initially it was reset (one day and free). It came back on. Flapper sensor valve replaced.($675 - second day). Light came on. Rechecked and determined to be a VW extended warranty repair item for an intake manifold probem.
60000 mi US $458	the coil for the spark generation went bad for one cylinder. All 4 were replaced.

79000 mi	Engine light was on. Mechanic diagnostic as a manifold problem. Stated VW would have to fix also stated that this is a known problem with this vehicle. I have not taken it to VW yet to fix. Mechanic estimated the cost to be around $800.
96000 mi US $2000	Had to replace all four fuel injectors
96000 mi US $600	turbo valve being broke. I was told it was wide open and thus pushing oil through the engine. Main rear seal was leaking oil like a sieve. The valve problem caused the seal to leak. The cost to repair the seal would have been over 2 grand, so I fixed the valve and traded in the vehicle within a week.

37000 mi	Faulty fuel injector. Repaired under certified used car warranty.
85000 mi US $1800	Needs new intake manifold, $650. Apparently, this is a common issue with Passats. The engine light will come on and you will notice a decrease in power. It should be brought in for repairs as soon as possible,. needed new fuel pump, $1150.
111500 mi US $350	I noticed a squeal coming from my engine and brought it to my independent repair shop the next day. The 'blower' stopped working and had to be replaced. About $170 for the part and $180 for labor.
115000 mi US $720	The water pump was leaking and needed to be replaced. replaced water pump
115000 mi US $750	replaced exhaust manifold. This is the 2nd time I've had it replaced. The first was at 80,000 miles.
186000 mi US $175	needed new spark plugs
194000 mi US $800	new water pump
203000 mi US $160	replaced exhaust clamps
220000 mi US $240	Turned off idiot light
219000 mi US $250	warning light came on but nothing was wrong