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My Passat 1.9 TDI 130 highline (auto) just passed MOT with 141,000 miles. It's a 2001.5 year and I bought it 3 years ago at 100,000 miles, one previous owner.
Good
Straight off I replaced the cambelt, water pump and performed a regular service. I deleted the EGR system and fitted a straight pipe. There is a remap and it has been lowered on AP coilovers. All front bushes are polyurethane. Results? I have had 40,000 trouble-free miles, during which time I have only replaced pads, tyres, bulbs. At 120,000 miles I replaced the auto transmission fluid and filter as a precautionary measure. A-road miles disappear effortlessly in total comfort. B-road miles are economical and passing is easy. The Passat is more of a 'luxo-barge' than a driving machine but with sensible modifications and sticky tyres it has proven to be capable. ie: It can keep pace through twisties with many supposedly more agile cars, eg: Focus, Calibra, Golf, A3, A4. The low-tech rear axle and pronounced front-heaviness do rather compromise its character at high speed, however. Into triple-digits, the diesel is better suited to cruising rather than accelerating (but 130mph is achievable without much fuss, considering).
Bad
Pollen filter water ingress gave me damp carpets. One rear door lock refuses to work via central locking, but mechanically is fine. Rear numberplate bulb holders corroded inside. Boot lock failed but took just 5 minutes to fix: the spring had worked itself loose. The bonnet latch sensor wiring is faulty or else the multi-function display itself is erroneously reporting the bonnet as open, all the time. Tiptronic switches failed a few times but replacement part is £20 and easy to fit. Understeer.
The Future
Suspension rebuild at the front next month, then 60,000 miles more, at which point the auto transmission may just give up. My dad's B5-shape 2000 Passat 1.9 TDI 90 manual is running to this day, 190,000 miles and has only needed servicing, one suspension rebuild (it had a hard B-road life, almost no motorway) and a clutch and flywheel -- indeed, all of that only when it reached 180,000 miles. Life in the old dog yet!
The Verdict
The 130 PD TDI is a must and the ZF 01V auto transmission is great at taking punishment (on a remap at that!). I found the stock suspension to be comfortable but terrible (soft) for B-road cornering, hence replacement. Also, steering feel is much improved with new front bushings. 30-58 mpg on offer after the remap. Not perfect but an all-round pleaser! Would buy an 04 or 05 tomorrow in a heartbeat, anything upto 130,000 mi if serviced well. Bar transmission failure (uneconomical to repair) I expect what will make me change this car will be giving in to indulgence. Mechanically it should perform reliably for several years to come.
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