A practical MPV variant of the Golf V with more headroom and cargo space, popular for families and commuters. The 1.9 TDI PD engine is generally considered robust and capable of 300,000+ km with proper care, but engine code matters significantly: the BKC (2005-2006) is most reliable, while the BXE and BLS (2007-2009) have a known connecting rod bearing failure issue. Critical: requires VW 505.01 spec oil to prevent camshaft wear. Timing belt must be changed every 90,000 km. The turbo on 105hp versions is prone to failure. EGR valve clogging and dual mass flywheel wear are common high-mileage issues. Verify Takata airbag recall completed.
Connecting rod bearing failure (BXE/BLS engines)€2,500 - €5,000
Con-rod bearing shells wear prematurely, can destroy engine - more- less
This is the most serious issue affecting 2007-2009 Golf Plus models with BXE or BLS engine codes. The upper bearing shells wear severely due to lubrication issues, eventually causing the connecting rod to punch through the engine block. One specialist reported replacing 10 BXE engines in a single year. Failures typically occur between 85,000-130,000 km, regardless of service history. Prevention: change oil every 9,000-10,000 km (not longlife intervals) using VW 505.01 spec 5W-40 oil. Some experts recommend replacing bearings preventively at 100,000 km. The BKC engine code (2005-2006 models) does not have this issue and is considered reliable.
Turbocharger failure€700 - €1,500
Variable vane turbo sticks or fails, especially on 105hp version - more- less
The 105hp 1.9 TDI is known for turbo failures. Common symptoms include a "police siren" whine at low RPM, loss of power, or limp mode. Variable vanes can stick from carbon buildup if the car is driven too gently. Failure typically occurs between 100,000-180,000 km. A rebuilt turbo fitted at an independent specialist costs around €700-900. VW dealer replacement with new turbo runs €1,200-1,500. Important: when replacing, always check the oil feed pipe for blockages - clogged feed lines cause repeat failures.
Dual mass flywheel wear€800 - €1,800
DMF develops rattle at idle, typically after 100,000-150,000 km - more- less
The dual mass flywheel absorbs engine vibrations but wears over time. The classic symptom is a rattling noise at idle in neutral that disappears when the clutch is pressed. City driving with frequent stop-start accelerates wear. DMF replacement alone costs around €800-1,000 at an independent garage. However, it's strongly recommended to replace the clutch at the same time (same labor), bringing total cost to €1,200-1,800. Use LUK or Sachs (OEM suppliers) parts. If ignored, a catastrophic DMF failure can destroy the gearbox.
EGR valve clogging€400 - €900
Carbon deposits block EGR, causing rough running and power loss - more- less
EGR valve clogging is extremely common on all diesel Golfs. Soot and oil vapor accumulate over time, preventing the valve from opening or closing properly. Symptoms include rough idle, loss of power, increased smoke, and check engine light. The valve is in a difficult location, requiring significant labor time. Cleaning may work temporarily but often needs repeating. Professional cleaning costs around €150-250. Replacement at an independent shop runs €400-600, while VW dealers charge €700-900+. Some owners delete the EGR (not legal in many countries).
Timing belt failure€500 - €900
Belt must be changed every 90,000 km or 4 years - engine destruction if it snaps - more- less
The 1.9 TDI is an interference engine - if the timing belt breaks, pistons will hit valves, destroying the engine. VW recommends replacement every 90,000 km or 4 years for pre-2003 vehicles, extended to 120,000 km for 2004+ models. However, many specialists recommend sticking to 90,000 km regardless. Always replace the tensioner, idler, and water pump at the same time - a failing tensioner can cause belt failure even with a new belt. Independent garage cost: €500-600. VW dealer: €750-900.
Camshaft wear (wrong oil)€1,500 - €3,500
PD engines require special 505.01 spec oil - wrong oil destroys camshaft - more- less
The Pumpe Duse (PD) injection system places extreme pressure on the camshaft lobes that actuate the injectors. VW 505.01 specification oil contains special anti-wear additives to protect these lobes. Using standard diesel oil (even full synthetic) will cause accelerated cam lobe wear. Symptoms include rough running, poor starting, and eventually engine failure as the injectors stop pressurizing. This is not covered under any warranty if wrong oil was used. Always use 5W-40 VW 505.01 approved oil (not 5W-30) and change every 10,000 km maximum, not longlife intervals.
Injector failure€400 - €1,200
PD injectors leak or fail after 150,000+ km - more- less
The unit injectors (Pumpe Duse) can develop leaks or stick open after high mileage. Symptoms include rough running, misfire on one cylinder, excessive smoke, and diesel smell. Often they can be removed, cleaned, and reinstalled. If replacement is needed, a single injector costs €200-300 plus €100-150 labor. The injector seals (copper washers) should be replaced during any removal. Full set of 4 new injectors: €800-1,200.
MAF sensor failure€150 - €400
Mass airflow sensor degrades, causing poor performance and economy - more- less
The MAF sensor measures incoming air and is critical for fuel metering. Contamination or age causes incorrect readings. Symptoms include loss of power, hesitation, poor fuel economy, black smoke, and check engine light (codes P0100-P0104). MAF issues are often misdiagnosed as turbo failure - always check MAF first. Cleaning may help temporarily. Replacement part costs €80-150 (aftermarket) to €200+ (OEM). Labor is minimal as it's easily accessible. Total replacement cost: €150-400.
Glow plug failure€200 - €500
Glow plugs fail around 100,000 km, causing hard cold starts - more- less
Glow plugs heat the combustion chamber for cold starting. When they fail, the engine takes longer to start in cold weather or won't start at all. One failed plug causes rough running until warm. All four plugs should be replaced together as they wear at similar rates. Important: do not mix Bosch and Beru brands - all must be the same or error codes will appear. Parts cost €60-100 for all four (Bosch). Labor can be tricky if plugs are seized. Total cost: €200-500.
Window regulator failure€200 - €400
Plastic clips and cables break, window drops into door - more- less
A common VW issue - the window regulator mechanism uses plastic components that become brittle with age and temperature cycling. When they fail, the window falls down into the door and won't move. Driver's window most commonly affected. Parts cost €60-150. Labor takes 1-2 hours. Total replacement cost: €200-400 at an independent garage.
Sunroof drain blockage€100 - €600
Blocked drains cause water leaks into cabin and electrical problems - more- less
If equipped with a sunroof, the drain tubes can become blocked with debris, causing water to overflow into the cabin. Water can reach the fuse box, causing electrical faults and corrosion. Symptoms include wet carpets, musty smell, and random electrical issues. Cleaning the drains is a simple DIY job if caught early. If water damage has occurred to electrical components, repairs can cost €300-600+. Preventive cleaning every 1-2 years is recommended.
Engine code is crucial - avoid BXE and BLS if possible
The Golf Plus 1.9 TDI can be extremely reliable with 300,000+ km possible, but only with the right engine code and proper maintenance. The BKC engine (2005-2006) is considered "bulletproof." The BXE and BLS engines (2007-2009) have the serious connecting rod bearing issue and should be avoided or purchased only with documented short-interval oil changes. Regardless of engine code, always use VW 505.01 spec 5W-40 oil and avoid longlife service intervals on high-mileage cars.
Pre-Purchase Inspection Checklist
General checks
Service history Complete service records are essential. Verify oil changes at proper intervals with correct VW 505.01 spec oil.
Tires Check tread depth, age (date codes), and uneven wear patterns. Standard size: 195/65 R15.
Cold start Must start engine completely cold. Listen for unusual sounds in first 30 seconds.
Body condition Check for rust, accident damage, paint mismatch. Inspect wheel arches and sills.
Test drive Minimum 20 minutes including highway speeds to get engine and turbo up to temperature.
Specific for this vehicle
Check engine code on data plate
Located on a sticker in the spare wheel well or service book. BKC is most reliable. Avoid BXE and BLS unless exceptional service history with short oil change intervals.
Listen for DMF rattle at idle
With engine warm, in neutral, listen for metallic rattling. Press clutch - if rattle stops, the dual mass flywheel is worn. Budget €1,200+ for DMF and clutch replacement.
Check turbo operation
Listen for "police siren" whine at low RPM. During test drive, ensure full boost is achieved without hesitation or smoke. Any turbo noise is a warning sign.
Verify timing belt change
Must have documented proof of timing belt replacement if over 90,000 km or 4 years. If unknown, budget €500-900 for immediate replacement.
Check oil condition and spec
Oil should be dark but not sludgy. Ask what oil was used - must be VW 505.01 spec 5W-40. Milky oil indicates head gasket or coolant issues.
Cold start observation
Engine must be completely cold. Start and listen: rattling for more than 2-3 seconds indicates timing chain tensioner issues (if equipped) or other problems. Excessive white smoke indicates glow plug issues.
Check EGR operation
During test drive, note any hesitation, rough idle, or loss of power. A badly clogged EGR will cause check engine light and limp mode.
Test all electrical systems
All windows, central locking, lights, dashboard displays. VW electrical issues are common. Check for water damage under carpets if equipped with sunroof.
EGR cooler replacement (various TSBs)Check with VW
The Takata airbag recall is critical - affected inflators can explode and cause serious injury. Use VW's official recall lookup with your VIN at vw.com/recalls or contact a VW dealer directly. The recall repair is free and takes approximately one hour.
Warranty Status
Factory warranty (2 years)Expired on all models
Emissions warranty (extended)Likely expired
Recall repairsFree regardless of age
All Golf Plus 1.9 TDI models (2005-2009) are well outside their factory warranty period. Recall repairs remain free regardless of vehicle age. Consider purchasing an extended warranty from a third-party provider, but carefully check exclusions for diesel-specific components like turbos, injectors, and DMF.
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.