Will try to sum everything up. I am about $1,000 in at this point as I personally have had replaced the valve cover gasket, the thermostat, and I did the PCV Valve yesterday.
The previous owner of the car who I know had the valve body re-done under warranty. He also had a fender bender and had a whole new front end put on the car. He said he also got the oil changed every 3k miles.
$1,000 is NOTHING when it comes to VW maintenance and repairs. You are not yet deep in the money pit for a VW and since you got it cheap you could turn it around and break even. If the problems are to the extent that you think it'd hurt your ability to sell to someone who isn't a friend then we can try to get them fixed and then sell for more and you can probably still break even or maybe make a small profit. Something to consider.
On the other hand, IF you trust the person who sold it to you or IF they can provide you with evidence that they did these very timely oil changes AND used a VW 502.00 spec approved FULLY synthetic oil AND an OEM Mann oil filter (which is absolutely crucial on these motors for proper oil pressure to be maintained) then you can probably get your 3 years out of it with minimal problems from here on out from a motor reliability standpoint (that doesn't necessarily include all the peripheral stuff which is notoriously fluky on VWs). I cannot stress enough how important it is that your acquaintance/friend made sure the oil changes were always a VW 502.00 spec approved FULLY synthetic oil AND an OEM Mann oil filter. If the car was always serviced at the dealer then they would have made sure this is the case. IF the car was serviced at any non-dealer or shop/garage that was NOT a euro-specialty shop then it is entirely possible they did not use an approved oil or OEM filter. VWs are EXTREMELY picky and dependent on these more than other cars. Many cars can get along fine with oils that aren't technically approved as long as the viscosity is what is recommended by the manufacturer. Many shops mechanics will truly think that they are doing fine if they use the right viscosity and use a semi-synthetic (half synthetic/half conventional oil) blend and many others don't even realize they are using semi-synthetic when they are; there are very convoluted laws around labeling of these oils. All oil manufacturers try to get over on their buyers by labeling their semi-synthetic oils with things like "synthetic technology" or "full synthese technology" and shit that is very close to the words "fully synthetic" but is NOT exactly those words. IF the bottle doesn't literally say "Fully synthetic" it is NOT and a lot of people, even a lot of mechanics, DO NOT know this and will accidentally use oil that is not suitable for a VW. Likewise they will also use the cheapest oil filter they can get a hold because they don't know that this actually matters too (because it doesn't in most cars). But a aftermarket filter of different size or just different ply will lead to oil pressure issues in these VW FSI/TSI motors and is well documented for pretty quickly causing serious engine reliability/longevity problems.
So moral of the story: learn from the above and make sure this was followed religiously or else the longevity of your VW cannot be guaranteed at all. It's just not enough to say that the oil was changed every 3K miles, we need to know about the specifics above to have a shot at estimating how reliable this thing is going to be. See this thread I posted on (post #6 has links to the best oil you can use and the proper filter:
http://www.passatworld.com/forums/v...ums/volkswagen-passat-b6-discussion/556585-help-i-used-non-502-00-spec-oil.html). With that oil it's totally fine to run 5-6K oil change intervals instead of the old-school 3K change rule. Just don't get carried away and listen to VW on their "10K oil interval" crap. That's just marketing. Wear will increase noticeably between around 6K - 10K miles as the additives responsible for wear protection start to shear a bit, even in a very good fully synthetic like the one linked above. You CAN do 10K miles between changes on fully synthetics but you SHOULDN'T if you want as much longevity out of your car as possible (as in if you want to see if you can get more than your 3 years, as many more years as possible).
The only codes showing are P0171 (too lean) & P2540 (low fuel pressure).
The mechanic I took it too said they couldn’t get their machines to connect to the fuel pump to test it.
Oh I see, I thought you meant they tried to data log from the ECU on fuel pressure and couldn't communicate with the ECU. It sounds like they tried to hook up equipment to test manually which would be difficult. Fortunately, that is not necessary. You can get accurate fuel pressure data from the ECU with VCDS/Vagcom. It's not cheap, but if you are planning to keep this vehicle it pays for itself MANY times over VERY quickly. It would pay for itself with the issues you are having because it would help diagnose things much quicker and more assuredly. If you ever sold the car and swore off VW you could sell the VCDS cable in a heartbeat on the forums and make most of your money back because it is in high demand. Alternately you could try to find someone nearby who has it and is familiar with data logging techniques. You're going to want to do one of the two and when you have either got VCDS or got someone with it let me know so that I can tell you how to log fuel pressure data and what to look for. There are a number of things that could be contributing to low fuel pressure code and ruling them out is going to require data logging to narrow down the possibilities.
When I personally checked the coils, they looked like new Duralast coils that you get from AutoZone. I didn’t take out the plugs to check them but certainly could do so.
Duralast coils (or any non-OEM coil) are a huge "no, no". You need to replace all 4 with the latest revision OEM coils. Earlier revision coils can sometimes be find for a tad cheaper but are not as reliable. Coil pack reliability has plagued VWs since the 1.8T/B5 generation particularly, and still does with your generation. This is why I stress the correct, latest revision. The link below is to the latest revision and is a great source for OEM parts cheap. This is a dealer out of NJ that runs this parts site and they get parts in bulk from VW so they can sell them at VERY VERY reduced prices compared to any other dealer. This is one of the cheapest places you'll find VW OEM parts on the web or physical stores in most cases. In this case, this is definitely the best price you'll get on the newest revision coil packs, I doubt any other place has the newest revision for cheaper than $25/each.
https://www.vwpartsvortex.com/oem-p...DUmcj0xJmE9dm9sa3N3YWdlbiZvPXBhc3NhdCZ5PTIwMTAmdD1rb21mb3J0JmU9Mi0wbC1sNC1nYXM=
There are also other sites to consider if you even find that the above site doesn't have the cheapest parts. ECSTuning is a good supplier (but rarely the cheapest), FCPEuro is a smaller supplier but with good prices and service too.
The engine cover is cracked just above the oil cap to on the left side and up to where the cut out is between that and where the MAF sensor would plug in. I thought about getting a new cover but not sure exactly where to get from.
I deleted my stock engine cover a long time ago and run a completely different intake system (also deleted the entire PCV system and run a custom routing with no failure prone check valves), among many other custom replacements for unreliable systems on the car, and I bring that up because frankly I haven't looked at the stock engine cover in a long time but if my memory serves then a crack going all the way up to near the MAF sensor slot is DEFINITELY cracked right over the air-box itself where the air filter is (If you take apart the engine cover you'll find the air filter is inside that larger compartment in the rear near the MAF). I would strongly recommend replacing it as this could be the culprit of your lean issue at least. Leaks and MAF issues can also present as "shifting" issues sometimes as well, although they have nothing to do with shifting in the mechanical sense and the timing/symptom is coincidental. Use any of the above suppliers to get the cheapest option. Expect to spend $100-$150. Replace the air filter for good measure too, with an OEM Mann part (only $10-$15). The engine covers MIGHT come with a new filter but I'm not sure, please verify before assuming they do.
Lastly from time to time the dash lights up all the gears and defaults to 2nd gear (on screen anyway) which I have been told is transmission going to ‘limp mode’ which seems ridiculous if the valve body was just re-done.
I am not intimately familiar with the DSG/auto trans on these cars like I am with the rest of them as I have never owned an auto (and hopefully never will, I'll keep my B6 forever and rebuild it time and again if the market decides to stop making manual trans). I'm a little old school when it comes to manual vs. auto. Auto trans of today are indisputably better (better fuel economy typically and faster shifting than even the best manual drivers) but they just aren't as enjoyable so that's where I'm coming from. BUT, that's just my personal taste, and not really important. All that to say, I was just pointing out I am not super familiar with the auto trans on your car so if this winds up being something really involved I may not be the best source of info on this one. But I can say this confidently for now: you had better take it to the dealer and insist they flash your TCU (transmission computer unit) to the latest software update. There definitely have been shifting issues solved with TCU software updates on early DSG trans (which I believe yours is one of). You had mentioned you're afraid the TCU could be damaged from that accident earlier I think; well you'll find out when they try to flash it with the update. If they can flash it successfully then it should be fine. They may charge labor time for the flash but that should be the only charge and it should be no more than 1 hour. It takes them less time but most dealers don't charge anything under 1 hour. You might be within your right to insist they don't charge as software updates are technically something you are entitled to as a VW owner. I don't know what the specific rules around suspending labor rates on those entitlements are though so to win that argument you'd probably need some documentation or else they'll just talk you down and insist on the labor rate. Well most dealers. Some are genuinely looking to do right by the customer. It's luck of the draw.
Also, you should have the trans gear oil flushed and refilled with whatever VW OEM gear oil is specified for the car. ABSOLUTELY NEVER use anything but the OEM gear oil on a VW DSG/auto trans, they are much more picky than manual trans from what I know. There might be some exceptions but I'd leave that to the companies that build race cars out of their VWs with DSG, for anyone else stick to the OEM gear oil for a DSG/auto trans. This probably isn't too hard to do yourself but you'll need to find a DIY. I can't help when it comes to DSG/auto oil changes as I've never worked on one. Probably not too much more involved than a manual but it will surely be messy as they usually are so you may want to just have the dealership do it when you get the software updated. This will likely cost a couple hundred. I would NOT trust a non-dealer or non-Euro specialty shop to do oil changes (whether engine or trans oil), for reasons pretty much stated in the opening paragraph. That brings up a good point; if you plan to keep the car find a good euro-specialty/enthusiast shop near you as a cheaper alternative to the dealer. They will provide similar or in some cases better quality of specialized knowledge/service but for a bit cheaper on labor rate.
Edit:
When I was talking about coil packs I forgot to mention that you should change the plugs too for good measure since you don't know how long they've been run and it is possible they are the original or were only changed once in the life of the vehicle. The platinum plugs that come from the factory can actually operate up to 100K miles before they have serious issues BUT that is certainly by far the exception rather than the rule and they will still not be working even close to optimally by that point. You should change them out since they are cheap and could be an issue or become an issue within short order. It's just a good thing to rule out now since it's so easy. You have a few options including some dealer/OEM options and some technically non-OEM options. I am going to present to you the non-OEM options because they are OEM equivalents and because they are cheaper and just as fine. Please keep in mind that this it is RARE that a non-OEM option is actually just as good for your car, especially when it comes to electrical. 95% of the time, OEM is the best/only way to go if you want stuff to work right and reliably.
1) NGK BKR6E - copper plug. Dirt cheap ($3 each at autozone). Works perfectly well for your application and should be gapped correctly (0.032 gap) right out of the box. Only downside is they don't last very long. I wouldn't run copper plugs more than 15K miles at most, personally. Normally I change them every, or every other oil change.
2) NGK BKR6EIX - Iridium version of the same plug. More expensive ($12 each at autozone). Last way longer, you can comfortably run them for 50K miles with no issues assuming everything else with your engine is proper. They could go longer but I wouldn't stretch them past 50K personally.
Please note: when tightening spark plugs they only need to go in at about 20ft-lbs which is basically snugging them up and then giving them a quarter turn further. DO NOT overtighten or you run the risk of stripping the soft aluminum threads of your motors head and then you're in a world of shit.