Hi there,
i was recently horrified to check under my space saver wheel in the boot. Water had been sitting and basically perforated away the metal. Maybe it's just because i am in the North of Scotland but the metal on these cars seems cr@p quality. I would be checking sills and as much of the underneath metal as i could, The post of @Pudding recently showed lurking rust behind the plastics sill guards. Exhaust Flexi downpipe at the front for leaks. Oil leaks seems to be another issue on these from my experience. Working air con. Make sure temp sits at 90 and moves fairly quickly from cold and doesn't hover in the minimum range - thermostat.
Just from my experience, more if it was manual.......
Good cars though and i hope you get a good one
Agreed with that. The MK5 was definitely an exercise in cost cutting. Decent galvanising did away with rust 2-3 decades ago, and yet here we are with the MK5. Interestingly, I never see rusty Passats or A3s of the same vintage. Same car essentially.
Unfortunately rust will be the undoing of these cars, which is really annoying for enthusiasts who like the car and want to keep it for as long as possible. They do look and drive really well though, which is why most of us persevere with them. Replacing wings and tailgates is fair enough and not the end of the world, but structural rust on welded-on panels.......that's when I throw the towel in. Can't be doing with it.
The engine is pretty solid though, save for the usual thermostat and oil pickup clogging issues, but having 2 chains, they both need doing at some point. One thing they are not tolerant of is abuse. Lots of them have clearly suffered skipped services judging by all the clogged oil pickups and dark brown staining under the cam cover.
Then there's the steering rack. Everyone will be forced over to the Gen 3 rack at some point because Gen 1 & 2 are so crap.
A/C is super fickle on these cars also, it either works or it doesn't. There doesn't seem to be any middle ground.
So all in all, these cars can be potentially ruinous to own, so get the youngest, lowest mileage, best condition one you can afford!
In spite of that laundry list of faults, I still love driving the sodding thing