I'm curious to know at what mileage people are needing to replace their DPF, EGR, turbo, HPFP, timing belt, etc... Also what the replacement cost for these items are. I'm hoping to drive my JSW for 200K+ but have heard that TDI's can get expensive to maintain.
Yes, they can indeed be expensive to maintain if you plan on driving it for several hundred thousand miles, but only because you will be repeating some of the more expensive services, such as timing belt/water pump and possibly DPF/Cat. And, as with any vehicle, the longer you drive and the more miles you put on, more "stuff" can happen.
Here's a rundown of the major maintenance/repairs done to my 2010 JSW DSG, currently at 347,500 miles, purchased new in May 2010. I've had zero issues with the HPFP and turbo. The first four years of ownership (May 2010-May 2014) were about 70/30 highway/city miles. Since then it's been more like 50/50.
1) DPF/Cat replaced under warranty at 25,000 miles
2) Timing belt kit/water pump at 125,000 miles ($1080)
3) DMF (flywheel) replaced at 175,000 miles ($1514)
4) A/C compressor and condenser replaced at 225,000 miles ($1500)
5) Radiator replaced at 258,000 miles (road debris damage) ($639)
6) DPF/Cat replaced again at 283,000 (ash load was 300 ml, definitely overdue) ($2400)
7) Serpentine belt and tensioner at 300,000 miles ($300)
8) EGR valve at 316,000 miles ($525)
9) 2nd Timing belt kit and water pump at 346,000 miles (yes, way overdue but I took a gamble and got lucky. Water pump was just starting to leak but timing belt was really not too worn, considering it had over 220,000 miles on it) ($925)
Original front brake pads lasted until 216,000 miles and had the original rotors machined at that time. Original rear brake pads and rotors were replaced at 267,000 miles. At 325,000 miles, I had the front brake pads and original rotors replaced. Been through 5 sets of tires, and within the next month or two will be putting on my 3rd set of Michelin Defenders (90,000 mile warranty).
Hoping to get 500-600,000 miles out of my JSW but will just run it until repairs cost more than the car is worth. Do NOT plan on putting another DPF/Cat on it.