NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
50 reports83,000 miles · Mar 19, 2014
Fuel System, Gasoline
TL* THE CONTACT OWNS A 2010 AUDI A3. THE CONTACT STATED THAT WHILE TRAVELING VARIOUS SPEEDS, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TOWEDTO THE NEAREST DEALER WHERE IT WAS FOUND THAT THE FUEL PUMP SUFFERED AN INTERNAL FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE FAILURE MIL…
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TL* THE CONTACT OWNS A 2010 AUDI A3. THE CONTACT STATED THAT WHILE TRAVELING VARIOUS SPEEDS, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TOWEDTO THE NEAREST DEALER WHERE IT WAS FOUND THAT THE FUEL PUMP SUFFERED AN INTERNAL FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS 83,000. UPDATED 04/29/14*LJ THE CONSUMER STATED AUDI PAID FOR THE REPAIRS. UPDATED 06/03/14
NHTSA ODI #10573440
70,000 miles · Mar 9, 2014
Fuel System, Diesel
CHECK VEHICLE (COIL) LIGHT FLASHED. VEHICLE LOST POWER AND STALLED WHILE DRIVING ON CALIFORNIA HWY 1. WAS ABLE TO COAST VEHICLE TO SAFE PLACE. DEALER DIAGNOSED FAILED DIESEL FUEL PUMP, SAID PUMP WAS DISINTEGRATED. SERVICE ADVISOR ADVISED THAT ENTIRE FUEL SYSTEM WOULD BE REPLACED BY AUDI. *TR
NHTSA ODI #10567992
104,600 miles · May 30, 2013
Fuel System, Diesel
CAR STARTED BUT MADE HORRIBLE RATTLING SOUND THEN DIED AND WOULD NOT START AGAIN. CAR LEFT ME STRANDED OVER 60 MILES FROM HOME ON A SUNDAY NIGHT ON THE MEMORIAL DAY WEEKEND WITH A YOUNG CHILD. THE CAR HAD TO BE TOWED TO DEALERSHIP IN AUSTIN. DUE TO THE LATE HOUR AND HOLIDAY, NO WAY TO RENT A CAR TO GET HOME, SO I HAD TO HAVE…
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CAR STARTED BUT MADE HORRIBLE RATTLING SOUND THEN DIED AND WOULD NOT START AGAIN. CAR LEFT ME STRANDED OVER 60 MILES FROM HOME ON A SUNDAY NIGHT ON THE MEMORIAL DAY WEEKEND WITH A YOUNG CHILD. THE CAR HAD TO BE TOWED TO DEALERSHIP IN AUSTIN. DUE TO THE LATE HOUR AND HOLIDAY, NO WAY TO RENT A CAR TO GET HOME, SO I HAD TO HAVE SOMEONE COME AND GET US. I WAS TOLD BY THE DEALERSHIP THE FUEL PUMP WENT OUT AND BASICALLY EXPLODED SENDING METAL FIBERS INTO ENGINE AND OTHER SYSTEMS. GIVEN ESTIMATE OF $7,500.00 TO FIX THE CAR. SERVICE DEPARTMENT ACKNOWLEDGED THAT THIS HAS HAPPENED BEFORE BUT REFUSED TO PAY FOR THE REPAIR SINCE MY EXTENDED WARRANTY ENDED AT 100,000 MILES, AND MY CAR WAS OUT OF WARRANTY BY 4,600 MILES. IT IS A DESIGN FLAW, THAT IF THE FUEL PUMP GOES BAD IN A DIESEL ENGINE THAT IT WILL DO SO MUCH DAMAGE TO THE ENGINE. *TR
NHTSA ODI #10514315
57,000 miles · May 15, 2013
Fuel/propulsion System
WAS DRIVING ALONG AT HIGHWAY SPEEDS WHEN GLOW BULB INDICATOR CAME ON IMMEDIATELY FOLLOWED BY LOSS OF POWER TO ACCELERATOR. WAS ABLE TO GET OFF THE HIGHWAY AFTER ABOUT 4 MILES AND CAR THEN EXPERIENCED COMPLETE ENGINE FAILURE AND WAS ROLLED TO THE SIDE OF THE ROAD. ENGINE WOULD NOT TURN OVER AFTER TWO ATTEMPTS TO RESTART THE ENG…
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WAS DRIVING ALONG AT HIGHWAY SPEEDS WHEN GLOW BULB INDICATOR CAME ON IMMEDIATELY FOLLOWED BY LOSS OF POWER TO ACCELERATOR. WAS ABLE TO GET OFF THE HIGHWAY AFTER ABOUT 4 MILES AND CAR THEN EXPERIENCED COMPLETE ENGINE FAILURE AND WAS ROLLED TO THE SIDE OF THE ROAD. ENGINE WOULD NOT TURN OVER AFTER TWO ATTEMPTS TO RESTART THE ENGINE. CAR WAS TOWED TO LOCAL SERVICE AT AUDI DEALERSHIP. SERVICE DEPARTMENT FROM LOCAL DEALERSHIP DESCRIBED THE CAUSE OF ENGINE FAILURE WAS DUE TO METAL FILINGS FOUND THROUGHOUT THE FUEL SYSTEM CAUSED EITHER BY FUEL PUMP FAILURE, OR BAD BATCH OF DIESEL FUEL. *TR
NHTSA ODI #10512294
38,753 miles · Oct 18, 2012
EngineFuel System, DieselFuel/propulsion System
THIS COMPLAINT RELATES TO A TDI VERSION OF THE AUDI A3. WHILE DRIVING MY KIDS TO SCHOOL, THE CAR STOPPED DEAD AND WOULD NOT RESTART. ON INSPECTION BY AN AUDI DEALER IT WAS DETERMINED THAT THE HIGH PRESSURE FUEL PUMP HAD FAILED. THE PUMP FAILURE CAUSED METAL PARTICLES FROM THE PUMP ITSELF TO CIRCULATE IN THE FUEL SYSTEM DOING …
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THIS COMPLAINT RELATES TO A TDI VERSION OF THE AUDI A3. WHILE DRIVING MY KIDS TO SCHOOL, THE CAR STOPPED DEAD AND WOULD NOT RESTART. ON INSPECTION BY AN AUDI DEALER IT WAS DETERMINED THAT THE HIGH PRESSURE FUEL PUMP HAD FAILED. THE PUMP FAILURE CAUSED METAL PARTICLES FROM THE PUMP ITSELF TO CIRCULATE IN THE FUEL SYSTEM DOING CATASTROPHIC DAMAGE TO THE FUEL SYSTEM AND POWER TRAIN. AS OF THIS DATE, THE CAR HAS BEEN IN THE SHOP FOR REPAIR LONGER THAN TWO WEEKS WITH NO ESTIMATED DATE OF COMPLETION. WE EXPERIENCED A SIMILAR CATASTROPHIC FUEL PUMP FAILURE WITH OUR AUDI Q7 TDI IN JUNE OF 2012 WHICH REQUIRED A NEW ENGINE, FUEL SYSTEM AND OTHER PARTS (SEE ODI # 10480946). ACCORDING TO THE DEALER, THE REASON FOR THE DELAY IN REPAIRING THE A3 RELATES TO THE LARGE NUMBER OF CARS WITH SIMILAR FUEL SYSTEM FAILURES WHICH HAS CAUSED A SCARCITY OF PARTS. WE HAVE BEEN TOLD BY THE DEALER THAT THIS SAME PROBLEM IS HAPPENING TO TDI VEHICLES FROM BOTH VOLKSWAGEN AND AUDI. I AM NO ENGINEER, BUT WIDESPREAD FUEL SYSTEM FAILURES SEEM POTENTIALLY DANGEROUS TO DRIVERS AND THEIR PASSENGERS. THIS PROBLEM DESERVES AN INVESTIGATION. *TR
NHTSA ODI #10480997
30,150 miles · Apr 30, 2012
Engine
WHILE DRIVING ON LOCAL ROADS, ENGINE LOST POWER AND STOPPED RUNNING SUDDENLY. I WAS ABLE TO RESTART THE CAR AFTER A MINUTE OR SO AND CONTINUED MY TRIP TO WORK. CAR IS AN AUTOMATIC AND THE ENGINE JUST QUIT LIKE A MANUAL LEFT IN GEAR AT A STOP SIGN...A SHUDDER THEN NOTHING. NOT SURE IF RELEVANT, BUT I COULD ONLY RESTART THE CAR…
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WHILE DRIVING ON LOCAL ROADS, ENGINE LOST POWER AND STOPPED RUNNING SUDDENLY. I WAS ABLE TO RESTART THE CAR AFTER A MINUTE OR SO AND CONTINUED MY TRIP TO WORK. CAR IS AN AUTOMATIC AND THE ENGINE JUST QUIT LIKE A MANUAL LEFT IN GEAR AT A STOP SIGN...A SHUDDER THEN NOTHING. NOT SURE IF RELEVANT, BUT I COULD ONLY RESTART THE CAR AFTER COMPLETELY TURNING IT OFF AND REMOVING THE KEY. *JS
NHTSA ODI #10456903
39,100 miles · Feb 4, 2012
Fuel System, Diesel
I OWN A 2010 AUDI A3 TDI. I WAS DRIVING ON A CITY STREET IN NORMAL TRAFFIC, BEGAN FEELING HESITATION/JERKING IN THE ENGINE, THEN THE "GLOW PLUG" LIGHT CAME ON JUST BEFORE THE ENGINE STOPPED RUNNING. ULTIMATELY THE CAR STALLED WITHIN 30 SECONDS FOLLOWING INITIAL HESITATION IN A MOVING LANE OF TRAFFIC. I WAS BARELY ABLE TO GET THE…
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I OWN A 2010 AUDI A3 TDI. I WAS DRIVING ON A CITY STREET IN NORMAL TRAFFIC, BEGAN FEELING HESITATION/JERKING IN THE ENGINE, THEN THE "GLOW PLUG" LIGHT CAME ON JUST BEFORE THE ENGINE STOPPED RUNNING. ULTIMATELY THE CAR STALLED WITHIN 30 SECONDS FOLLOWING INITIAL HESITATION IN A MOVING LANE OF TRAFFIC. I WAS BARELY ABLE TO GET THE CAR TO COAST UP INTO A PARKING LOT TO SAFETY AND HAD TO BE TOWED INTO THE DEALER. IT WAS IN FOR REPAIR FOR APPROXIMATELY ONE WEEK. METAL SHAVINGS WERE FOUND IN THE FUEL FILTER INITIALLY THEN THROUGHOUT THE ENTIRE FUEL SYSTEM, INCLUDING THE FUEL TANK WHICH ALSO HAD TO BE REPLACED. SERVICEMEN FIRST SUSPECTED I HAD ACCIDENTALLY PUT UNLEADED IN IT WHICH WAS ABSOLUTELY NOT THE CASE THOUGH I HAVE HEARD FROM OTHER OWNERS WHO WERE ACCUSED OF THE SAME AND FORCED TO PAY OUT OF POCKET FOR REPAIR. I AM THE ONLY DRIVER AND ONLY GO TO HIGHEST QUALITY STATIONS WITH LABELS OF "ULTRA-LOW SULFUR DIESEL". IF IT DOESN'T STATE THAT THEN I HAVE GONE ELSEWHERE. EVERYTHING FUEL-RELATED WAS REPLACED UNDER WARRANTY. REPAIRMEN WERE UNABLE TO TELL ME HOW THE METAL SHAVINGS CAME ABOUT THOUGH THEY WERE INSISTENT IT WOULDN'T HAPPEN AGAIN. I HAVE SERIOUS DOUBTS SINCE THEY DID REPORT, AFTER I QUESTIONED THEM, THAT THE EXACT SAME PARTS REPLACED THE OLD ONES. I AM A HIGH MILEAGE DRIVER WHICH IS WHY I PURCHASED A DIESEL ENGINE. MY WARRANTY WILL SOON EXPIRE. WHEN THE SAME ISSUE OCCURS AGAIN, IF I STILL OWN THE VEHICLE, I GUESS I WILL HAVE TO COME OUT OF POCKET OVER $8000 WHICH WAS THE ESTIMATE ON PAPER FROM THE DEALER. I HOPE AUDI FURTHER INVESTIGATES THE PROBLEM VERY SOON AND ISSUES A RECALL SO I CAN HAVE PEACE OF MIND! *TR *KB
NHTSA ODI #10446661
8,000 miles · Nov 24, 2011
Power Train
THE CAR HAS AN AUTOMATIC TRANSMISSION THAT DOWNSHIFTS ON ITS OWN FROM AUTOMATIC (D) TO M1 (THE LOWEST MANUAL GEAR). WHEN THIS HAPPENS THE CAR IMMEDIATELY SLOWS AND THE ENGINE RPMS INCREASE TOWARD THE RED LINE. IT HAPPENS ABOUT EVERY 250 MILES OR SO, USUALLY WHEN I AM GOING ABOUT 20-25 MILES AN HOUR IN CITY DRIVING. THE LAST T…
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THE CAR HAS AN AUTOMATIC TRANSMISSION THAT DOWNSHIFTS ON ITS OWN FROM AUTOMATIC (D) TO M1 (THE LOWEST MANUAL GEAR). WHEN THIS HAPPENS THE CAR IMMEDIATELY SLOWS AND THE ENGINE RPMS INCREASE TOWARD THE RED LINE. IT HAPPENS ABOUT EVERY 250 MILES OR SO, USUALLY WHEN I AM GOING ABOUT 20-25 MILES AN HOUR IN CITY DRIVING. THE LAST TIME IT HAPPENED, I WAS HOLDING A CUP OF COFFEE AND IT SPILLED OVER MY LAP. I AM WORRIED THAT IT COULD HAPPEN WHEN ANOTHER CAR IS FOLLOWING CLOSELY AND RESULT IN A REAR END COLLISION. THERE WOULD BE NO WARNING OF THE SLOW DOWN TO THE OTHER DRIVER SINCE THE BRAKE LIGHTS WOULD NOT GO ON. *TR
NHTSA ODI #10437213
22,000 miles · Oct 27, 2011
Fuel System, Gasoline
IN 30-35 MPH TRAFFIC, GLOW-PLUG LIGHT BEGAN FLASHING. I PULLED OVER, CHECKED THE MANUAL, AND CALLED THE DEALERSHIP. I WAS TOLD THE CAR WAS SAFE TO DRIVE, AND WAS GIVEN A SERVICE APPOINTMENT FOR THE FOLLOWING MORNING. UPON RESTARTING THE CAR, I NOTICED NOT ONLY THE FLASHING GLOW-PLUG LIGHT, BUT THE CHECK-ENGINE LIGHT, WHICH HA…
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IN 30-35 MPH TRAFFIC, GLOW-PLUG LIGHT BEGAN FLASHING. I PULLED OVER, CHECKED THE MANUAL, AND CALLED THE DEALERSHIP. I WAS TOLD THE CAR WAS SAFE TO DRIVE, AND WAS GIVEN A SERVICE APPOINTMENT FOR THE FOLLOWING MORNING. UPON RESTARTING THE CAR, I NOTICED NOT ONLY THE FLASHING GLOW-PLUG LIGHT, BUT THE CHECK-ENGINE LIGHT, WHICH HAD COME ON AS WELL. ALSO, WHEN I PULLED OUT, POWER SEEMED LIMITED AND ACCELERATION DIFFICULT. NOW ON A TWO LANE COUNTRY ROAD WITH NO SHOULDER, I CALLED THE DEALERSHIP AGAIN, AND WAS TOLD TO STOP THE CAR IMMEDIATELY AND HAVE IT TOWED IN. SINCE I WAS CLOSE TO HOME, AND UNABLE TO FIND A GOOD PLACE TO STOP, I DROVE HOME. THE FOLLOWING MORNING, THE CAR WOULD NOT START, AND AUDI SENT A TOW TRUCK. THE CAR WAS NOT LOOKED AT FOR 24 HOURS (TDI-TRAINED MECHANICS IN A MEETING OR SOME SUCH), BUT ON THURSDAY I GOT A REPORT. THE FUEL PUMP HAD FAILED CATASTROPHICALLY, SENDING METAL DEBRIS THROUGHOUT THE FUEL SYSTEM. TOTAL REPLACEMENT OF THE FUEL SYSTEM WAS REQUIRED, INCLUDING THE FUEL TANK. THE FIRST-SUSPECTED CAUSE -CONTAMINATED FUEL- HAD BEEN RULED OUT. I WAS TOLD THE FAILURE WAS A 1-IN-100,000 FLUKE, BUT NOTHING ABOUT THE FACT THAT THERE HAD BEEN OVER 100 COMPLAINTS TO THE NHTSA AS OF EARLY 2011, PROMPTING AN NHTSA INVESTIGATION. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT
NHTSA ODI #10433092
10,334 miles · Aug 9, 2011
Fuel System, Diesel
2010 AUDI A3 TDI HIGH PRESSURE FUEL PUMP FAILURE AT 10,000 MI. *TR
NHTSA ODI #10418288
Official recalls
5Jan 30, 2018
Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2006-2013 Audi A3, 2007-2009 A4 Cabriolet and S4 Cabriolet, 2008 RS4 Cabriolet, 2009-2012 Q5, and 2010-2012 Audi A5 Cabriolet and S5 Cabriolet vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may cause the inflator to explode.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could explode with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: Audi will notify owners, and dealers will replace the driver's frontal air bag inflator with an alternative inflator, free of charge. The recall began February 23, 2018. Owners may contact Volkswagen customer service at 1-800-253-2834. Volkswagen's number for this recall is 69R6. Note: This recall partially supersedes recall 16V-078.
Feb 10, 2016
Volkswagen Group of America, Inc. (Volkswagen) is recalling certain model year 2006 Volkswagen Passat sedans and wagons, 2005-2013 Audi A3, and 2006-2009 Audi A4 Cabriolet vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may cause the inflator to rupture.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Volkswagen will notify owners, and dealers will replace the driver's frontal air bag inflators, free of charge. The recall began March 2017. Volkswagen owners may contact Volkswagen customer service at 1-800-893-5298. Audi owners may contact Audi customer service at 1-800-253-2834.
Oct 3, 2011
VOLKSWAGEN IS RECALLING CERTAIN MODEL 2009-2012 JETTA AND JETTA SPORTWAGEN VEHICLES, MANUFACTURED FROM MAY 2008 THROUGH SEPTEMBER 2011, MODEL YEAR 2010-2012 VOLKSWAGEN GOLF VEHICLES, MANUFACTURED FROM MAY 2009 THROUGH SEPTEMBER 2011, AND MODEL YEAR 2010-2012 AUDI A3 VEHICLES, MANUFACTURED FROM SEPTEMBER 2009 THROUGH SEPTEMBER 2011, THAT ARE EQUIPPED WITH A 2.0L TDI COMMON RAIL DIESEL ENGINE/CLEAN DIESEL ENGINE. THE FUEL INJECTION PULSES COULD COINCIDE WITH THE NATURAL FREQUENCY OF THE INJECTOR LINE #2, IN SPECIFIC LOAD AND RPM CONDITIONS. THIS RESONANCE CREATES ADDITIONAL STRESS IN THE FUEL LINE.
Consequence & remedy
Consequence: DUE TO THE RESONANCE CONDITION, INJECTOR LINE NUMBER 2 COULD DEVELOP SMALL CRACKS WHICH COULD LEAD TO FUEL LEAKAGE. LEAKING FUEL IN THE PRESENCE OF AN IGNITION SOURCE, MAY LEAD TO A FIRE.
Remedy: VOLKSWAGEN WILL INSTALL AN IMPROVED FUEL INJECTOR LINE FOR THE NUMBER 2 CYLINDER ON CERTAIN VEHICLES AND WILL INSTALL VIBRATION DAMPERS ON ALL OF THE INJECTOR LINES. VOLKSWAGEN AND AUDI WILL NOTIFY OWNERS TO HAVE THE VEHICLES REPAIRED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING NOVEMBER 2011. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.
Sep 30, 2009
VOLKSWAGEN IS RECALLING CERTAIN MODEL YEAR 2006 THROUGH 2010 AUDI A3, TT, AND TT ROADSTER PASSENGER VEHICLES MANUFACTURED BETWEEN SEPTEMBER 29, 2005 AND AUGUST 26, 2009. THE CLOSING FORCE OF AN INTERNAL SPRING OF THE FUEL TANK VENTILATION VALVE IS NOT ADEQUATE ENOUGH TO HOLD THE VALVE CLOSED UNDER EXTREME DRIVING CONDITIONS POSSIBLY ALLOWING FUEL TO LEAK.
Consequence & remedy
Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A VEHICLE FIRE COULD OCCUR.
Remedy: VOLKSWAGEN WILL NOTIFY OWNERS AND AUDI DEALERS WILL REPLACE THE FUEL TANK VENTILATION VALVE WITH AN IMPROVED VALVE FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 16, 2009. OWNERS MAY CONTACT AUDI AT 1-800-253-2834.
Aug 20, 2009
VOLKSWAGEN IS RECALLING CERTAIN MODEL YEAR 2009 AND 2010 PASSENGER CARS MANUFACTURED BETWEEN SEPTEMBER 2008 AND AUGUST 2009. THE WIRING HARNESS OF A TEMPERATURE SENSOR IN THE DIRECT SHIFT GEARBOX (DSG) MAY HAVE CONNECTOR WIRES THAT WERE INSUFFICIENTLY CRIMPED. WITH INSUFFICIENTLY CRIMPED CONNECTOR WIRES, A TEMPERATURE SENSOR HAS THE POTENTIAL TO FALSELY DETECT A HIGH GEARBOX OIL TEMPERATURE, CAUSING THE TRANSMISSION TO ABRUPTLY SHIFT TO NEUTRAL. IF THIS HAPPENS, THE SELECTOR LEVER POSITION INDICATOR WITHIN THE INSTRUMENT PANEL WILL FLASH. IN ADDITION, THE "DEPRESS BRAKE PEDAL" INDICATOR LIGHT WILL BE ILLUMINATED, ALERTING THE DRIVER TO APPLY THE BRAKES.
Consequence & remedy
Consequence: THE ABRUPT SHIFT TO NEUTRAL COULD LEAD TO A CRASH WITHOUT WARNING.
Remedy: VOLKSWAGEN WILL REPROGRAM THE TRANSMISSION CONTROL MODULE WITH UPDATED SOFTWARE FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 20, 2009. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4PE11023 · Diesel Fuel Injector Line Leakage
Opened Aug 2, 2011 · Closed Dec 2, 2011
Status: closed (inferred from source dates) · Fuel System, Diesel
By letter dated October 3, 2011, Volkswagen Group of America, Inc. (VW) notified the National Highway Traffic Safety Administration (NHTSA) that it will conduct a safety recall to address a defect in approximately 168,275 model year (MY) 2009-2012 Volkswagen Jetta, Jetta Sportwagen, Golf, and Audi A3 vehicles equipped with the 2.0L TDI Common Rail Clean Diesel engine (NHTSA Recall No. 11V-490).The recalled Jetta and Jetta Sportwagen vehicles were built from May 2008 through September 2011, the Golf vehicles were built from May 2009 through September 2011, and the Audi A3 vehicles were built from September 2009 through September 2011.According to Volkswagen, in U.S. applications of the above cited TDI vehicles including engine codes CJAA and CBEA, the fuel injection pulses could coincide with the natural frequency of the injector line #2 in specific load and RPM conditions.This resonance creates additional stress on the fuel line which a small number of parts (based on the statistic spread of line strength) cannot withstand over its lifetime.As a contributing factor, VW indicated that a supplier used tube material with scratch marks from a grinding process during certain production periods.Lines manufactured in these periods were installed in vehicles produced in the following 10 months:December 2008, January-February 2009, October 2009, March-April 2010 and September-December 2010.Injector lines using this material exhibit a significantly higher failure rate.Dealers will replace injector line #2 in all vehicles built in these months.In addition, as a precautionary measure, all recalled vehicles will have vibration dampers installed on all four fuel injector lines.Analysis of NHTSA complaints, VW complaints, VW field reports and warranty claims found allegations of injector line leakage in 443 subject vehicles.The leaking line was not identified in 62 of the vehicles.For the 381 that did provide information about which injector lines were leaking and/or replaced, 358 (94%) involved an injector line #2 leak/repair.Almost three-quarters of the injector line #2 leak/repair incident vehicles were built in the 10 months identified by VW, which accounted for approximately one-quarter of the recalled vehicles.The failure rate for injector line #2 in vehicles built in the 10 months affected by the supplier line scratching issue is 6.0 incidents per thousand vehicles (IPTV).The failure rate for injector line #2 in other production months of recalled vehicles is 0.8 IPTV.The leak/repair rates for the other injector lines are all well under 1 IPTV.The action taken by Volkswagen is sufficient to resolve the issues raised by this investigation. The agency will continue to monitor this issue and reserves the right to take further action if warranted by the circumstances. Accordingly, this investigation is closed.
EA11003 · High-Pressure Fuel Pump Failure
Opened Feb 7, 2011 · Closed Mar 27, 2015
Status: closed (inferred from source dates) · Fuel System, Diesel; Fuel System, Other:delivery:fuel Pump
The Office of Defects Investgation (ODI) opened EA11-003 on February 7, 2011, based on 160 complaints to ODI and Volkswagen involving high pressure fuel pump (HPFP) failures in model year (MY) 2009 through 2010 Volkswagen Jetta and Golf and Audi A3 TDI vehicles and questions regarding fuel sample results provided by Volkswagen as part of its response to PE10-034.During EA11-003, ODI analyzed design information, field experience and test data for MY 2009 through 2012 Volkswagen Jetta, Golf and Touareg and Audi A3 and Q7 vehicles equipped with TDI engines. Volkswagen has not identified any design or manufacturing defects in the subject TDI Clean Diesel pumps and has stated that the subject pumps were designed, tested and approved for use in the United States market, with substantial design margins for fuels that are out of specification.Volkswagen believes that misfueling with gasoline is the primary cause of HPFP drivetrain failures in the field.Only the Q7 vehicles were built with misfuel protection devices.In May 2013 Volkswagen initiated a service campaign to install misfuel protection devices in all MY 2009 through 2012 Jetta, Golf and A3 vehicles.Volkswagen implemented misfuel protection devices in all of the subject models beginning in MY 2013. ODI?s analysis of HPFP drivetrain failure incidents indicates that most failures do not result in engine stall while driving and, when pump drivetrain failure does result in stall while driving, it is usually preceded by numerous warning symptoms (e.g., glow plug warning lamp, chime, limp mode, and driveability symptoms).The failure data for the subject vehicles show relatively low stalling rates (less than one percent at three years in service) for each of the pump designs used in the subject vehicles.There have been no reports of crashes, injuries or fatalities related to the alleged defect. Based on these facts, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.For additional information, see the closing report in the document file for EA11-003.
Additional source detail variants (2)
Fuel System, Diesel
The Office of Defects Investgation (ODI) opened EA11-003 on February 7, 2011, based on 160 complaints to ODI and Volkswagen involving high pressure fuel pump (HPFP) failures in model year (MY) 2009 through 2010 Volkswagen Jetta and Golf and Audi A3 TDI vehicles and questions regarding fuel sample results provided by Volkswagen as part of its response to PE10-034.During EA11-003, ODI analyzed design information, field experience and test data for MY 2009 through 2012 Volkswagen Jetta, Golf and Touareg and Audi A3 and Q7 vehicles equipped with TDI engines. Volkswagen has not identified any design or manufacturing defects in the subject TDI Clean Diesel pumps and has stated that the subject pumps were designed, tested and approved for use in the United States market, with substantial design margins for fuels that are out of specification.Volkswagen believes that misfueling with gasoline is the primary cause of HPFP drivetrain failures in the field.Only the Q7 vehicles were built with misfuel protection devices.In May 2013 Volkswagen initiated a service campaign to install misfuel protection devices in all MY 2009 through 2012 Jetta, Golf and A3 vehicles.Volkswagen implemented misfuel protection devices in all of the subject models beginning in MY 2013. ODI?s analysis of HPFP drivetrain failure incidents indicates that most failures do not result in engine stall while driving and, when pump drivetrain failure does result in stall while driving, it is usually preceded by numerous warning symptoms (e.g., glow plug warning lamp, chime, limp mode, and driveability symptoms).The failure data for the subject vehicles show relatively low stalling rates (less than one percent at three years in service) for each of the pump designs used in the subject vehicles.There have been no reports of crashes, injuries or fatalities related to the alleged defect. Based on these facts, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.For additional information, see the closing report in the document file for EA11-003.
Fuel System, Other:delivery:fuel Pump
The Office of Defects Investgation (ODI) opened EA11-003 on February 7, 2011, based on 160 complaints to ODI and Volkswagen involving high pressure fuel pump (HPFP) failures in model year (MY) 2009 through 2010 Volkswagen Jetta and Golf and Audi A3 TDI vehicles and questions regarding fuel sample results provided by Volkswagen as part of its response to PE10-034.During EA11-003, ODI analyzed design information, field experience and test data for MY 2009 through 2012 Volkswagen Jetta, Golf and Touareg and Audi A3 and Q7 vehicles equipped with TDI engines. Volkswagen has not identified any design or manufacturing defects in the subject TDI Clean Diesel pumps and has stated that the subject pumps were designed, tested and approved for use in the United States market, with substantial design margins for fuels that are out of specification.Volkswagen believes that misfueling with gasoline is the primary cause of HPFP drivetrain failures in the field.Only the Q7 vehicles were built with misfuel protection devices.In May 2013 Volkswagen initiated a service campaign to install misfuel protection devices in all MY 2009 through 2012 Jetta, Golf and A3 vehicles.Volkswagen implemented misfuel protection devices in all of the subject models beginning in MY 2013. ODI?s analysis of HPFP drivetrain failure incidents indicates that most failures do not result in engine stall while driving and, when pump drivetrain failure does result in stall while driving, it is usually preceded by numerous warning symptoms (e.g., glow plug warning lamp, chime, limp mode, and driveability symptoms).The failure data for the subject vehicles show relatively low stalling rates (less than one percent at three years in service) for each of the pump designs used in the subject vehicles.There have been no reports of crashes, injuries or fatalities related to the alleged defect. Based on these facts, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.For additional information, see the closing report in the document file for EA11-003.
PE10034 · High Pressure Fuel Pump Failure (hpfp)
Opened Aug 26, 2010 · Closed Feb 8, 2011
Status: closed (inferred from source dates) · Fuel System, Diesel
The Office of Defects Investigation (ODI) and Volkswagen (VW) have received a total of 160 complaints and field reports alleging incidents of engine stall and/or loss of power that appear to be related to high pressure fuel pump (HPFP) failures in certain model year (MY) 2009 through 2010 Volkswagen Jetta and MY 2010 Volkswagen Golf and Audi A3 vehicles equipped with TDI clean diesel engines.Approximately half of the reports indicate that the failure resulted in an engine stall incident, with many of these alleging stall incidents at highway speeds in traffic with no restart.There has been one minor crash alleged to have resulted from HPFP failure in the subject vehicles.In response to ODI's information request for PE10-034, VW indicated that it had found no defect related to motor vehicle safety with relation to the TDI Clean Diesel fuel system at issue in this investigation and attributed problems with HPFP failure to operation with gasoline contaminated diesel fuel.Volkswagen stated that even a small amount of gasoline in the diesel fuel may disrupt the necessary lubrication required and may cause the HPFP to fail.In response to concerns that fuel contamination was the major cause of HPFP and related fuel system failures, VW issued a Technical Service Bulletin in May 2010 (VW TB V011011 2023624 and Audi TB A011008 2023360-1), with instructions to inspect the diesel fuel for vehicles requiring fuel system service that have symptoms associated with HPFP failure.The bulletin states that fuel system damage incurred by use of fuel not complying to ASTM-D-975 Grade 2 S15 (B5 or less biodiesel content) standards will not be covered under warranty. Volkswagen also provided information about 121 mis-fueling incidents reportedly acknowledged by consumers or dealers and test results for about 50 diesel fuel samples taken from complaint vehicles in late-August through early-October 2010.The mis-fueling incidents include about 20 reports involving incorrect fueling by dealer sales or service personnel and generally report symptoms such as rough running, stalling and/or no start within a few miles of refueling the vehicle with gasoline.Volkswagen indicated that the testing of fuel samples from complaint vehicles found that nearly 90 percent contained high amounts of gasoline.Volkswagen implemented design changes for the HPFP in May 2008, September 2009 and November 2010 to improve the robustness of the pump when used with poor quality fuel.ODI analysis of HPFP failures identified from all sources shows failure rates of 0.53% for MY 2009 vehicles and 0.11% for MY 2010 vehicles.This investigation has been upgraded to an Engineering Analysis (EA11-003) to continue to investigate the issues with mis-fueling and HPFP design identified during the Preliminary Evaluation.
PE09035 · Vehicle Stall/loss Motive Power
Opened Jul 17, 2009 · Closed Nov 19, 2009
Status: closed (inferred from source dates) · Power Train:manual Transmission
THE SUBJECT VEHICLES ARE EQUIPPED WITH DIRECT SHIFT GEARBOX (DSG) TRANSMISSIONS, WHICH FEATURE A 6-SPEED AUTOMATIC GEARBOX WITH TWO WET RUNNING CLUTCHES (DUAL CLUTCH) IN WHICH THE CLUTCH MECHANISM AND GEAR CHANGES ARE ELECTROHYDRAULICALLY OPERATED BY A MECHATRONIC CONTROL UNIT.THE DSG MECHATRONIC CONTROLLER INCLUDES EXTENSIVE SELF DIAGNOSTIC FUNCTIONS AND STRATEGIES TO ENSURE SAFE OPERATION AND PREVENT SYSTEM/COMPONENT DAMAGE IN THE EVENT OF COMPONENT FAILURES OR HARSH OPERATING CONDITIONS.THE BASIC HIERARCHY OF FAULT MODES INCLUDES SOME THAT ONLY RESULT IN THE STORAGE OF A DIAGNOSTIC TROUBLE CODE (DTC) AND CAUSE NO LOSS OF FUNCTION, SOME THAT STORE A DTC AND REDUCE VEHICLE OPERATION TO A LIMP HOME MODE, AND SOME THAT STORE A DTC AND CAUSE AN INTERRUPTION OF MOTIVE POWER (I.E., OPEN CLUTCH).THE DRIVER IS ALERTED TO THE LATTER TWO MODES BY THE DASH GEAR POSITION INDICATOR (PRNDS) FLASHING. ONE OF THE CONDITIONS THAT RESULTS IN INTERRUPTION OF MOTIVE POWER IS EXCESS GEARBOX TEMPERATURE.THE SYSTEM INITIALLY RESPONDS TO INCREASED GEARBOX TEMPERATURE BY RAMPING DOWN ENGINE TORQUE.IF THE TEMPERATURE KEEPS RISING THE MECHATRONIC UNIT RESPONDS BY OPENING THE CLUTCH.IN A DEFECT INFORMATION REPORT SUBMITTED TO NHTSA ON AUGUST 20, 2009, VOLKSWAGEN DESCRIBED A POTENTIAL DEFECT IN THE WIRING HARNESSES OF THE DSG GEARBOX TEMPERATURE SENSORS USED IN APPROXIMATELY 16,000 MODEL YEAR (MY) 2009 AND 2010 VOLKSWAGEN (EOS, JETTA AND GTI) AND AUDI (A3 AND TT/TT ROADSTER) VEHICLES EQUIPPED WITH DSG TRANSMISSIONS AND BUILT FROM SEPTEMBER 2008 THROUGH AUGUST 2009 (NHTSA RECALL NO. 09V-333, VOLKSWAGEN RECALL NO. 37E3/S7 AND AUDI RECALL NO 37E4/J7). VOLKSWAGEN PROVIDED THIS DESCRIPTION OF THE DEFECT, THE WIRING HARNESS OF A TEMPERATURE SENSOR IN THE DSG MAY HAVE CONNECTOR WIRES THAT WERE INSUFFICIENTLY CRIMPED BY THE CONNECTOR SUPPLIER DURING A LIMITED PRODUCTION PERIOD.WITH INSUFFICIENTLY CRIMPED CONNECTOR WIRES, A TEMPERATURE SENSOR HAS THE POTENTIAL TO FALSELY DETECT A HIGH GEARBOX OIL TEMPERATURE, CAUSING THE TRANSMISSION TO ABRUPTLY SHIFT TO NEUTRAL.IF THIS HAPPENS, THE SELECTOR LEVER POSITION INDICATOR WITHIN THE INSTRUMENT PANEL WILL FLASH.IN ADDITION, THE DEPRESS BRAKE PEDAL INDICATOR LIGHT WILL BE ILLUMINATED, ALERTING THE DRIVER TO APPLY THE BRAKES.IN HEAVY TRAFFIC, THE ABRUPT SHIFT TO NEUTRAL COULD LEAD TO A CRASH WITHOUT WARNING.VOLKSWAGEN ESTIMATED THAT LESS THAN ONE PERCENT OF THE RECALLED VEHICLES MAY CONTAIN THE DEFECT CONDITION. ODI IDENTIFIED 40 COMPLAINTS THAT APPEAR TO BE RELATED TO THE TEMPERATURE SENSOR DEFECT CONDITION DESCRIBED BY VOLKSWAGEN.VOLKSWAGEN RECEIVED 139 COMPLAINTS RELATED TO THE CONDITION, WITH 7 INVOLVING VEHICLES REPORTED TO ODI, RESULTING A 172 TOTAL COMPLAINTS TO ODI AND VOLKSWAGEN.ALL OF THESE COMPLAINTS INVOLVE THE MY 2009 AN 2010 VEHICLES SUBJECT TO RECALL 09V-333. ODI ALSO IDENTIFIED COMPLAINTS OF HARSH/JERKY SHIFTING IN SOME VOLKSWAGEN VEHICLES WITH DSG.VOLKSWAGEN ATTRIBUTED THIS CONDITION, WHICH TYPICALLY OCCURS AT VERY LOW SPEEDS, TO EXCESSIVE WEAR IN THE BUSHINGS OF THE TWO SOLENOID VALVES IN THE MECHATRONIC UNIT THAT CONTROL CLUTCH OPERATION.VOLKSWAGEN DOES NOT BELIEVE THAT THE THIS CONDITION IS A SAFETY DEFECT BECAUSE THE CHANGES IN SHIFT QUALITY DEVELOP GRADUALLY OVER TIME, DO NOT CAUSE A LOSS OF MOTIVE POWER AND HAVE NOT RESULTED IN ANY FATALITIES, INJURIES OR SERIOUS CRASHES (THERE WERE THREE REPORTED PROPERTY DAMAGE INCIDENTS RESULTING IN MINOR BODY DAMAGE IN VERY LOW SPEED, PARKING MANEUVERS).VOLKSWAGEN ADDRESSED THIS PROBLEM IN THE FIELD WITH A CUSTOMER SERVICE PROGRAM THAT INCLUDES THE REPLACEMENT OF POTENTIALLY AFFECTED MECHATRONIC UNITS AS WELL
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