Service Brakes, Hydraulic. Review the 160 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine And Engine Cooling. Review the 94 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

11 crash reports25 fire reports10 injury reports

Engine And Engine Cooling complaints

94 reports

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Mileage unknown · Jan 5, 2007

Engine And Engine CoolingFire

OWNER PARKED THE VEHICLE AT A DOCTOR'S OFFICE. SHORTLY AFTER HE WENT INTO THE DOCTOR'S OFFICE, THE VEHICLE CAUGHT FIRE. FIRE BURNED THROUGHOUT ENGINE COMPARTMENT AND PASSENGER COMPARTMENT AND CAUSED SEVERE SCORCHING TO THE FRONT OF THE FLOOR PAN. EXHAUST HEAT SHIELD MELTED. *NM

NHTSA ODI #10177870

Mileage unknown · Jan 5, 2007

Engine And Engine CoolingFire

OWNER DROVE THE VEHICLE APPROXIMATELY 7 MILES, WENT INTO A STORE, CAME OUT, AND OBSERVED A FIRE IN THE VEHICLE. HEAT SHIELD ABOVE RIGHT SIDE CATALYTIC CONVERTER MELTED AND SOME WIRING IN THE DASH WAS BURNED.

NHTSA ODI #10177866

Mileage unknown · Jan 5, 2007

Engine And Engine CoolingFire

OWNER HAD THE CATALYTIC CONVERTERS AND OXYGEN SENSORS REPLACED. A FEW WEEKS LATER, OWNER WAS DRIVING THE VEHICLE AND THEN STOPPED AND WAS SITTING IN HER DRIVEWAY USING HER CELL PHONE WHEN SHE SMELLED SMOKE. SHE GOT OUT OF THE VEHICLE AND LOOKED AT THE ENGINE AND SAW FIRE. EXHAUST SYSTEM HAD OVERHEATED, CAUSING MELTING OF THE EXH…

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NHTSA ODI #10177864

Mileage unknown · Nov 27, 2006

Electrical SystemEngine And Engine Cooling

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I'VE HAD MY 2000 PASSAT NOW FOR 3 YEARS, MY HUSBAND AND MYSELF SEE TO IT THAT OUR CARS HAVE ANNUAL TUNE-UPS AND REGULAR OIL CHANGES. FOR THE PAST MONTH THE ABS AND BRAKE LIGHT HAS BEEN FLASHING NON-STOP. DURING MY MOST RECENT TUNE UP, I WAS INFORMED THAT THE CATALYTIC CONVERTERS HAVE TO BE REPLACED. MY MECHANIC WAS CONVINCED THAT A RECALL HAD TO BE IN PLACE BECAUSE HE WAS SEEING THIS PROBLEM OCCURRING FREQUENTLY. I CALLED THE VW DEALERSHIP WHERE I PURCHASED THE VEHICLE AND WAS INFORMED THAT $100 WAS NEEDED TO EVEN LOOK AT THE CAR. ALL OF THIS HAS ME FURIOUS. A RECALL IS NEEDED--RIGHT A WAY!!!!! *JB

NHTSA ODI #10174480

Mileage unknown · Nov 3, 2006

Engine And Engine Cooling

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2000 PASSAT OIL SLUDGE BUILD UP CAUSED ENGINE TO FAIL. *TS WHILE DRIVING THE OIL INDICATOR LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A SERVICE DEALER WHO EXPLAINED THAT THE OIL PRESSURE WAS LOW, BUT CLOSE TO MANUFACTURERS SPECIFICATIONS. THE OIL PUMP, PVC SYSTEM, AND TURBO TUBES WERE REPLACED. LESS THAN THREE MONTHS LATER THE CONSUME STARTED HEARING A RUMBLING NOISE WHICH SEEMED TO BE COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN BACK TO THE SERVICE DEALER WHERE ID WAS DETERMINED THAT HE NOISE WAS PROBABLY ROD KNOCK AND THE REMEDY WAS TO REPLACED THE ENGINE. THE CONSUMER FEELS THAT VW SHOULD BE RESPONSIBLY FRO REPLACING THE ENGINE BECAUSE THEY WERE AWARE THAT THE OIL FILTER WAS TOO SMALL. *NM

NHTSA ODI #10173277

73,000 miles · Jul 14, 2006

Engine And Engine CoolingService Brakes, Hydraulic

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THE ENGINE LIGHT HAS BEEN ON FOR A WHILE. I HAD THE CATALYTIC CONVERTER REPLACED LAST YEAR IN 08/05 WHEN IT INITIALLY OCCURRED. THE PROBLEM WENT OFF. IT CAME BACK ON JUST YESTERDAY 07/11/2006. THE MESSAGE SAYS IT IS EMISSION WORKSHOP. I HAVE NOT TAKEN IT TO A VW DEALER, HOWEVER, I SUSPECT IT IS THE SAME CATALYTIC CONVERTER PROBLEM. ANOTHER PROBLEM I HAVE HAD IS THE STOP - BRAKE FAULT MESSAGE. THE ABS LIGHT IS ON WHILE THE BRAKE LIGHT IS ILLUMINATING. I HAVE TAKEN MY CAR TO TWO DIFFERENT INDEPENDENT MECHANICS TO CHECK ON THE ISSUES. THEY MENTIONED THAT THE BRAKE PADS WERE ALL FINE. AND SO WAS THE FLUID BRAKE RESERVOIR LEVEL. THEY WERE GUESSING IT WAS ELECTRICAL PROBLEM OR ABS SENSOR PROBLEM. *JB

NHTSA ODI #10162391

65,000 miles · Jun 14, 2006

Engine And Engine CoolingInjury

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2000 PASSAT GLS 4-MOTION V6 HAS BEEN REGULARLY SERVICED. OIL CHANGES EVERY 3000 MILES. AT APPX 65000 MILES, WITH NO WARNING, THE CAR OVERHEATED WHILE IDLING (IT HAD BEEN IDLING FOR LESS THAN 8 MINUTES, IT WAS ONLY 50 DEGREES OUTSIDE, THE COOLANT HAD BEEN CHECKED A FEW WEEKS PREVIOUS AT THE CAR'S LAST OIL CHANGE). THE TEMPERATURE GAUGE IN THE DASH MAXED OUT AND STEAM AND SMOKE STARTED ISSUING FROM UNDER THE HOOD. TURNED THE CAR OFF & LET IT COOL FOR APPX 20 MINUTES BEFORE OPENING HOOD. CHECKED COOLANT, IT HAD COMPLETELY BOILED AWAY. REPLACED COOLANT, LET CAR CONTINUE TO COOL FOR APPX ANOTHER 1.5 HRS. STARTED CAR AND DROVE IT (SLOWLY) TO A GARAGE SPECIALIZING IN EUROPEAN CARS. (MY REGULAR MECHANIC.) REPLACED THE WATER PUMP AND THERMOSTAT, BOTH OF WHICH HAD STOPPED WORKING. VW RECOMMENDS THAT THE TIMING BELT BE REPLACED AT 80000 MILES. MECHANIC TOLD ME THAT THE TIMING BELT LOOKED SIGNIFICANTLY WORN AND THAT IT SHOULD BE REPLACED NOW FOR FEAR IT MIGHT BREAK BEFORE THE REGULARLY SCHEDULED REPLACEMENT. REPLACED TIMING BELT. TOTAL COST OF REPLACING WATER PUMP, THERMOSTAT AND TIMING BELT: $725. DUE TO EXCESSIVE ENGINE TEMPERATURE FROM THE WATER PUMP AND THERMOSTAT FAILURE, PISTONS AND VALVES IN ENGINE NOW KNOCK AND ENGINE IS NOISY, PARTICULARLY WHEN FIRST STARTED. ENGINE NO LONGER SEEMS TO BE AS RESPONSIVE, POWER WISE, AS IT WAS PREVIOUSLY. 65000 MILES SEEMS A BIT YOUNG TO BE EXPERIENCING A WATER PUMP FAILURE. THE FACT THAT THE ENGINE OVERHEATED SO QUICKLY AND WITH NO PRIOR INDICATION OF AN IMPENDING PROBLEM, AND THAT THIS RESULTED IN SUCH STRESS TO THE ENGINE LEADS ME TO BELIEVE THAT THERE MAY HAVE BEEN A DESIGN FLAW INVOLVED. (HAVE HAD WATER PUMPS GO OUT IN OTHER CARS, BUT NEVER PRIOR TO 80000 MILES, NEVER IN UNDER 8 MINUTES AND NEVER WITH SUCH DIRE RESULTS AND HIGH REPAIR COSTS. *NM

NHTSA ODI #10159858

87,000 miles · May 2, 2006

Engine And Engine Cooling

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I AM THE ORIGINAL OWNER OF A 2000 VW PASSAT, 4 CYL. ON 3/24/06, THE DEFROST NO LONGER WORKED PROPERLY IN THE VEHICLE. PINKISH-ORANGE COOLANT STARTED SPRAYING OUT ON MY FEET WHILE DRIVING, WHITE SMOKE CAME SPILLING OUT OF THE VENTS & THE COOLANT SPREAD ITSELF THICK ON THE INTERIOR OF THE WINDSHIELD & WINDOWS. THIS LEFT IT CLOUDY & I HAD TO PULL THE VEHICLE OVER AND WIPE THE WINDOWS WITH CLEANER AND PAPER TOWELS. WITH IT BECOMING IMMEDIATELY CLOUDY, I LOST VISIBILITY OF THE CARS IN FRONT OF ME. COOLANT ALSO LEAKED ONTO THE PASSENGER FLOOR BOARD/MAT. I IMMEDIATELY LOOKED ONLINE FOR FEEDBACK AND FOUND IT COULD POSSIBLY BE A CRACKED HEATER CORE (WHICH IS NOT COVERED UNDER MY EXTENDED WARRANTY). I TOOK IT BY A VW DEALER FOR A DRIVE BY DIAGNOSIS, IT WAS CONFIRMED IT WAS THE HEATER CORE. I CONTACTED VW OF AMERICA IMMEDIATELY TO NOTIFY THEM OF THIS PROBLEM AND ASKED IF THEY COULD ASSIST WITH 50%-100% OF THE REPAIRS BECAUSE IT WAS A REPORTED PROBLEM EVERYWHERE. VW CUSTOMER CARE SAID I NEEDED TO SET UP A DIAGNOSIS APPT WITH THE VW DEALER, WHICH WAS ON 4/24/06. 10 MINUTES AFTER I DROPPED MY CAR OFF, MY SERVICE CONSULTANT RUSSELL DILLEY W/MIRAMAR VW IN SAN DIEGO, CA CALLED MY CELL PHONE AND SAID "YES IT IS THE HEATER CORE". PRIOR TO LEAVING MY CAR WITH HIM, HE BELIEVED IT TO BE A CRACKED HEATER CORE, JUST WITH MY FEW SYMPTOMS EXPLAINED AND HE SAID HE HAS SEEN THIS PROBLEM MANY TIMES BEFORE AND HE CONFIRMED VW OF AMERICA HAD COVERED THE COST OF THE REPAIRS. I NOTIFIED VW OF AMERICA CUSTOMER CARE THAT THE DIAGNOSIS WAS PERFORMED AND READY. I HAD TO PAY $99.00 FOR THE SO CALLED ONE HOUR DIAGNOSIS APPT, EVEN THOUGH IT WAS CONFIRMED IN 10 MINUTES. CUSTOMER CARE SAID THEY WOULD CONTACT ME WITHIN 48 HOURS TO LET ME KNOW THEIR DECISION W/THE ASSISTANCE OF THE REPAIR. I RECEIVED A CALL YESTERDAY 5/1/06 FROM MARLINA, SHE SAID VW OF AMERICA WILL NOT BE ABLE TO ASSIST WITH THE REPAIR OF THE CRACKED HEATER CORE BECAUSE OF THE AGE OF THE VEHICLE & THE MILEAGE. YEAR 2000, MILEAGE 89K. *NM

NHTSA ODI #10156651

79,000 miles · Feb 27, 2006

Engine And Engine Cooling

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WHILE DRIVING MY 2000 PASSAT, THE STOP ENGINE LIGHT CAME ON TO NOTIFY ME THAT THERE WAS A PROBLEM WITH OIL PRESSURE. THERE WAS NOTHING PRIOR TO THIS WARNING THAT WOULD HAVE LEAD ME TO BELIEVE THAT THERE WAS A PROBLEM. NO ODD NOISES IN THE CAR AND IT WAS DRIVING FINE. I TOOK THE CAR TO THE DEALER AND WAS INFORMED THAT THE ENGINE WAS TOTALED AND IT NEEDED TO BE REPLACED AT A COST OF $7,000. I DID FIND OUT THAT IN AUGUST OF 2004, VW OF AMERICA ISSUES A SERVICE NOTICE TO ALL THE SERVICE DEPARTMENTS THAT DUE TO A MALFUNCTIONING FUEL PUMP, OIL SLUDGE MAY BUILD UP IN THE ENGINE, ULTIMATELY LEADING TO ENGINE FAILURE. THIS WAS NOT SENT TO ANY OF THE VEHICLE OWNERS. IN THE NOTICE, VWOA SAID THAT THEY WOULD EXTEND THE WARRANTY OF THE CAR AND REPLACE THE MOTOR, ONLY IF THERE WAS PROOF THAT THE OIL WAS CHANGED EVERY 5000 MILES. BECAUSE I HAVE GAPS IN MY OIL CHANGES WITH THE DEALER, THEY WILL NOT HONOR THIS EXTENDED WARRANTY AND ARE TRYING TO CHARGE ME FOR THE NEW MOTOR. I'VE HAD THE CARE IN A NUMBER OF TIMES BETWEEN AUGUST OF 2004 AND FEBRUARY 19, 2006 WHEN THE LIGHT CAME ON AND WAS NEVER NOTIFIED THAT THERE MAY BE A PROBLEM. I ASKED THE SERVICE MANAGER AT THE DEALER WHY I WASN'T NOTIFIED OF THIS ISSUE AND HE SAID THAT VWOA ISSUES A NUMBER OF SERVICE MEMOS AND WAS HE TO TELL ALL OF THE CUSTOMERS EVERYTIME ONE WAS ISSUED. HAD I BEEN NOTIFIED THAT THIS MIGHT BE THE END RESULT OF THE OIL PUMP NOT BEING REPLACED IN 2004, I WOULDN'T BE IN MY CURRENT SITUATION. I HAVE READ A NUMBER OF WEB POSTS WITH PEOPLE THAT HAVE HAD SIMILAR PROBLEMS WITH THEIR LOCAL DEALERS AND VWOA. *JB

NHTSA ODI #10151287

49,500 miles · Feb 21, 2006

Engine And Engine Cooling

OIL SLUDGE BUILD UP IN ENGINE. 2000 VOLKSWAGEN PASSAT 1.8 TURBO 4 CYLINDER 49000. *JB

NHTSA ODI #10150715

Official recalls

08V156000 · Fuel System, Gasoline:delivery

Apr 7, 2008

VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN LEAK DUE TO FRACTURE.

Consequence & remedy

Consequence: A HEAT SHIELD THAT MAY CONTACT THE EXHAUST SYSTEM CAN RESULT IN A VEHICLE FIRE. IN ADDITION, A FUEL LEAK FROM A FUEL LINE OR FUEL TANK VENTILATION VALVE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN LEAD TO A VEHICLE FIRE.

Remedy: DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY SOFTWARE UPDATE. DEALERS WILL ALSO INSPECT AND ADJUST THE FUEL LINE ROUTING ON 1.8T VEHICLES AND THE FUEL TANK VENTILATION VALVE ON 4MOTION/ALL WHEEL DRIVE VEHICLES, AND REPLACE COMPONENTS IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON JUNE 13, 2008. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

02V026000 · Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap

Jan 25, 2002

ON SOME PASSENGER VEHICLES, THE FUEL TANK FILLER NECK CAN SUFFER ABRASION DAMAGE IF THE REAR TIRE GOES FLAT AND THE VEHICLE IS DRIVEN UNTIL THE TIRE DISINTEGRATES.

Consequence & remedy

Consequence: FUEL LEAKAGE CAN OCCUR INCREASING THE RISK OF A FIRE.

Remedy: DEALERS WILL FIT PASSAT VEHICLES WITH A NEW WHEEL HOUSE LINER THAT WILL BETTER PROTECT THE CAR'S FILLER NECK. JETTA VEHICLES WILL BE FITTED WITH A DIFFERENT METAL SHIELD DESIGNED TO ENHANCE ABRASION PROTECTION IN THE EVENT OF TIRE DISINTEGRATION. OWNER NOTIFICATION BEGAN JUNE 13, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

01V157000 · Fuel System, Gasoline:storage:tank Assembly

May 3, 2001

VEHICLE DESCRIPTION: PASSENGER VEHICLES. SULFUR IN FUEL INTERACTS WITH CERTAIN ADDITIVES FOUND IN WIDELY AVAILABLE GASOLINE CAUSING SULFUR TO BECOME DEPOSITED ON THE CONTACT POINTS OF THREE FUEL SENDING UNITS MOUNTED INSIDE THE FUEL TANK. THIS COULD CAUSE THE FUEL GAUGE TO READ FULL WHILE THE FUEL TANK MAY NOT IN FACT BE FULL OR COULD BE EMPTY.

Consequence & remedy

Consequence: RUNNING OUT OF FUEL WITHOUT WARNING WHILE THE FUEL GAUGE INDICATES THAT THERE IS SUFFICIENT FUEL IN THE TANK LEAD TO SAFETY PROBLEMS.

Remedy: DEALERS WILL REMOVE THE EXISTING FUEL LEVEL SENDING UNITS AND REPLACE THEM WITH FUEL LEVEL SENDING UNITS USING A NEW ALLOY COMPOSED OF GOLD, SILVER, AND A SMALL AMOUNT OF NICKEL, WHICH WILL NOT CHEMICALLY REACT WITH SULFUR. VW/AUDI WILL ALSO CALL BACK VEHICLES THAT WERE REPAIRED UNDER A PREVIOUS RECALL LAST JUNE IN ORDER TO INSTALL THE UPDATED FUEL SENDING UNITS NHTSA 00V137/AUDI LB). OWNER NOTIFICATION BEGAN MAY 1, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT AUDI AT 1-866-892-2834.

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

EA07014 · Passenger Engine Compartment Fires

Opened Sep 28, 2007 · Closed Jul 7, 2008

Status: closed (inferred from source dates) · Electrical System:ignition; Engine And Engine Cooling:exhaust System

THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.

Additional source detail variants (2)

Electrical System:ignition

Engine And Engine Cooling:exhaust System

PE07024 · Passenger/engine Compartment Fires

Opened May 10, 2007 · Closed Sep 28, 2007

Status: closed (inferred from source dates) · Electrical System:ignition

MANY OF THE FIRE REPORTS ALLEGE THAT THE VEHICLE FIRE WAS ATTRIBUTED TO IGNITION COIL FAILURE.VW PROVIDED ADDITIONAL DATA REGARDING ITS ANALYSIS OF VEHICLE FIRES AND A DETAILED DESCRIPTION OF THE THREE DIFFERENT ENGINES AND IGNITION SYSTEMS FOR THE SUBJECT VEHICLES.ODIFINDS THE NEED TO FURTHER INVESTIGATE THIS ISSUE.TO FACILITATE ACQUISITION AND ANALYSIS OF ADDITIONAL INFORMATION, THIS INVESTIGATIONHAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-014).

DP05004 · Engine Stalling

Opened Aug 11, 2005 · Closed Dec 8, 2005

Status: closed (inferred from source dates) · Electrical System:ignition:module

BY LETTER RECEIVED ON JUNE 24, 2005, MR. RONALD M. STRICKLAND OF RALEIGH, NC, SUBMITTED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE THE PERFORMANCE OF THE IGNITION COIL PLUGS ON MODEL YEAR (MY) 2000-2003 VOLKSWAGEN JETTA, GOLF AND PASSAT SEDANS.THE PETITIONER ALLEGES THAT HE HAD EXPERIENCED MULTIPLE STALLING EVENTS AS A RESULT OF ONE OR MORE IGNITION COIL PLUGS MALFUNCTIONING ON HIS 2002 VW JETTA SEDAN.AS A RESULT OF THE ENGINE STALLING, THE PETITIONER EXPERIENCED A LOSS OF POWER STEERING AND INCREASED BRAKING EFFORTS WHEN HE PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD TO CONTROL THE VEHICLE.AFTER A FEW MINUTES PARKED ON THE SHOULDER HE WAS ABLE TO RESTART THE VEHICLE ALTHOUGH THE ENGINE OPERATED AT REDUCED POWER.VW ISSUED A CUSTOMER SATISFACTION CAMPAIGN (CSC) ON JANUARY 31, 2003 TO INSTRUCT THEIR DEALERSHIPS TO INSPECT THE VEHICLES FOR ANY MALFUNCTIONING IGNITION COIL PACKS AND TO REPLACE THEM AT NO COST TO THE CONSUMER.CONSUMERS WERE NOTIFIED TO BRING THEIR VEHICLES TO THEIR DEALERSHIPS VIA OWNER LETTERS MAILED OUT ON JUNE 6, 2003.WHILE VW INITIALLY INSTRUCTED THE DEALERSHIPS TO ONLY REPLACE THE MALFUNCTIONING IGNITION COIL PACKS, A REVISED CSC WAS ISSUED TO DEALERSHIPS IN DECEMBER 2003 AND JANUARY 2004, INSTRUCTING DEALERSHIPS TO REPLACE ALL IGNITION COIL PACKS REGARDLESS OF THEIR PERFORMANCE.A REMINDER TO THE DEALERSHIPS WAS SENT BY VW ON APRIL OF 2004.ALTHOUGH THE CONCERNS OF THE PETITIONER COULD THEORETICALLY CREATE A SAFETY PROBLEM, THE RISK IS VERY SMALL, DUE TO THE ENGINE STILL RUNNING ON EITHER 3, 5, OR 7 CYLINDERS.THERE ARE NO REPORTED CRASHES OR INJURIES DUE TO THE ALLEGED DEFECT.ONCE DRIVERS ARE AWARE OF THE PROBLEM (LOSS OF POWER DUE TO ONE OF THE IGNITION COIL PACKS MALFUNCTIONING), DRIVERS ARE ABLE TO TAKE PRECAUTIONARY AND COMPENSATORY MEASURES AND STILL MAINTAIN CONTROL OF THEIR VEHICLES.IN ADDITION, FOUR FIRES WERE REPORTED TO ODI.THESE WERE IGNITION COIL BURNOUTS WITH NO ADDITIONAL DAMAGE TO THE VEHICLE AND WERE LOCALIZED ON TOP OF THE ENGINE. DURING THE LAST 24 MONTHS THE NUMBER OF STALL AND DRIVABILITY COMPLAINTS REPORTED TO ODI HAS GREATLY DIMINISHED FROM A PEAK OF 195 IN JANUARY OF 2003 TO ONLY 3 IN AUGUST OF 2005.THIS COINCIDES WITH THE CSC RELEASED BY VW.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

EA03020 · Passenger Air Bag Lid Failure

Opened Oct 7, 2003 · Closed Apr 23, 2004

Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal

THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.

Additional source detail variants (2)

Air Bags:frontal

Air Bags

PE03021 · Passenger Sir Door Mounting Stud Failure

Opened May 23, 2003 · Closed Oct 7, 2003

Status: closed (inferred from source dates) · Air Bags:frontal

ODI OPENED A PRELIMINARY EVALUATION (PE03-021) BASED ON TWO REPORTS OF FAILED BOLT STUDS THAT ATTACH THE PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) DOOR COVER TO THE INSTRUMENT PANEL (IP) ON THE VOLKSWAGEN (VW) PASSAT (MODEL YEARS 2000, 2002).VW HAS INDICATED TO ODI THAT IT HAS NO ADDITIONAL REPORTS.VW IMPLEMENTED A PROCESS CHANGE ON MARCH 1, 2002.THIS PROCESS CHANGE CONSISTED OF CHANGING THE BOLT APPLICATION THAT FASTENS THE PSIR DOOR TO THE IP FROM A WELD ON APPLICATION TO A PRESS ON APPLICATION.VW ALSO CHANGED THE MATERIAL OF THE BOLT.VW STATED THAT THE CHANGES WERE MADE TO EASE PRODUCTION BY ELIMINATING A WELDING PROCESS.ODI HAS UPGRADED ITS INVESTIGATION TO ENGINEERING ANALYSIS (EA03-020).

EA00028 · Fuel Tank Puncture

Opened Dec 28, 2000 · Closed Jan 29, 2002

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

No summary supplied.

PE00033 · Fuel Tank Puncture

Opened Aug 10, 2000 · Closed Dec 28, 2000

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

THE OFFICE OF DEFECTS INVESTIGATION OPENED THIS INVESTIGATION ON AUGUST 10, 2000 BASED ON 9 REPORTS REGARDING PUNCTURED FUEL TANKS INVOLVING THE JETTA, PASSAT, AND CABRIO MODELS.THE REPORTS INDICATE ADDITIONAL REPORTS IN ITS RESPONSE TO THE PRELIMINARY EVALUATION.THIS INVESTIGATION HAS BEEN UPGRADED FOR FURTHER STUDY.