NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
92 reportsClear category filter30 miles · Feb 9, 2007
Engine And Engine Cooling
I HAVE A 2001 VW PASSAT THAT I PURCHASED A 18 MONTHS AGO. THE CAR WAS A CERTIFIED VW AND HAD A WARRANTY EXTENDED TILL 74,000 MILES. AT 70,000 MILES WHILE DRIVING I HAD THE STOP LOW OIL PRESSURE LIGHT COME ON- IT WAS TIME FOR AN OIL CHANGE SO I TOOK IT IN FOR AN OIL CHANGE AND FOR THE DEALER TO FIND THE PROBLEM. NO ISSUE WAS F…
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I HAVE A 2001 VW PASSAT THAT I PURCHASED A 18 MONTHS AGO. THE CAR WAS A CERTIFIED VW AND HAD A WARRANTY EXTENDED TILL 74,000 MILES. AT 70,000 MILES WHILE DRIVING I HAD THE STOP LOW OIL PRESSURE LIGHT COME ON- IT WAS TIME FOR AN OIL CHANGE SO I TOOK IT IN FOR AN OIL CHANGE AND FOR THE DEALER TO FIND THE PROBLEM. NO ISSUE WAS FOUND. NOW AT 75,500 MILES THE LIGHT COMES ON AGAIN- THIS TIME MORE ISSUES. I PULLED OVER IMMEDIATELY TO FIND THAT ALL MY OIL WAS LEAKING OUT OF THE CAR. TOWED VEHICLE TO CLOSEST VW DEALER AS I WAS 120 MILES AWAY FROM HOME. DEALER INFORMS ME THAT THE CAMSHAFT ADJUSTERS WERE LEAKING OIL BADLY AND THE COST TO FIX IS $2,600. - CAR IS STILL IN THE SHOP AND HOPEFULLY NO MORE PROBLEMS WILL BE FOUND. 1,500 MI OUTSIDE WARRANTY AND VW CAN DO NOTHING TO HELP LOWER THE EXPENSE- EVEN THOUGH I HAD A ISSUE W/ LOW OIL WHILE WITHIN MY WARRANTY PERIOD. *JB
NHTSA ODI #10182056
70,000 miles · Jan 25, 2007
Engine And Engine Cooling
WITH JUST ABOUT 70000 MILES ON THE VOLKSWAGEN PASSAT, THE ENGINE STARTED LEAKING OIL FROM 4 AREAS: CAM SEALS, VALVE GASKETS AND SOME LEAKS ON TOP OF THE CATALYTIC CONVERTER. THE OILS LEAKED ONTO THE CATALYTIC CONVERTER CAUSING TOXIC FUMES. THE PROBLEM RECURS CONSISTENTLY EVEN AFTER FIXING IT. THE VOLKSWAGEN PASSAT 2001 MODEL IS …
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WITH JUST ABOUT 70000 MILES ON THE VOLKSWAGEN PASSAT, THE ENGINE STARTED LEAKING OIL FROM 4 AREAS: CAM SEALS, VALVE GASKETS AND SOME LEAKS ON TOP OF THE CATALYTIC CONVERTER. THE OILS LEAKED ONTO THE CATALYTIC CONVERTER CAUSING TOXIC FUMES. THE PROBLEM RECURS CONSISTENTLY EVEN AFTER FIXING IT. THE VOLKSWAGEN PASSAT 2001 MODEL IS EXTREMELY DANGEROUS WITH SUCH RUDIMENTARY ENGINE PROBLEMS AND COULD POTENTIALLY CAUSE DEATH. THERE IS NO CLEAR DOCUMENTATION ON WHAT PARTS ARE COVERED UNDER WARRANTY AVAILABLE TO THE CUSTOMER. WITH THE NEAREST DEALERSHIP 30 MILES AWAY, IT BECOMES EXTREMELY DIFFICULT TO TAKE THE CAR TO THE DEALER EVERYTIME THIS HAPPENS JUST TO CHECK IF THE PARTS WILL BE COVERED UNDER WARRANTY AND IT COSTS NEARLY $3000 TO FIX THESE PROBLEMS. *NM
NHTSA ODI #10180686
78,000 miles · Jan 19, 2007
Engine And Engine Cooling
WATER PUMP FAILED ON FREEWAY, UNABLE TO DRIVE VEHICLE. *JB
NHTSA ODI #10179205
98,994 miles · Jan 8, 2007
Engine And Engine Cooling
HAVING AN OIL SLUDGE PROBLEM WITH A 2001 1/2 MODEL YEAR VW PASSAT WITH A 1.8T ENGINE. RECENTLY HAD A LOW OIL PRESSURE WARNING LIGHT COME ON, REQUIRING THE VEHICLE TO BE TOWED TO A LOCAL VW DEALERSHIP. DEALERSHIP DIAGNOSED AS AN OIL PUMP PROBLEM, MOST LIKELY CAUSED BY AN OIL SLUDGE PROBLEM. IF IT IS CAUSED BY OIL SLUDGE, THEN …
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HAVING AN OIL SLUDGE PROBLEM WITH A 2001 1/2 MODEL YEAR VW PASSAT WITH A 1.8T ENGINE. RECENTLY HAD A LOW OIL PRESSURE WARNING LIGHT COME ON, REQUIRING THE VEHICLE TO BE TOWED TO A LOCAL VW DEALERSHIP. DEALERSHIP DIAGNOSED AS AN OIL PUMP PROBLEM, MOST LIKELY CAUSED BY AN OIL SLUDGE PROBLEM. IF IT IS CAUSED BY OIL SLUDGE, THEN ENGINE DAMAGE IS LIKELY TO BE FOUND AS IT SEEMS TO BE A COMMON PROBLEM BASED ON WEB FORUM POSTINGS BY OTHER PASSAT OWNERS WHO HAVE EXPERIENCED THE SAME PROBLEM. VEHICLE IS UNOPERABLE AT THIS TIME. VW IS REFUSING TO COVER TO THE REPAIR UNDER WARRANTY DUE TO INSUFFICIENT DOCUMENTATION OF OIL CHANGES. ALL VW SERVICE INTERVALS WERE COMPLETED FOR THE VEHICLE INCLUDING ALL OIL CHANGES AND ARE BACKED UP WITH DOCUMENTATION. I AM STILL TRYING TO GET CLARIFICATION FROM VW AS TO WHY THE DOCUMENTATION IS CONSIDERED INSUFFICIENT. VEHICLE HAS 99,004 MILES ON IT. OIL CHANGES PRIOR TO 30,000 SERVICE INTERVAL WERE COMPLETED AT VW DEALERSHIPS AND INCLUDED VW APPROVED NON-SYNTHETIC OIL. OIL CHANGES FROM 30,000 MILES/JANUARY 2002 FORWARD WERE COMPLETED USING SYNTHETIC OIL. VW RECOGNIZED THE SLUDGE PROBLEM AND ISSUED A WARRANTY EXTENSION IN AUGUST 2004 ALONG WITH REQUIREMENT TO USE SYNTHETIC OILS (NHTSA TSB #10009888 AND #10009873). A PREVIOUS PROBLEM OCCURED AT 78,400 WHERE A DEFECTIVE HEAD GASKET WAS REPLACED. DURING THAT SERVICE THE HEAD GASKET, OIL COOLER, OIL PUMP, AND ASSOCIATED PARTS WERE REPLACED UNDER WARRANTY. BASED ON WEB POSTINGS FROM OTHER OWNERS THIS MAY ALSO BE ASSOCIATED WITH THE OIL SLUDGE PROBLEM. *NM
NHTSA ODI #10178149
65,000 miles · Dec 29, 2006
Engine And Engine Cooling
I AM THE OWNER OF A 2001 VW PASSAT WITH 65,000 MILES. I HAVE OWNED APPROX 6 - 7 CARS IN MY LIFETIME AND HAVE TAKEN CARE OF THEM THE SAME. NEVER HAVE I EXPERIENCED THIS WITH A DEALER WHO REQUIRES ALL RECEIPTS. I WAS UNABLE TO LOCATE 2 RECEIPTS AND THEREFORE WAS GIVEN THE VERDICT OF A $9000 BILL TO REPLACE THE 1.8 TURBO ENGINE…
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I AM THE OWNER OF A 2001 VW PASSAT WITH 65,000 MILES. I HAVE OWNED APPROX 6 - 7 CARS IN MY LIFETIME AND HAVE TAKEN CARE OF THEM THE SAME. NEVER HAVE I EXPERIENCED THIS WITH A DEALER WHO REQUIRES ALL RECEIPTS. I WAS UNABLE TO LOCATE 2 RECEIPTS AND THEREFORE WAS GIVEN THE VERDICT OF A $9000 BILL TO REPLACE THE 1.8 TURBO ENGINE. I AM SERIOUSLY APPALLED. MY FEELING THAT THAT THE DEALERS ARE AWARE OF THIS PROBLEM NEED TO TAKE SOME RESPONSIBLITY RATHER THAN POUR THIS IN THE LAP OF THE OWNER. I WOULD EVEN THINK THAT THEY WOULD CONSIDER 50 TO 70% OF THE BILL. I HAD TO PURCHASE ANOTHER CAR THEREBY HAVE TWO CAR PAYMENTS BECAUSE I CANNOT AFFORD $9000 AND NEEDED TO GET TO WORK AND CHILD TO SCHOOL, ETC. I WILL NEVER SUGGEST THIS CAR TO ANYONE!!
NHTSA ODI #10177303
98,069 miles · Nov 30, 2006
Engine And Engine Cooling
I HAD A SYNTHETIC OIL CHANGE ON MY 2001 VW PASSAT, NOVEMBER 7,2006 AT HERITAGE VW (DEALERSHIP) AND THEN ON NOVEMBER 22,2006 THE VEHICLE SLOWED AND THE DISPLAY SHOWED STOP WITH AN OIL ICON. I IMMEDIATELY STOPPED THE CAR AND CHECKED THE OIL. THERE WAS OIL IN THE CAR BUT I CALLED THE DEALERSHIP AND THEY SAID DO NOT DRIVE THE CAR, …
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I HAD A SYNTHETIC OIL CHANGE ON MY 2001 VW PASSAT, NOVEMBER 7,2006 AT HERITAGE VW (DEALERSHIP) AND THEN ON NOVEMBER 22,2006 THE VEHICLE SLOWED AND THE DISPLAY SHOWED STOP WITH AN OIL ICON. I IMMEDIATELY STOPPED THE CAR AND CHECKED THE OIL. THERE WAS OIL IN THE CAR BUT I CALLED THE DEALERSHIP AND THEY SAID DO NOT DRIVE THE CAR, THERE IS PROBABLY SLUDGE IN THE CAR. I TOWED IT IN THE DEALERSHIP AND THEY SAID IT NEEDED A NEW OIL PUMP WITH A NEW OIL SCREEN AND IT DID HAVE SLUDGE. THIS REPAIR WAS $1267.00. I WAS NOT OFFERED ANY WARRANTY REIMBURSEMENT AT THAT TIME. LATER I FOUND OUT THAT THIS IS A WIDESPREAD PROBLEM WITH VW. WHY DID THEY NOT SEE THE SLUDGE WHEN THEY DID THE OIL CHANGE NOV 7,2006? *NM
NHTSA ODI #10174805
65 miles · Oct 25, 2006
Engine And Engine Cooling
10/24/06 MY 2001 VOLKSWAGON PASSAT HAS A STOP WARNING LIGHT COME ON STATING LOW OIL PRESSURE. COME TO FIND OUT THE 1.8 LITRE TURBO ENGINE WHICH MY CAR HAS IS NON TO HAVE OIL SLUDGE PROBLEMS AND THAT VW IS AWARE OF THIS. I NEVER RECEIVED A LETTER FROM THEM STATING THIS OR THE FACT THAT I SHOULD USE SYNTHETIC OIL. CALLED THE HU…
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10/24/06 MY 2001 VOLKSWAGON PASSAT HAS A STOP WARNING LIGHT COME ON STATING LOW OIL PRESSURE. COME TO FIND OUT THE 1.8 LITRE TURBO ENGINE WHICH MY CAR HAS IS NON TO HAVE OIL SLUDGE PROBLEMS AND THAT VW IS AWARE OF THIS. I NEVER RECEIVED A LETTER FROM THEM STATING THIS OR THE FACT THAT I SHOULD USE SYNTHETIC OIL. CALLED THE HUNTSVILLE, AL VW DEALERSHIP AND THEY SAID THAT UNLESS I HAVE PRISTEEN SERVE RECORDS THEY WILL NOT PAY TO FIX IT AT A COST TO ME OF OVER $1800. MY HUSBAND CHANGES THE OIL IN MY CAR SO OF COURSE I DO NOT HAVE THE SERVICE RECORDS VW IS REQUIRING. I HEAR THE NO LONGER MAKE THE 1.8 LITER TURBO BUT ARE NOT WILLING TO HONOR FIXING A PROBLEM WE KNEW NOTHING ABOUT.
NHTSA ODI #10171806
76,000 miles · Oct 20, 2006
Engine And Engine Cooling
PURCHASED 2001 PASSAT IN MAY, 2005. HAD SAME 'NON-COVERED' OIL PUMP PROBLEM AS MANY ON THE LIST HAVE. LAST MONTH, NOTICED A POOL OF OIL ON THE GARAGE FLOOR AFTER BACKING IT OUT. LOOKED UNDER THE HOOD, NOTICED THAT THE ANTIFREEZE OVERFLOW LOOKED LIKE A CHOCOLATE MILKSHAKE. OIL COOLER AND OIL COOLER SEALS HAD TO BE REPLACED. …
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PURCHASED 2001 PASSAT IN MAY, 2005. HAD SAME 'NON-COVERED' OIL PUMP PROBLEM AS MANY ON THE LIST HAVE. LAST MONTH, NOTICED A POOL OF OIL ON THE GARAGE FLOOR AFTER BACKING IT OUT. LOOKED UNDER THE HOOD, NOTICED THAT THE ANTIFREEZE OVERFLOW LOOKED LIKE A CHOCOLATE MILKSHAKE. OIL COOLER AND OIL COOLER SEALS HAD TO BE REPLACED. 76000 MILES. *NM
NHTSA ODI #10171465
Mileage unknown · Sep 9, 2006
Engine And Engine Cooling
TRACKING NUMBER: [XXX] DATE: SEPTEMBER 09TH 2006 11:24:34 AM COMPLAINANT: [XXX] - RE: 2001 PASSAT VWS AND THE ONGOING SLUDGE PROBLEMS!!! *JB COMPLAINT: MY COMPLAINT IS THE SAME AS EVERYONE ELSE WITH REGARD TO VW PASSATS. SLUDGE!!!! I JUST SPENT $2000 TRYING TO FIX THE PROBLEM AND IT HAPPENED AGAIN 2 DAYS LATER. MY MECHANIC …
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TRACKING NUMBER: [XXX] DATE: SEPTEMBER 09TH 2006 11:24:34 AM COMPLAINANT: [XXX] - RE: 2001 PASSAT VWS AND THE ONGOING SLUDGE PROBLEMS!!! *JB COMPLAINT: MY COMPLAINT IS THE SAME AS EVERYONE ELSE WITH REGARD TO VW PASSATS. SLUDGE!!!! I JUST SPENT $2000 TRYING TO FIX THE PROBLEM AND IT HAPPENED AGAIN 2 DAYS LATER. MY MECHANIC TELLS ME THAT HE DID SOME RESEARCH AND THAT THERE IS AN INHERENT PROBLEMS OF SLUDGE IN THESE CARS ESPECIALLY. I WOULD LIKE TO FILE A COMPLAINT AND ASK IF YOU HAVE ANY REFERRAL ATTORNEYS FAMILIAR WITH THIS PROBLEM. PLEASE LET ME KNOW AS SOON AS POSSIBLE. I HAVE TO RENT A CAR AT $30 DOLLARS A DAY AND MY INSURANCE DOESN'T COVER IT. IF THIS IS BEEN GOING ON SO LONG, WHY IS THERE NOT A CLASS SUIT? IF YOU HAVE A NUMBER I CAN CALL FOR SAME, PLEASE ADVISE. THANK YOU, [XXX]. YOU CAN REACH ME BY PHONE AT EITHER [XXX] HOME, OR [XXX]I LOOK FORWARD TO HEARING FROM SOMEONE SOON, AND YOUR HELP IS MUCH APPRECIATED. *JB INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10167737
85,000 miles · Aug 29, 2006
Engine And Engine Cooling
DT*: THE CONTACT STATED WHILE DRIVING 45 MPH ON THE HIGHWAY, THE ENGINE STALLED AND THERE WAS A LOSS OF ALL POWER WITHOUT WARNING. THE ENGINE WOULD NOT RESTART AND THE CONTACT PUSHED THE VEHICLE OFF THE ROAD. THE VEHICLE WAS TOWED TO A DEALER WHO DETERMINED THERE WAS EXCESSIVE OIL SLUDGE AND THE ENGINE NEEDED TO BE REPLACED. …
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DT*: THE CONTACT STATED WHILE DRIVING 45 MPH ON THE HIGHWAY, THE ENGINE STALLED AND THERE WAS A LOSS OF ALL POWER WITHOUT WARNING. THE ENGINE WOULD NOT RESTART AND THE CONTACT PUSHED THE VEHICLE OFF THE ROAD. THE VEHICLE WAS TOWED TO A DEALER WHO DETERMINED THERE WAS EXCESSIVE OIL SLUDGE AND THE ENGINE NEEDED TO BE REPLACED. THE MANUFACTURER WAS ALERTED.
NHTSA ODI #10166878
NHTSA investigations
7EA11002 · Engine Compartment Fire
Opened Jan 26, 2011 · Closed Feb 17, 2012
Status: closed (inferred from source dates) · Electrical System; Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, 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 monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Additional source detail variants (2)
Electrical System
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, 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 monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, 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 monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
PE08008 · Fuel Tank Leak
Opened Jan 31, 2008 · Closed May 30, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly; Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Additional source detail variants (4)
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
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
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.
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.
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
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.
Air Bags
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.
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).
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