NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
55 reportsClear category filter120,000 miles · May 26, 2011
Fuel System, Gasoline
TL* THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT STATED THAT FUMES WERE ENTERING THE VEHICLE THROUGH THE VENTILATION SYSTEM AND THE CHECK ENGINE LIGHT WAS ILLUMINATED. THE CONTACT ALSO MENTIONED THAT DUE TO THE FAILURE, THE VEHICLE WAS UNABLE TO PASS STATE INSPECTION. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE …
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TL* THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT STATED THAT FUMES WERE ENTERING THE VEHICLE THROUGH THE VENTILATION SYSTEM AND THE CHECK ENGINE LIGHT WAS ILLUMINATED. THE CONTACT ALSO MENTIONED THAT DUE TO THE FAILURE, THE VEHICLE WAS UNABLE TO PASS STATE INSPECTION. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DIAGNOSE THE FAILURE AND STATED THAT IN ORDER TO FIND THE CAUSE OF FAILURE, THEY WOULD HAVE TO DROP THE FUEL TANK. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE BUT DID NOT OFFER ANY ASSISTANCE SINCE BECAUSE THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER NHTSA CAMPAIGN ID NUMBER: 08V156000 ( FUEL SYSTEM, GASOLINE: DELIVERY). THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 120,000.
NHTSA ODI #10402831
120,000 miles · Feb 1, 2011
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. AFTER ADDING FUEL TO THE VEHICLE THE CONTACT SMELLED A STRONG ODOR OF GASOLINE INSIDE THE VEHICLE. THE CONTACT WAS ABLE TO CONTINUE DRIVING WITHOUT INCIDENT; HOWEVER, AFTER THE VEHICLE WAS PARKED THE FUEL TANK WAS LEAKING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT REPAIR SHOP WHERE TH…
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TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. AFTER ADDING FUEL TO THE VEHICLE THE CONTACT SMELLED A STRONG ODOR OF GASOLINE INSIDE THE VEHICLE. THE CONTACT WAS ABLE TO CONTINUE DRIVING WITHOUT INCIDENT; HOWEVER, AFTER THE VEHICLE WAS PARKED THE FUEL TANK WAS LEAKING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT REPAIR SHOP WHERE THEY WERE UNABLE TO DIAGNOSE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 120,000.
NHTSA ODI #10379800
Mileage unknown · Sep 13, 2010
Fuel System, Gasoline
I OWN A 2002 VOLKSWAGEN PASSAT. IT HAS STALLED WHILE DRIVING AND UNABLE TO START RIGHT AWAY. IT SOMETIMES FAILS TO START WHEN I GET IN, THEN STARTS AGAIN LATER. THE FUEL PUMP/FUEL LINE FAILURE HAS LEFT ME STRANDED IN THE MIDDLE OF THE ROAD ON SEVERAL OCCASIONS AND I HAVE ALSO BEEN STRANDED, WHILE WAITING FOR MY CAR TO START AGAI…
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I OWN A 2002 VOLKSWAGEN PASSAT. IT HAS STALLED WHILE DRIVING AND UNABLE TO START RIGHT AWAY. IT SOMETIMES FAILS TO START WHEN I GET IN, THEN STARTS AGAIN LATER. THE FUEL PUMP/FUEL LINE FAILURE HAS LEFT ME STRANDED IN THE MIDDLE OF THE ROAD ON SEVERAL OCCASIONS AND I HAVE ALSO BEEN STRANDED, WHILE WAITING FOR MY CAR TO START AGAIN. I BELIEVE THERE IS A RECALL FOR THIS PROBLEM AND I WOULD LIKE TO KNOW WHAT I CAN DO ABOUT IT IN ORDER TO REMEDY THIS ISSUE W/ MY 2002 PASSAT. *TR
NHTSA ODI #10355132
89,500 miles · Sep 8, 2010
Fuel System, Gasoline
FUEL TANK LEAKS WHEN 7/8 TO 8/8 FULL. LEAKING GAS DAMAGES ASPHALT AND POSES A FIRE THREAT. *TR
NHTSA ODI #10354525
123,000 miles · Mar 29, 2010
Fuel System, Gasoline
FUEL LEAKS WHEN GAS TANK IS MORE THAN ABOUT HALF TO THREE QUARTERS FULL. VERY STRONG ODOR INSIDE AND OUTSIDE VEHICLE. SOME WETNESS AROUND FUEL TANK, BUT NO VISIBLE DRIPS WHEN INSPECTED BY OWNER. WHEN DRIVING AT 60 MPH SOON AFTER FILLING TANK, FUEL RANGE INDICATOR DECREASES BY 5 MILES FOR EVERY 1 TO 2 MILES TRAVELLED. ASSUMING NO…
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FUEL LEAKS WHEN GAS TANK IS MORE THAN ABOUT HALF TO THREE QUARTERS FULL. VERY STRONG ODOR INSIDE AND OUTSIDE VEHICLE. SOME WETNESS AROUND FUEL TANK, BUT NO VISIBLE DRIPS WHEN INSPECTED BY OWNER. WHEN DRIVING AT 60 MPH SOON AFTER FILLING TANK, FUEL RANGE INDICATOR DECREASES BY 5 MILES FOR EVERY 1 TO 2 MILES TRAVELLED. ASSUMING NORMAL FUEL CONSUMPTION SHOULD BE 20 MPG, IN 1.5 MINUTES VEHICLE SHOULD USE 0.075 GAL, BUT ACTUALLY USES 0.250 GAL SO THE LEAK RATE IS APPROXIMATELY 0.12 GAL/MIN OR 45 ML/MIN. SUCH LEAKAGE WOULD BE EVIDENT AS DRIPS IF THE LEAK WAS BELOW THE LIQUID LEVEL WHEN THE CAR IS STATIONARY SO IT IS SUSPECTED TO BE IN THE AREA OF THE GAS TANK VENTS. VEHICLE HAS NOT YET BEEN INSPECTED BY VW. (VEHICLE WAS RECENTLY PURCHASED USED FROM PRIVATE SELLER WITHOUT MAINTENANCE RECORDS).
NHTSA ODI #10322587
125,000 miles · Mar 10, 2010
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. AFTER THE VEHICLE WAS REPAIRED PER NHTSA RECALL # 08V156000: FUEL SYSTEM, GASOLINE, DELIVERY, THE CONTACT NOTICED A CRACK IN THE FUEL LINE NEAR THE FIRE WALL. HE ALSO NOTICED THAT GASOLINE SPILLED OVER THE ENGINE AND THE CATALYTIC CONVERTER. THE CONTACT IS CONCERNED THAT THE MANUFACT…
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TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. AFTER THE VEHICLE WAS REPAIRED PER NHTSA RECALL # 08V156000: FUEL SYSTEM, GASOLINE, DELIVERY, THE CONTACT NOTICED A CRACK IN THE FUEL LINE NEAR THE FIRE WALL. HE ALSO NOTICED THAT GASOLINE SPILLED OVER THE ENGINE AND THE CATALYTIC CONVERTER. THE CONTACT IS CONCERNED THAT THE MANUFACTURER DID NOT PERFORM THE RECALL PROPERLY. WHEN THE DEALER WAS NOTIFIED OF THE FAILURE THEY REFUSED TO REPAIR THE VEHICLE AGAIN UNDER THE RECALL UNLESS THE CONTACT WOULD PAY FOR THE REPAIRS. THE CURRENT AND FAILURE MILEAGES WERE 125,000. UPDATED 04/22/10 *BF THE CONSUMER STATED TO THE BEST OF HIS KNOWLEDGE THE FUEL LINES ON HIS VEHICLE HAD NOT BEEN REPLACED UNDER THE RECALL. THE CONSUMER STATED THE DEALER REFUSED TO MAKE THE REPAIRS FREE CHARGE. UPDATED 07/01/10.*JB
NHTSA ODI #10318547
155,000 miles · Feb 10, 2010
Fuel System, Gasoline
WHILE DRIVING HOME LAST NIGHT, MY 2002 VW PASSAT BEGAN TO LOSE POWER AND CUT OFF. I WAS ABLE TO LET IT COAST TO THE SIDE OF THE ROAD BUT IN THE LANE OF AN EXIT RAMP FOR TRAFFIC EXITING THE HIGHWAY. I ENGAGED MY FLASHERS AND CALLED 911 AND A TOW TRUCK. I TRIED STARTING THE CAR AGAIN AND IT WOULD NOT CRANK. ONCE THE POLICE CAM…
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WHILE DRIVING HOME LAST NIGHT, MY 2002 VW PASSAT BEGAN TO LOSE POWER AND CUT OFF. I WAS ABLE TO LET IT COAST TO THE SIDE OF THE ROAD BUT IN THE LANE OF AN EXIT RAMP FOR TRAFFIC EXITING THE HIGHWAY. I ENGAGED MY FLASHERS AND CALLED 911 AND A TOW TRUCK. I TRIED STARTING THE CAR AGAIN AND IT WOULD NOT CRANK. ONCE THE POLICE CAME, HE PUSHED MY CAR INTO SAFETY AND AWAITED THE TOW TRUCK. MY CAR WAS TOWED TO THE VW DEALER. THIS MORNING, I RECEIVED A CALL FROM THE DEALER WHO SAID THE FUEL FLOW TO THE ENGINE WAS INTERRUPTED AND CAUSED BY A INOPERATIVE FUEL PUMP. MY COMPLAINT IS WHEN I CHECKED ONLINE FOR RECALLS, I FOUND A RECALL THAT WAS POSTED IN SEPT 2002 FOR THE SAME ISSUE I AM HAVING WITH MY CAR. MY CAR WAS PURCHASED IN FEB 2002 AND THE RECALL IS FOR 2003 MODELS. I CALLED VW OF AMERICA AND EXPLAINED THE ISSUE WITH THEM AND THE ONLY OFFER THEY GAVE ME WAS $1000 TOWARDS A NEW VW. UNBELIEVABLE! BECAUSE THE RECALL WAS FOR 2003 MODELS, THEY COULD NOT ASSIST ME BECAUSE MY VEHICLE IS A 2002. EVEN THOUGH I AM HAVING THE SAME ISSUES WITH MY VEHICLE AS THE 2003 RECALL. THE DEALER QUOTED $589 FOR THE REPAIR. THIS STALL COULD HAVE BEEN WORSE THAN IT WAS DUE TO THE INCLEMENT WEATHER, NIGHT TIME AND THE EXIT RAMP. THIS SHOULD BE INCLUDED IN A SAFETY RECALL BECAUSE THERE IS NO WARNING BEFORE THE VEHICLE CUTS OFF WHICH CAUSES A POTENTIAL FOR A CRASH, WHICH IS WHAT I WAS FACED WITH LAST NIGHT. I AM NOT ASKING TO BE SINGLED OUT, BUT TO LOOK INTO THIS 6-MONTH GAP OF THE RECALL IN SEPT 2002 AND THE PURCHASE DATE OF MY VEHICLE FEB 2002. I WAS ALSO TOLD AT VW OF AMERICA THAT THEY COULD ONLY ASSIST ME WITH MY ISSUE IF MY VIN NUMBER MATCHED THE RECALLS. SO MY QUESTION, WHAT IF THE STALL OF MY VEHICLE CAUSED AN ACCIDENT AND SERIOUS INJURIES OR FATALITIES WERE INVOLVED, WOULD VW LOOK INTO THE 2002 RECALL THEN OR JUST TELL THE FAMILIES, SORRY, YOU DIDN'T HAVE A 2003. *TR
NHTSA ODI #10308351
Mileage unknown · Sep 14, 2009
Fuel System, Gasoline
I AM A THE OWNER OF A 2002 VOLKSWAGEN PASSAT 4MOTION WITH AN AUTOMATIC TRANSMISSION. I AM CONTACTING YOU TO SEEK ACTION IN REGARDS TO NHTSA CAMPAIGN NUMBER FOR A RECALL FOR FAULTY GAS TANKS. I PURCHASED THIS CAR AS A CERTIFIED USED VEHICLE IN 2004. I TOOK THE CAR TO A VW DEALERSHIP 4 TIMES WITH A PROBLEM WITH SOMETHING LEAKI…
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I AM A THE OWNER OF A 2002 VOLKSWAGEN PASSAT 4MOTION WITH AN AUTOMATIC TRANSMISSION. I AM CONTACTING YOU TO SEEK ACTION IN REGARDS TO NHTSA CAMPAIGN NUMBER FOR A RECALL FOR FAULTY GAS TANKS. I PURCHASED THIS CAR AS A CERTIFIED USED VEHICLE IN 2004. I TOOK THE CAR TO A VW DEALERSHIP 4 TIMES WITH A PROBLEM WITH SOMETHING LEAKING UNDER THE CAR, AND TOLD THERE WAS NOT A LEAK FOUND. AFTER SMELLING GAS, AND FINDING FUEL ON MY GARAGE FLOOR, THE DEALERSHIP WAS ABLE TO DETERMINE THAT THE VEHICLE HAD A CRACKED FUEL TANK, AND REPAIRED THE VEHICLE FOR $3000. AFTER COMPLAINING TO VW OF AMERICA, THE COSTS WERE COVERED AND SHORTLY THEREAFTER I RECEIVED A RECALL LETTER FOR THE SAME ISSUE. NOW, ONE YEAR LATER, I AGAIN SMELLED FUMES, AND FOUND GASOLINE ON THE FLOOR. THE DEALERSHIP STATED THAT IT IS THE SAME PROBLEM. VW OF AMERICA HAS OFFERED TO COVER THE COST OF THE REPAIR. MY CAR IS PARKED IN OUR GARAGE WHERE OUR GAS HOT WATER IS LOCATED. THE FUEL ON THE FLOOR WAS NO MORE THAN 15 FT FROM THE HOT WATER HEATER. HAD THERE BEEN A SPARK, I AM CERTAIN THAT THERE WOULD HAVE BEEN A MAJOR FIRE, WITH POTENTIAL FATAL OUTCOMES. I WILL NOT BRING THIS VEHICLE BACK TO MY HOUSE FOR FEAR OF A REPEAT FAILURE. I ALSO HAVE CONCERNS SELLING A DEFECTIVE VEHICLE TO A 3RD PARTY KNOWING THE POTENTIAL SEVERE SAFETY HAZARDS. VOLKSWAGEN HAS CLEARLY DESIGNED A FAULTY PRODUCT THEY REFUSE TO STAND BEHIND, AND AS A CONSUMER, I WILL HAVE TO INCUR A FINANICAL LOSS TO REPLACE THIS VEHICLE. THESE PROBLEMS STEM FROM NEGLIGENT DESIGN AND ARE A VERY SERIOUS POTENTAIL HAZARD. THE 4MOTION CARS SHOULD BE REMOVED FROM SERVICE AND COMPENSATIONS SHOULD BE ALLOWED TO OWNERS. I DESPERATELY SEEK YOUR ASSISTANCE ON THIS ISSUE TO REVIEW WHETHER A SECOND RECALL MAY BE NECESSARY. THANK YOU FOR YOUR ASSISTANCE. *TR
NHTSA ODI #10283895
68,000 miles · Sep 10, 2009
Fuel System, Gasoline
HELLO, MY NAME IS ROBERT CAMPBELL AND I AM A THE OWNER OF A 2002 VOLKSWAGEN PASSAT 4MOTION WITH AN AUTOMATIC TRANSMISSION. I AM CONTACTING YOU TO SEEK ACTION IN REGARDS TO NHTSA CAMPAIGN NUMBER 08V156000, WHICH CLEARLY INDICATES A RECALL FOR FAULTY GAS TANKS ON THIS PARTICULAR MAKE/MODEL DUE TO FRACTURED VENTILATION VALVES. …
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HELLO, MY NAME IS ROBERT CAMPBELL AND I AM A THE OWNER OF A 2002 VOLKSWAGEN PASSAT 4MOTION WITH AN AUTOMATIC TRANSMISSION. I AM CONTACTING YOU TO SEEK ACTION IN REGARDS TO NHTSA CAMPAIGN NUMBER 08V156000, WHICH CLEARLY INDICATES A RECALL FOR FAULTY GAS TANKS ON THIS PARTICULAR MAKE/MODEL DUE TO FRACTURED VENTILATION VALVES. UPON PURCHASING THE CAR AS A CERTIFIED USED VEHICLE IN 2006, I HAD TO HAVE THE GAS TANK REPLACED WITHIN THE FIRST WEEK OF OWNERSHIP DUE TO THIS VERY SAME DEFECT. THIS WAS COVERED BY THE TWO YEAR WARRANTY PROVIDED BY THE DEALERSHIP. A WEEK AGO, MY GAS TANK STARTED TO LEAK AGAIN. FUEL IS NOW LEAKING ON THE EXHAUST SYSTEM CREATING A SEVERE SAFETY HAZARD. UPON INSPECTION BY THE DEALER, THEY HAVE SURMISED THE SECOND TANK HAS ONCE AGAIN FAILED - DUE TO A FRACTURED VENTILATION VALVE. BOTH VOLKSWAGEN OF AMERICAN AND MY LOCAL DEALER ARE REFUSING TO ACKNOWLEDGE THIS RECALL AND WILL ONLY REPLACE THE TANK IF I AGREE TO REPAIR COSTS TOTALING $1,800. VOLKSWAGEN HAS CLEARLY DESIGNED A FAULTY PRODUCT THEY REFUSE TO STAND BEHIND, AND AS A CONSUMER, I SHOULD NOT BE FINANCIALLY OBLIGATED TO PAY FOR REPAIRS THAT CLEARLY STEM FROM NEGLIGENT DESIGN. I DESPERATELY SEEK YOUR ASSISTANCE ON THIS ISSUE AND WILL GLADLY OFFER MY FULL COOPERATION. *TR
NHTSA ODI #10283595
77,000 miles · Aug 12, 2009
Fuel System, GasolineFire
I PUT GASOLINE IN MY CAR. I BEGAN SMELLING GASOLINE AND NOTICED THE FUEL METER HADN'T REGISTERED THE INCREASE IN FUEL. I WAS STOPPED AT A STOP LIGHT AT THIS POINT. I HEARD A BIG BOOM AND THEN PEOPLE AROUND ME WERE SHOUTING AT ME TO "GET OUT OF THE CAR". I LOOKED TO THE RIGHT AND NOTICED FLAMES SHOOTING UP THE RIGHT SIDE OF THE C…
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I PUT GASOLINE IN MY CAR. I BEGAN SMELLING GASOLINE AND NOTICED THE FUEL METER HADN'T REGISTERED THE INCREASE IN FUEL. I WAS STOPPED AT A STOP LIGHT AT THIS POINT. I HEARD A BIG BOOM AND THEN PEOPLE AROUND ME WERE SHOUTING AT ME TO "GET OUT OF THE CAR". I LOOKED TO THE RIGHT AND NOTICED FLAMES SHOOTING UP THE RIGHT SIDE OF THE CAR. I JUMPED OUT OF THE DRIVERS SEAT TO SAFETY. A GOOD SAMARITAN WAS ABLE TO GRAB A FIRE EXTINGUISHER FROM A NEAR BY BUSINESS; AND ANOTHER PERSON CAME RUNNING OUT OF A NEARBY BUSINESS WITH ANOTHER AND THE WERE ABLE TO EXTINGUISH THE FIRE. THE FLAMES WERE PRIMARILY UNDER THE VEHICLE AND TOWARD THE PASSENGER SIDE. POLICE AND FIRE PERSONNEL ARRIVED ON SCENE. MADE SURE FIRE WAS COMPLETELY OUT; THEN PUSHED CAR TO SAFETY. A TOW TRUCK WAS CALLED, AS MY CAR WAS COMPLETELY UN-DRIVABLE (ALL THE BELTS, HOSES WERE MELTED, INCLUDING THE BRAKE CABLE). THE TOW TRUCK DRIVER (ALSO A MECHANIC) TOLD ME THAT THE FUEL INJECTOR HAD EXPLODED. HE THEN SAID IT WAS A DEFECT; A MANUFACTURER ISSUE. *TR
NHTSA ODI #10280222
NHTSA investigations
9EA11002 · 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.
PE10027 · Engine Compartment Fire
Opened Jul 26, 2010 · Closed Feb 7, 2011
Status: closed (inferred from source dates) · Electrical System; Engine And Engine Cooling
ODI has received 11 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 9 complaints of ignition coil failure that did not result in a fire.Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated.The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once.The scope of PE10-027 focused on Model Years (MY)2002-2003 Passat vehicles.Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles as well as other MY Passat vehicles.ODI needs to further investigate this issue.To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an Engineering Analysis, EA11-002.
Additional source detail variants (2)
Electrical System
ODI has received 11 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 9 complaints of ignition coil failure that did not result in a fire.Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated.The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once.The scope of PE10-027 focused on Model Years (MY)2002-2003 Passat vehicles.Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles as well as other MY Passat vehicles.ODI needs to further investigate this issue.To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an Engineering Analysis, EA11-002.
Engine And Engine Cooling
ODI has received 11 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 9 complaints of ignition coil failure that did not result in a fire.Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated.The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once.The scope of PE10-027 focused on Model Years (MY)2002-2003 Passat vehicles.Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles as well as other MY Passat vehicles.ODI needs to further investigate this issue.To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an Engineering Analysis, EA11-002.
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).
PE07018 · Water/ice In Brake Booster
Opened Apr 3, 2007 · Closed Sep 4, 2007
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist:vacuum
DURING THIS INVESTIGATION, VOLKSWAGEN OF AMERICA (VW) IDENTIFIED A PROBLEM WITH WATER ACCUMULATION IN THE FRESH AIR PLENUM THAT COULD, IN CERTAIN CIRCUMSTANCES, RESULT IN REDUCED BRAKE POWER ASSIST IN MODEL YEAR (MY) 2002 PASSAT VEHICLES.VW INDICATED THAT PROBLEM IS CAUSED BY LEAVES AND OTHER DEBRIS CLOGGING THE PLENUM DRAINS, WHICH MAY RESULT IN WATER FILLING THE PLENUM TO THE LEVEL OF THE BRAKE BOOSTER AIR INTAKE.THE BOOSTER AIR INTAKE IS LOCATED IN THE FRESH AIR PLENUM IN THE MY 2002 PASSAT VEHICLES, BUT NOT IN THE MY 2001 OR 2003 VEHICLES WHICH DRAW BOOSTER AIR FROM THE CABIN.VW TESTING SHOWED THAT BRAKE ASSIST COULD BE REDUCED IF WATER ENTERS THE BOOSTER AND FREEZES.VW IS ADDRESSING THE PROBLEM WITH A SERVICE CAMPAIGN, WHICH BEGAN IN AUGUST 2007.THE FRESH AIR PLENUM IN THE SUBJECT VEHICLES IS AN ENCLOSED SPACE AT THE BASE OF THE WINDSHIELD FROM WHICH THE VEHICLE VENTILATION SYSTEM DRAWS THE FRESH AIR SUPPLY VIA A POLLEN FILTER.RAIN WATER THAT FLOWS OFF THE WINDSHIELD INTO THE PLENUM IS DRAINED THROUGH TWO VALVES LOCATED BELOW THE BATTERY AND BRAKE BOOSTER.STRAINERS AT THE BASE OF THE WINDSHIELD AND IN THE PANEL COVERING THE TOP OF THE PLENUM BLOCK LEAVES, PINE NEEDLES AND OTHER DEBRIS.OVER TIME, DEBRIS MAY ENTER THE PLENUM THROUGH OPENINGS IN THE PLENUM PANEL OR AROUND THE HOOD HINGES.IF CLOGGED DRAINS ALLOW APPROXIMATELY 3-4 GALLONS OF WATER TO ACCUMULATE IN THE PLENUM, THE WATER MAY ENTER THE BOOSTER THROUGH THE AIR INTAKE.WATER ACCUMULATION IN THE PLENUM MAY ALSO RESULT IN COMPLAINTS OF WET CARPETS IN THE VEHICLE INTERIOR IF THE WATER REACHES THE LEVEL OF THE FRESH AIR INTAKE/POLLEN FILTER. VW STATED THAT ITS TESTING SHOWED THAT BRAKE PERFORMANCE AND ACTUATING FORCE (I.E., PEDAL EFFORT) ARE NOT AFFECTED WHEN THE BOOSTER IS FILLED WITH THE MAXIMUM AMOUNT OF WATER POSSIBLE (UP TO THE HEIGHT OF THE BOOSTER ENGINE VACUUM CONNECTION, THROUGH WHICH WATER DRAWN INTO THE BOOSTER IS EVACUATED).VW'S TESTING SHOWED THAT BRAKE PERFORMANCE AND ACTUATING FORCE COULD BE AFFECTED BY WATER FREEZING IN THE BOOSTER.HOWEVER, WHEN TESTED WITH RELATIVELY LOW VOLUMES OF FROZEN WATER IN THE BOOSTER, VW SHOWED THAT THE EFFECTS WERE SIGNIFICANTLY LESS SEVERE THAN FOR CONDITIONS THAT RESULT IN A COMPLETE LOSS OF VACUUM ASSIST.WHILE VW INDICATED THAT THE EFFECTS WOULD BE MORE SEVERE WITH GREATER VOLUMES OF FROZEN WATER, IT MAINTAINED THAT THE CHANCES OF THIS OCCURRING WERE REMOTE AND WOULD BE READILY DISCERNABLE TO THE DRIVER UPON THE INITIAL BRAKE APPLICATION AFTER VEHICLE START-UP.ODI'S ANALYSIS OF COMPLAINTS AND WARRANTY DATA SHOWED DISPROPORTIONATE CONCENTRATIONS IN WINTER MONTHS AND IN NORTHERN STATES WITH COLDER WINTER CLIMATES. ODI IDENTIFIED THREE MINOR CRASHES RELATED TO THE ALLEGED DEFECT IN MY 2002 PASSAT VEHICLES.TWO OF THE CRASHES OCCURRED INGARAGES/DRIVEWAYS AND THE THIRD OCCURRED IN A DEALER SERVICE GARAGE.THERE WERE NO INJURIES ALLEGED IN THE CRASHES BUT A FOOT INJURY WAS ALLEGED IN A FOURTH INCIDENT WHERE EXCESSIVE BRAKE EFFORT REQUIRED DURING A HARD STOP. VOLKSWAGEN IS CONDUCTING A SERVICE CAMPAIGN TO REMEDY THIS CONDITION IN MY 2002 PASSAT AND AUDI A4 AND A6 VEHICLES.THE REMEDY PROCEDURE REQUIRES VW DEALERS TO INSPECT, CLEAN AND MODIFY THE AIR PLENUM DRAIN, AS WELL AS MODIFY THE SUNROOF DRAIN (IF EQUIPPED) AND INSTALL AN IMPROVED SEAL FOR THE POLLEN FILTER.IN ADDITION, VW HAS AGREED TO PROVIDE THE FOLLOWING INFORMATION TO ODI1. QUARTERLY COMPLETION REPORTS FOR ONE YEAR; AND 2. PROMPTLY REPORTING ALL CRASHES ATTRIBUTED TO THE ALLEGED DEFECT. THIS INVESTIGATION IS CLOSED BASED UPON THE ACTIONS TAKEN BY VW.THE CLOSING OF THIS INVESTIGATION DOES NOT C
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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