NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
55 reportsClear category filter115,243 miles · Oct 19, 2007
Fuel System, GasolineInjury
THIS COMPLAINT IS ABOUT A 2002 PASSAT 4-MOTION V6 CAR. GAS ODOR ENTERED MY HOUSE FOR 2 WEEKS AND I DID NOT KNOW WHAT WAS CAUSING THE PROBLEM. I CALLED THE GAS COMPANY TO SEE IF I HAD A GAS LEAK WITH MY FURNACE. THE GAS COMPANY CAME AND TESTED BUT FOUND NOTHING WRONG WITH MY FURNACE OR EQUIPMENT USING NATURAL GAS. I DECIDED T…
Read full complaint
THIS COMPLAINT IS ABOUT A 2002 PASSAT 4-MOTION V6 CAR. GAS ODOR ENTERED MY HOUSE FOR 2 WEEKS AND I DID NOT KNOW WHAT WAS CAUSING THE PROBLEM. I CALLED THE GAS COMPANY TO SEE IF I HAD A GAS LEAK WITH MY FURNACE. THE GAS COMPANY CAME AND TESTED BUT FOUND NOTHING WRONG WITH MY FURNACE OR EQUIPMENT USING NATURAL GAS. I DECIDED TO FIND THE ROOT CAUSE AND BEGAN RULING OUT POSSIBILITIES. I OBSERVES THE GAS SMELL WAS IN MY GARAGE. I OBSERVED WHENEVER MY GAS TANK WAS FILLED, MORE ODOR CAME INTO THE HOUSE. I FILLED THE GAS TANK ON 10/1/07 AND PARKED THE CAR OUT ON THE STREET. ON 10/2/07, WHEN I ENTERED THE CAR IN THE EARLY AM HOURS, THE GAS SCENT MADE ME THROW UP AND I BECAME DIZZY. I HAD NO IDEA WHAT WAS WRONG AND I DROVE - WHILE PRAYING - THE CAR TO THE DEALER. THEY IMMEDIATELY TOLD ME THEY WOULD NOT LET ME DRIVE THE CAR OUT OF THERE WITHOUT FINDING OUT THE PROBLEM BECAUSE OF THE VERY STRONG GAS ODOR. I WAS LATER TOLD IF ANYONE HAD THROWN A CIGARETTE BY MY CAR, IT WOULD HAVE CAUGHT ON FIRE! THE CAR WAS DRIPPING GAS AS I DROVE TO THE DEALER! THE DEALERSHIP FOUND THE PROBLEM WAS CAUSE BY A LEAK ON MY FUEL TANK. A NEW FUEL TANK WAS NEEDED - THAT IS THE ONLY WAY IT COULD BE FIXED. I REQUESTED MY OLD TANK AND SAID IT HAS TO BE BROUGHT AND SHOWN TO THE GOVERNMENT AGENCY OVER TRANSPORTATION AND THE ENVIRONMENT BECAUSE I COULD HAVE DIED AND NO ONE WOULD HAVE KNOWN IT WAS A FAULTY MANUFACTURER'S PART. THE OLD TANK SHOWS 3 PLASTIC TUBES USED ON THE GAS TANK THAT DRAINS THE GAS! PLASTIC ! ONE OF THE PLASTIC TUBES BROKE OFF CAUSING THE GAS LEAK! I VISITED A WEBSITE AND FOUND SO MANY OTHER PASSAT OWNERS HAVE HAD THIS PROBLEM AND VW IS DOING NOTHING TO CHANGE THE DESIGN! I SPOKE TO VW AND I WAS TOLD THERE IS NOTHING THEY CAN DO AND I HAVE TO PAY THE COST OF THE REPAIR! I AM ASKING YOUR OFFICE TO INVESTIGATE THIS SAFETY ISSUE. THIS IS A DANGEROUS SAFETY ISSUE TO ALL PASSAT OWNERS! I HAVE MY OLD GAS TANK AND WILL BE HAPPY TO BRING IT TO YOUR OFFICE . *TR
NHTSA ODI #10206373
41,970 miles · Oct 7, 2007
Electrical SystemFuel System, Gasoline
FUEL SYSTEM FAILED. THE CAR RAN LIKE A TRACTOR, MISFIRING AND EMITTING EXPLOSIVE LIKE SOUNDS. THE DASHBOARD WARNING LIGHT CAME ON AND STAYED ON. WE LIMPED TO THE NEXT VW DEALER WHO FOUND IT NECESSARY TO REPLACE THE IGNITION COILS. THE COILS WERE ALREADY ONCE REPLACED UNDER WARRANTY ON JULY 23, 20003. WHY DO WE HAVE TO PAY $200.4…
Read full complaint
FUEL SYSTEM FAILED. THE CAR RAN LIKE A TRACTOR, MISFIRING AND EMITTING EXPLOSIVE LIKE SOUNDS. THE DASHBOARD WARNING LIGHT CAME ON AND STAYED ON. WE LIMPED TO THE NEXT VW DEALER WHO FOUND IT NECESSARY TO REPLACE THE IGNITION COILS. THE COILS WERE ALREADY ONCE REPLACED UNDER WARRANTY ON JULY 23, 20003. WHY DO WE HAVE TO PAY $200.44 PLUS TAX FOR THESE OBVIOUSLY UNRELIABLE PARTS? *JB
NHTSA ODI #10205159
80,500 miles · Sep 26, 2007
Fuel System, Gasoline
IF FUEL TANK IS FILLED MORE THAN APPROX. 3/4 FULL, THE ODOR OF GAS IS APPARENT VERY SOON AFTER. IT PERMEATED MY GARAGE OVERNIGHT AND OVERWHELMED ME WHEN I OPENED THE DOOR. MY MECHANIC TOLD ME A VENT TUBE ON THE TOP OF THE FUEL TANK IS DEFECTIVE AND HAS SEEN A NUMBER OF THESE, AS HAS THE DEALERS MECHANIC. THEY HAVE TOLD ME THE…
Read full complaint
IF FUEL TANK IS FILLED MORE THAN APPROX. 3/4 FULL, THE ODOR OF GAS IS APPARENT VERY SOON AFTER. IT PERMEATED MY GARAGE OVERNIGHT AND OVERWHELMED ME WHEN I OPENED THE DOOR. MY MECHANIC TOLD ME A VENT TUBE ON THE TOP OF THE FUEL TANK IS DEFECTIVE AND HAS SEEN A NUMBER OF THESE, AS HAS THE DEALERS MECHANIC. THEY HAVE TOLD ME THE ONLY REMEDY IS TO REPLACE THE TANK. I PERSONALLY HAVE NOT BEEN IN ANY ACCIDENTS, AND HAVE OWNED THE CAR FOR OVER A YEAR. MY LOCAL VW DEALER WILL BE REPLACING THIS FOR FREE BASED ON THE APPROVAL OF A REGIONAL VW MANAGER, BUT I CALLED VW OF AMERICA AND WAS TOLD THAT THIS ISSUE WAS NEWS TO THEM, AND NO SUCH RECALLS OR EXTENDED WARRANTIES APPLIED. I FEEL THAT THIS IS A SIGNIFICANT SAFETY ISSUE, AND I WAS ONLY SAVED THE ~$3,000 IN REPAIR EXPENSE BECAUSE ONE SPECIFIC DEALERS ADVISER HAPPENED TO BE AWARE OF A "SOFT RECALL," AS HE PUT IT. HE TOLD ME A NUMBER OF THESE TANKS ARE FAILING ON MY PARTICULAR VEHICLE, AND HAVE ORDERED EXTRA FUEL TANKS TO ACCOMMODATE CUSTOMERS. VW SHOULD BE NOTIFYING CUSTOMERS OR AT THE VERY LEAST HAVE INFORMATION ON IT THROUGH THEIR NATIONAL CUSTOMER CARE CENTER. *TR
NHTSA ODI #10204196
91,000 miles · Sep 25, 2007
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT SMELLED GASOLINE AND NOTICED A LEAK COMING FROM THE REAR DRIVER SIDE OF THE VEHICLE. THE FLOAT ASSEMBLY WAS REPLACED, BUT IT DID NOT CORRECT THE FAILURE. THE DEALER STATED THAT A NEW FUEL TANK WAS NEEDED AND WOULD COST $1,700. THEY ALSO STATED THAT THE METAL FLANGE SE…
Read full complaint
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT SMELLED GASOLINE AND NOTICED A LEAK COMING FROM THE REAR DRIVER SIDE OF THE VEHICLE. THE FLOAT ASSEMBLY WAS REPLACED, BUT IT DID NOT CORRECT THE FAILURE. THE DEALER STATED THAT A NEW FUEL TANK WAS NEEDED AND WOULD COST $1,700. THEY ALSO STATED THAT THE METAL FLANGE SEAL AND TANK WERE CONNECTED AND WOULD NOT BE REPLACED. THE MANUFACTURER INVESTIGATED THE FAILURE AND STATED THAT THERE WERE NO RECALLS AND THE VEHICLE WAS OUT OF WARRANTY. THE CURRENT AND FAILURE MILEAGES WERE 91,000.
NHTSA ODI #10204095
Mileage unknown · Sep 25, 2007
Fuel System, Gasoline
I AM COMPLAINING ABOUT A 2002 VOLKSWAGEN PASSAT 1.8T. WITH 76,000 MILES ON THE CAR BASED ON THE LATEST NEWS FROM THE DEALER TODAY I WILL HAVE INVESTED OVER $1000 ON VARIOUS FAILURES OF THE FUEL EVAP SYSTEM. FIRST IT WAS VACUUM HOSES AND NOW IT IS THE CHARCOAL CANISTER AND PURGE VALVE. THERE HAS BEEN ONE RECALL ON ONE PART OF THE…
Read full complaint
I AM COMPLAINING ABOUT A 2002 VOLKSWAGEN PASSAT 1.8T. WITH 76,000 MILES ON THE CAR BASED ON THE LATEST NEWS FROM THE DEALER TODAY I WILL HAVE INVESTED OVER $1000 ON VARIOUS FAILURES OF THE FUEL EVAP SYSTEM. FIRST IT WAS VACUUM HOSES AND NOW IT IS THE CHARCOAL CANISTER AND PURGE VALVE. THERE HAS BEEN ONE RECALL ON ONE PART OF THE SYSTEM WHICH OF COURSE WAS NOT WHAT WAS WRONG AT ANY POINT WITH MY VEHICLE. THE ENTIRE FUEL EVAP SYSTEM IS FAULTY AND VW KNOWS IT AND REFUSES TO DO ANYTHING ABOUT. IT IS A GREAT MONEYMAKER FOR THEM AS ONLY THEY HAVE THE ACCESS TO THE ELECTRONIC CODES AND PARTS TO REPAIR THE SYSTEM AND TREMENDOUSLY OVER INFLATED PRICES. *JB
NHTSA ODI #10204046
48,068 miles · Aug 8, 2007
Fuel System, Gasoline
CHECK ENGINE LIGHT CAME ON FOR 6 TIMES SINCE PURCHASED NEW. LATEST INCIDENT, IN FIRST WEEK OF AUGUST, 2007 - THE DIAGNOSIS WAS "FOUND FAULT FOR EVAP SYSTEM INCORRECT PURGE FLOW, TESTED PURGE VALVE AND FOUND TO BE STUCK". FOR 6 DEALER VISITS, 2 IDENTICAL DIAGNOSIS WITH 2 REPLACEMENTS. IS THIS A DESIGN FAULT? DEFECTIVE PART? …
Read full complaint
CHECK ENGINE LIGHT CAME ON FOR 6 TIMES SINCE PURCHASED NEW. LATEST INCIDENT, IN FIRST WEEK OF AUGUST, 2007 - THE DIAGNOSIS WAS "FOUND FAULT FOR EVAP SYSTEM INCORRECT PURGE FLOW, TESTED PURGE VALVE AND FOUND TO BE STUCK". FOR 6 DEALER VISITS, 2 IDENTICAL DIAGNOSIS WITH 2 REPLACEMENTS. IS THIS A DESIGN FAULT? DEFECTIVE PART? WHY THE REPETITIVE ISSUE WITH THE SAME AREA. CAR ONLY HAS 48,000 MILES. *TR
NHTSA ODI #10198879
66,082 miles · Jul 3, 2007
Fuel System, Gasoline
THE 2002 VOLKSWAGEN PASSAT GLX 4 MOTION WITH JUST OVER 66,000 MILES HAD JUST BEEN REFUELED WITH A FULL TANK OF GAS AND DRIVEN INTO OUR GARAGE WHEN MY WIFE SMELLED STRONG GASOLINE FUMES AND NOTICED PUDDLES UNDERNEATH THE VEHICLE. I BROUGHT IT TO VOLKSWAGEN DEALERSHIP, AND WAS CHARGED $70 FOR THE DIAGNOSIS , AND THEN A TOTAL OF …
Read full complaint
THE 2002 VOLKSWAGEN PASSAT GLX 4 MOTION WITH JUST OVER 66,000 MILES HAD JUST BEEN REFUELED WITH A FULL TANK OF GAS AND DRIVEN INTO OUR GARAGE WHEN MY WIFE SMELLED STRONG GASOLINE FUMES AND NOTICED PUDDLES UNDERNEATH THE VEHICLE. I BROUGHT IT TO VOLKSWAGEN DEALERSHIP, AND WAS CHARGED $70 FOR THE DIAGNOSIS , AND THEN A TOTAL OF $302.77 TO REPLACE THE GASKET FOR THE FUEL PUMP. THEY DID NOT FILL THE TANK TO CONFIRM THAT THE PROBLEM NO LONGER EXISTED, BUT SAID THAT THE PROBLEM WAS FIXED. A WEEK LATER THE SAME SITUATION, GASOLINE FUMES AND PUDDLES UNDER VEHICLE. RETURNED TO DEALERSHIP, AND THEY KEPT CAR FOR 4 DAYS TO DIAGNOSE. BOTTOM LINE ,THEY INFORMED ME THAT "THE VEHICLE MAY NEED A NEW FUEL TANK , $1,622. AND /OR NEW FUEL LINES, $922.25. THEY WILL NEED TO LOWER THE FUEL TANK TO COMPLETELY DIAGNOSE" AT A COST OF $700 BECAUSE OF 5 HOURS. LABOR. WE HAD ALREADY SPENT OVER $300 FOR REPAIRS THAT APPARENTLY WASN'T NECESSARY BECAUSE IT DID NOT FIX THE PROBLEM. THEY DID NOT REFUND OUR $300. ALSO , MY WIFE CALLED VOLKSWAGEN OF AMERICA, AND WE WERE TOLD THAT THE CAR WAS OUT OF WARRANTY, SO THEY WOULD OFFER NO HELP. I PURCHASED THIS CAR BRAND NEW. IT WAS TOP OF THE LINE I EXPECT BETTER PERFORMANCE AND SERVICE AS I HAVE HAD A NUMBER OF VOLKSWAGENS AND NONE HAD GIVEN ME GRIEF UNTIL THIS ONE. A GASOLINE TANK AND FUEL LINES WERE SAFETY ISSUES AND IF THEY FAIL IN SUCH A SHORT TIME THEY WOULD HAVE TO BE EITHER DEFECTIVE OR POORLY DESIGNED, AND THE RESPONSIBILITY TO CORRECT THEM SHOULD LIE WITH THE MANUFACTURER. ANY REASONABLE PERSON WOULD THINK THAT THE $300 REPAIR BILL WOULD BE ACCEPTABLE BUT NOT ANYWHERE BETWEEN $2000 AND $3000. WHY SHOULD THE CUSTOMER PAY FOR A POOR DESIGN THAT INVOLVED $700 JUST TO DIAGNOSE? FROM THE LOOK OF SOME OF THE OTHER COMPLAINTS FOUND ON THIS SITE THEY WOULD ALREADY KNOW AND GLADLY EXTEND SOME GOOD WILL TO THE OWNERS OF THESE VEHICLES. *AK
NHTSA ODI #10195278
7,586 miles · May 8, 2007
Electrical SystemFuel System, Gasoline
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT WAS DRIVING WITH THE CRUISE CONTROL SET AT 67 MPH WHEN THE VEHICLE SHUT OFF. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS REPAIRED. THE CURRENT MILEAGE IS 70,000 AND FAILURE MILEAGE WAS 7,586.
NHTSA ODI #10190202
57,000 miles · Apr 18, 2007
Fuel System, Gasoline
MY 2002 VOLKSWAGEN PASSAT DEVELOPED A MAJOR FUEL LINE LEAK INSIDE THE ENGINE COMPARTMENT. A METAL HIGH PRESSURE FUEL LINE THAT IS MOUNTED TO THE FIREWALL EITHER CRACKED OR SOMEHOW BLEW A HOLE IN THE LINE. A HIGH PRESSURE STREAM OF GASOLINE WAS BEING SPRAYED DIRECTLY ON TOP OF THE ENGINE. THIS GASOLINE ERUPTION AS I WILL CALL …
Read full complaint
MY 2002 VOLKSWAGEN PASSAT DEVELOPED A MAJOR FUEL LINE LEAK INSIDE THE ENGINE COMPARTMENT. A METAL HIGH PRESSURE FUEL LINE THAT IS MOUNTED TO THE FIREWALL EITHER CRACKED OR SOMEHOW BLEW A HOLE IN THE LINE. A HIGH PRESSURE STREAM OF GASOLINE WAS BEING SPRAYED DIRECTLY ON TOP OF THE ENGINE. THIS GASOLINE ERUPTION AS I WILL CALL IT BECAUSE THE WORD LEAK IS INADEQUATE TO DESCRIBE THE AMOUNT OF GASOLINE THAT WAS SPRAYING OUT OF THE HOSE IN A LOCATION THAT IS DIRECTLY ADJACENT TO A FUEL LINE MOUNTING BRACKET ON THE FIREWALL. IT IS VERY VISIBLE IN THE PHOTOS I TOOK. AK WHEN I OPENED THE HOOD OF THE VEHICLE I FOUND A GASOLINE MIST HAD COVERED THE ENTIRE INSIDE OF THE ENGINE COMPARTMENT. THE LEAK WAS SO BAD I INITIALLY PARKED THE VEHICLE IN MY GARAGE BUT COULD SMELL THE GASOLINE INSIDE MY HOME SO I HAD TO MOVE IT OUTSIDE. THE NEXT DAY I HAD A DEALER LOOK AT. HE INFORMED OF HE FOUND THE LEAK, I CAME INTO SEE THE LEAK BEFORE HE REPAIRED IT, HE STARTED THE VEHICLE WITH THE HOOD OPEN AND WITHIN SECONDS THE TOP OF THE ENGINE HAD GASOLINE SPILLING ON TOP OF IT. I TOOK SOME PHOTOGRAPHS THAT CLEARLY SHOW THE SPRAY OF GASOLINE ONTO THE ENGINE. I REQUESTED THAT THE DEALER SAVE THE FUEL LINES THAT HE REMOVED FROM MY VEHICLE, SO I NOW HAVE THOSE AT MY HOME. I WOULD BE HAPPY TO SUPPLY THESE FAILED COMPONENTS AS WELL AS SEND IN THE PHOTOS. I CONTACTED VOLKSWAGEN REGARDING THIS INCIDENT AND THEY EXPRESSED NO INTEREST IN TAKING THIS OPPORTUNITY TO LEARN WHAT COULD CAUSE THIS MAJOR FUEL LINE LEAK. THEY HAVE NOT YET CALLED THE DEALER TO LEARN MORE ABOUT THE REPAIR, AND THEY WERE NOT INTERESTED IN ME SENDING THEM THE FAILED FUEL LINE PARTS. I AM APPALLED AT VOLKSWAGEN'S LACK OF CONCERN OVER THIS ISSUE. I FEEL VERY STRONGLY THAT SAFETY NEEDS TO BE A TOP CONCERN FOR AUTO MANUFACTURERS AND I DO NOT BELIEVE THAT VOLKSWAGEN IS GIVING THIS INCIDENT THE APPROPRIATE ATTENTION. PLEASE INVESTIGATE THIS, I WILL BE MORE THAN WILLING TO ASSIST IN ANY WAY I CAN.*AK
NHTSA ODI #10188197
82,996 miles · Jan 31, 2007
Fuel System, Gasoline
VOLKSWAGEN 2002 PASSAT 1.8L TURBO. ENGINE STALLED COMPLETELY GOING 60 MPH ON FREEWAY. COASTED TO SIDE OF ROAD. WAS ABLE TO RESTART. VERY DANGEROUS. ISSUE SOUNDS IDENTICAL TO FUEL PUMP ISSUE WITH 2003 PASSAT WHICH CAUSES DANGEROUS STALLING WITHOUT WARNING. *NM
NHTSA ODI #10181198
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).
Illustration