NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
636 reports84,000 miles · Nov 16, 2007
Engine And Engine Cooling
I PAY $1500 FOR USED 2002 PASSAT VW TWO YEARS AGO NOW DEALER WANTS TO CHARGE ME $ 6700 FOR NEW ENGINE. OLD ENGINE WAS DAMAGE DUE TO ENGINE SLUDGE. I SUBMITTED REGULAR OIL CHANGE RECEIPTS AND WAS DENIED WARRANTY. MY PASSAT HAS 84,000 MILE AND ONLY TWO YEARS OF RIDING ENJOYMENT. MY CAR SITTING AT DEALERSHIP FOR ALMOST TWO WEEK…
Read full complaint
I PAY $1500 FOR USED 2002 PASSAT VW TWO YEARS AGO NOW DEALER WANTS TO CHARGE ME $ 6700 FOR NEW ENGINE. OLD ENGINE WAS DAMAGE DUE TO ENGINE SLUDGE. I SUBMITTED REGULAR OIL CHANGE RECEIPTS AND WAS DENIED WARRANTY. MY PASSAT HAS 84,000 MILE AND ONLY TWO YEARS OF RIDING ENJOYMENT. MY CAR SITTING AT DEALERSHIP FOR ALMOST TWO WEEKS. PLEASE HELP CAR NEEDED FOR WORK. *TR
NHTSA ODI #10209104
25,359 miles · Nov 5, 2007
Service Brakes, Hydraulic
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE REAR BRAKE PADS WEAR OUT EVERY 15,000 MILES, WHICH IS ABOUT FOUR TIMES FASTER THAN A NORMAL VEHICLE. THIS IS UNEXPECTED ON A VEHICLE WITH SUCH LOW MILEAGE AND COULD CAUSE BRAKE FAILURE. IN FEBRUARY OF 2006, AT 25,359 MILES, THE DEALER INFORMED THE CONTACT OF THIS POSSIBILITY. …
Read full complaint
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE REAR BRAKE PADS WEAR OUT EVERY 15,000 MILES, WHICH IS ABOUT FOUR TIMES FASTER THAN A NORMAL VEHICLE. THIS IS UNEXPECTED ON A VEHICLE WITH SUCH LOW MILEAGE AND COULD CAUSE BRAKE FAILURE. IN FEBRUARY OF 2006, AT 25,359 MILES, THE DEALER INFORMED THE CONTACT OF THIS POSSIBILITY. HE NOTIFIED THE MANUFACTURER AND THEY DENIED ANY KNOWLEDGE OF THE FAILURE. THE CURRENT MILEAGE WAS 39,722 AND FAILURE MILEAGE WAS 25,359.
NHTSA ODI #10207950
115,243 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
35,000 miles · Oct 17, 2007
Exterior LightingFire
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT NOTICED THAT THE HEADLIGHTS WERE NOT WORKING. SHE TOOK THE VEHICLE TO THE DEALER AND THEY INFORMED HER THAT THE BULBS WERE BURNED OUT AND THE PASSENGER SIDE HEADLIGHT HARNESS MELTED. SHE SEARCHED ONLINE AND FOUND THAT THIS WAS A COMMON MANUFACTURER DEFECT ON OLDER MODE…
Read full complaint
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT NOTICED THAT THE HEADLIGHTS WERE NOT WORKING. SHE TOOK THE VEHICLE TO THE DEALER AND THEY INFORMED HER THAT THE BULBS WERE BURNED OUT AND THE PASSENGER SIDE HEADLIGHT HARNESS MELTED. SHE SEARCHED ONLINE AND FOUND THAT THIS WAS A COMMON MANUFACTURER DEFECT ON OLDER MODELS OF HER VEHICLE MAKE, BUT NOT FOR HER YEAR. SHE CALLED THE MANUFACTURER AND THEY REFUSED TO TAKE RESPONSIBILITY FOR THE DEFECT. THE POWERTRAIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 35,000.
NHTSA ODI #10206011
91,000 miles · Oct 11, 2007
Electrical SystemFire
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT STATED THAT HIS VEHICLE CAUGHT FIRE WITH FLAMES RISING APPROXIMATELY THREE FEET ABOVE THE HOOD. THE FIRE AND POLICE DEPARTMENTS ARRIVED AT THE SCENE. A POLICE REPORT WAS FILED. THE FIRE WAS EXTINGUISHED, HOWEVER, THE VEHICLE WAS DESTROYED. THE CONTACT HAS NOT SPOKEN …
Read full complaint
TL*THE CONTACT OWNS A 2002 VOLKSWAGEN PASSAT. THE CONTACT STATED THAT HIS VEHICLE CAUGHT FIRE WITH FLAMES RISING APPROXIMATELY THREE FEET ABOVE THE HOOD. THE FIRE AND POLICE DEPARTMENTS ARRIVED AT THE SCENE. A POLICE REPORT WAS FILED. THE FIRE WAS EXTINGUISHED, HOWEVER, THE VEHICLE WAS DESTROYED. THE CONTACT HAS NOT SPOKEN WITH THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE 91,000. UPDATED 01-15-08. * BF THE FIRE WAS DUE TO AN ELECTRICAL SHORT IN THE GROUND OF AN ELECTRICAL HARNESS. THE WIRING SHORTED OUT AGAINST THE VEHICLE'S STEEL COWL WITH TEMPERATURES HIGH ENOUGH TO WELD THE 12 GAUGE AGAINST THE BODY PANEL . UPDATED *JB
NHTSA ODI #10205407
78,800 miles · Oct 8, 2007
Electrical SystemService Brakes, Hydraulic
THE ABS CONTROL MODULE FAILED ON MY CAR CAUSING THE ABS SYSTEM AND THE ASR (ANTI-SLIP REGULATION) TRACTION CONTROL SYSTEMS TO NO LONGER FUNCTION. THIS HAPPENED WITHOUT WARNING WITH NO SIGNS LEADING UP TO THE FAILURE. THIS HAS ALSO CAUSED OTHER STRANGE ELECTRICAL ISSUES WHERE MY KEYLESS ENTRY WILL NO LONGER WORK. ALSO, THE ERRO…
Read full complaint
THE ABS CONTROL MODULE FAILED ON MY CAR CAUSING THE ABS SYSTEM AND THE ASR (ANTI-SLIP REGULATION) TRACTION CONTROL SYSTEMS TO NO LONGER FUNCTION. THIS HAPPENED WITHOUT WARNING WITH NO SIGNS LEADING UP TO THE FAILURE. THIS HAS ALSO CAUSED OTHER STRANGE ELECTRICAL ISSUES WHERE MY KEYLESS ENTRY WILL NO LONGER WORK. ALSO, THE ERROR LIGHTS CONTINUE TO FLASH ON THE INSTRUMENT PANEL AND THE RADIO REMAINS TURNED ON (UNLESS I MANUALLY TURN IT OFF) EVEN AFTER THE CAR HAS BEEN TURNED OFF AND THE KEY HAS BEEN REMOVED FROM THE IGNITION. THIS CAUSED A DEAD BATTERY AFTER 4 DAYS OF FLASHING (RADIO WAS OFF). IT HAS ALSO CAUSED AN ERROR BETWEEN THE COMMUNICATION PATHS FROM MY TRANSMISSION CONTROL MODULE (TCM) AND MY ENGINE'S ECU AND INSTRUMENT PANEL AS EVIDENCED BY THE ERROR CODES PRODUCED. THE LAST ISSUE THAT HAS BEEN CAUSED BY THE ABS FAILURE IS THAT THE CAR CONTINUES TO RUN FOR SEVERAL SECONDS AFTER THE IGNITION HAS BEEN TURNED OFF AND THE KEY HAS BEEN REMOVED. IT WILL THEN SPUTTER OUT AND TURN OFF. FROM MY RESEARCH, THIS APPEARS TO BE A COMMON PROBLEM ON THESE CARS: HTTP://WWW.PASSATWORLD.COM/FORUMS/SHOWTHREAD.PHP?T=173334 *TR
NHTSA ODI #10205178
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
58,000 miles · Sep 28, 2007
Engine And Engine Cooling
ON SEPTEMBER 6TH OF THIS YEAR, A MESSAGE APPEARED ON THE DASHBOARD DISPLAY LOW OIL PRESSURE, STOP MOTOR. I IMMEDIATELY CALLED THE DEALERSHIP IN POMPTON PLAINS, NJ (THE CLOSEST DEALERSHIP TO MY HOUSE) TO ARRANGE SERVICING, SINCE THE CAR WAS NOT TO BE DRIVEN. THE VOLKSWAGEN REPRESENTATIVE WITH WHOM I SPOKE ON THE PHONE INSTRUCTE…
Read full complaint
ON SEPTEMBER 6TH OF THIS YEAR, A MESSAGE APPEARED ON THE DASHBOARD DISPLAY LOW OIL PRESSURE, STOP MOTOR. I IMMEDIATELY CALLED THE DEALERSHIP IN POMPTON PLAINS, NJ (THE CLOSEST DEALERSHIP TO MY HOUSE) TO ARRANGE SERVICING, SINCE THE CAR WAS NOT TO BE DRIVEN. THE VOLKSWAGEN REPRESENTATIVE WITH WHOM I SPOKE ON THE PHONE INSTRUCTED ME TO BRING MY CAR TO THE DEALERSHIP. WHEN I FINALLY BROUGHT THE CAR IN, SERVICE MANAGER JOE INFORMED ME THAT WHAT I EXPERIENCED WAS LIKELY ENGINE TROUBLE REQUIRING OF MULTIPLE PART REPLACEMENT AND CALLED OIL SLUDGE. I WAS TOLD THAT IT WOULD COST $2,800 FOR REPAIRS BECAUSE THE WARRANTY ON MY FIVE-YEAR-OLD/56,000-MILE CAR RAN OUT. I CALLED CUSTOMER CARE AT 1-800-822-8987 AND SPOKE WITH REPRESENTATIVE NAMED FRODET AND HER SUPERVISOR, JAMES CUSTER, BOTH OF WHOM TOLD ME THAT THIS PROBLEM IS NOT UNHEARD OF AND HAS EVEN BEEN TERMED OIL SLUDGE AND IS COVERED UNDER VW'S SPECIAL EXTENDED WARRANTY 8 YEARS/UNLIMITED MILES. FRODET OPENED CASE NO. 70295194 IN MY NAME AND CALLED SERVICE MANAGER. I RECEIVED A CALL NEXT DAY. I WAS TOLD THAT IN ORDER TO FIX THIS PROBLEM UNDER VW?S SPECIAL EXTENDED WARRANTY, I NEEDED TO PROVIDE ALL ELEVEN RECEIPTS FOR OIL CHANGES THAT TOOK PLACE WITHIN THE ENTIRE FIVE-YEAR PERIOD OF OWNERSHIP. AFTER SCOURING MY FILES, I FOUND THAT I HAVE A TOTAL OF 20 RECEIPTS PERTAINING TO SERVICE AND MAINTENANCE OF THE VEHICLE, SEVENTEEN OF WHICH WERE NOT FROM THE CREST MONT DEALERSHIP. I FAXED THESE SEVENTEEN RECEIPTS TO THE ATTENTION OF SERVICE MANAGER JOE. THE VERY NEXT DAY SEPTEMBER 18TH, JOE CALLED ME AGAIN TO LET ME KNOW ME THAT A FIELD FACTORY REPRESENTATIVE REVIEWED THESE RECEIPTS AND REFUSED TO ADMIT SIXTEEN OF THEM. THESE RECEIPTS WERE FROM MY PERSONAL MECHANIC TO WHOM I HAD ENTRUSTED THE CARE AND SERVICE OF EVERY CAR I HAD. BUT, BECAUSE MY MECHANIC FAILED TO SPECIFY MY CAR'S VIN, LICENSE PLATE NUMBER, AND OIL FILTER PART NUMBERS IN THE RECEIPTS, I WAS OUT OF LUCK. *TR
NHTSA ODI #10204376
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
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