NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
636 reports27,561 miles · Oct 23, 2006
Engine And Engine Cooling
I WOULD LIKE TO LODGE A COMPLAINT REGARDING THE EXCESSIVE FAILURE OF VACUUM HOSES CAUSING THE ENGINE MALFUNCTION INDICATOR LIGHT TO COME ON REPEATEDLY ON THE 2002 VW PASSAT WAGON. ON AUGUST 2, 2006, THE VACUUM HOSE FAILED (REPLACED WITH P/N 06B-133-783 BC). THE COST OF THE REPAIR WAS $271.63. ON SEPTEMBER 11, 2006, THE VACUUM HO…
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I WOULD LIKE TO LODGE A COMPLAINT REGARDING THE EXCESSIVE FAILURE OF VACUUM HOSES CAUSING THE ENGINE MALFUNCTION INDICATOR LIGHT TO COME ON REPEATEDLY ON THE 2002 VW PASSAT WAGON. ON AUGUST 2, 2006, THE VACUUM HOSE FAILED (REPLACED WITH P/N 06B-133-783 BC). THE COST OF THE REPAIR WAS $271.63. ON SEPTEMBER 11, 2006, THE VACUUM HOSE WAS REPLACED AS PER VEHICLE RECALL (REPLACED WITH P/N 06B-103-221P). AND ON OCTOBER 18, 2006, THE VACUUM HOSE FAILED (REPLACED WITH P/N 1N-020-353-5). THE COST OF THIS REPAIR WAS $137.93. ALSO TO BE CONSIDERED IS THE INCONVENIENCE OF TAKING THE CAR TO A REPAIR FACILITY TIME AFTER TIME. *NM
NHTSA ODI #10171678
45,000 miles · Oct 16, 2006
SeatsFire
I GOT INTO MY CAR FOR THE FIRST TIME THAT DAY - AROUND 11:00 AM. I STARTED THE CAR, ADJUSTED THE HEAT AND PUT ON THE DRIVER'S SIDE SEAT WARMER. AFTER ABOUT 15 SECONDS, I SMELLED SOMETHING BURNING, BUT WAS UNAWARE OF WHAT IT WAS. AT THE SAME TIME I FELT SOMETHING CUTTING IN TO MY LEG. I PUT MY HAND UNDER MY LEG TO SEE WHAT WA…
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I GOT INTO MY CAR FOR THE FIRST TIME THAT DAY - AROUND 11:00 AM. I STARTED THE CAR, ADJUSTED THE HEAT AND PUT ON THE DRIVER'S SIDE SEAT WARMER. AFTER ABOUT 15 SECONDS, I SMELLED SOMETHING BURNING, BUT WAS UNAWARE OF WHAT IT WAS. AT THE SAME TIME I FELT SOMETHING CUTTING IN TO MY LEG. I PUT MY HAND UNDER MY LEG TO SEE WHAT WAS POKING INTO ME BUT COULDN'T FIND ANYTHING. THE SMELL WAS GETTING WORSE AND THE STABBING PAIN IN MY LEG WAS STILL THERE. AFTER ABOUT 60 SECONDS THERE WAS SMOKE COMING FROM MY SEAT AND I REALIZED THE SMELL WAS COMING FROM INSIDE MY CAR AND THE SEAT WARMER WAS BURNING. I PULLED OVER, SHUT THE CAR OFF AND JUMPED OUT OF MY CAR. I PRESSED MY HANDS TO THE SEAT IN AN ATTEMPT TO STOP THE BURNING AND SMOKE. I WAITED A FEW MINUTES AND WHEN I WAS CONVINCED THE BURNING HAD STOPPED, JUMPED IN MY CAR AND HEADED BACK TO THE HOTEL I HAD BEEN AT. I REMOVED THE FUSE FOR THE SEAT WARMERS. *NM
NHTSA ODI #10170977
92,030 miles · Oct 10, 2006
SeatsInjury
AFTER TURNING ON THE HEATED SEAT OPTION OF MY CAR I STARTED TO SMELL SOMETHING BURNING. AFTER ABOUT A MINUTE I FELT SOMETHING STING THE LEFT SIDE OF MY BUTTOCKS TOWARDS THE SIDE. WITH IN SECONDS I REALIZED THAT IT WAS MY SEAT BURNING MY BOTTOM. NOT ONLY MY BOTTOM, BUT A WHOLE RIGHT THROUGH THE SEAT AND MY JOGGING PANTS. I QUI…
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AFTER TURNING ON THE HEATED SEAT OPTION OF MY CAR I STARTED TO SMELL SOMETHING BURNING. AFTER ABOUT A MINUTE I FELT SOMETHING STING THE LEFT SIDE OF MY BUTTOCKS TOWARDS THE SIDE. WITH IN SECONDS I REALIZED THAT IT WAS MY SEAT BURNING MY BOTTOM. NOT ONLY MY BOTTOM, BUT A WHOLE RIGHT THROUGH THE SEAT AND MY JOGGING PANTS. I QUICKLY TURNED OFF THE HEAT TO MY SEAT. LOOKS LIKE A CIGARETTE BURN. MY HUSBAND AND I WERE AFRAID TO LEAVE THE CAR IN THE GARAGE IN CASE IT WAS STILL SMOLDERING AND POTENTIALLY START A FIRE. I CALLED OUR DEALER AND WAS TOLD THAT MY CAR WAS NO LONGER UNDER WARRANTY. PAST MILEAGE. THEY SUGGESTED THAT I CONTACT THE MANUFACTURER WHICH I HAVE NOT DONE QUITE YET. I AM AFRAID TO TURN IT ON AGAIN OF COURSE! *JB
NHTSA ODI #10170460
Mileage unknown · Oct 6, 2006
Structure
FOLLOWING A HEAVY RAIN, ENTIRE FLOORBOARD WET WITH NO EVIDENCE OF OVERHEAD OR SIDE PANEL WETNESS. WATER DRAINED DIRECTLY INTO CAR BUT NOT THROUGH DOOR SEALS OR WINDOWS. DRAIN PLUGS IN UNDERCARRIAGE REMOVED AND WATER STREAMED OUT FOR APPROX. 10 MINUTES. INITIAL ASSESSMENT BY DEALER INDICATES WATER DAMAGED COMFORT MODULE (CON…
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FOLLOWING A HEAVY RAIN, ENTIRE FLOORBOARD WET WITH NO EVIDENCE OF OVERHEAD OR SIDE PANEL WETNESS. WATER DRAINED DIRECTLY INTO CAR BUT NOT THROUGH DOOR SEALS OR WINDOWS. DRAIN PLUGS IN UNDERCARRIAGE REMOVED AND WATER STREAMED OUT FOR APPROX. 10 MINUTES. INITIAL ASSESSMENT BY DEALER INDICATES WATER DAMAGED COMFORT MODULE (CONTROLLING ALL POWERED COMPONENTS LIKE WINDOWS, DOOR LOCKS, SUNROOF, CRUISE, SEATS, ETC.) AND TRANSMISSION MODULE AND CONNECTORS. OVER $4500 ESTIMATE (NOT FINISHED TO DATE). SOURCE OF LEAK NOT YET FOUND BY DEALER. *NM
NHTSA ODI #10170072
42,000 miles · Oct 6, 2006
Electrical System
THE ENGINE SPUTTERS AND APPEARS TO MISFIRE AFTER THE CAR HAS BEEN SITTING OR DRIVEN IN THE RAIN. PRECEDING AND AFTER THIS EVENT THE CHECK ENGINE LIGHT COMES ON. THIS HAPPENED TWICE DURING THE WEEK OF SEPTEMBER 11, 2006. THE DEALERSHIP COULD NOT IDENTIFY THE PROBLEM AND SAID THE CAR WAS SAFE TO DRIVE, BUT SUGGESTED WE GET A TU…
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THE ENGINE SPUTTERS AND APPEARS TO MISFIRE AFTER THE CAR HAS BEEN SITTING OR DRIVEN IN THE RAIN. PRECEDING AND AFTER THIS EVENT THE CHECK ENGINE LIGHT COMES ON. THIS HAPPENED TWICE DURING THE WEEK OF SEPTEMBER 11, 2006. THE DEALERSHIP COULD NOT IDENTIFY THE PROBLEM AND SAID THE CAR WAS SAFE TO DRIVE, BUT SUGGESTED WE GET A TUNE UP, INCLUDING GETTING THE SPARK PLUGS CHANGED (THE CAR DIDN'T NEED IT!). ON A RAINY OCTOBER 6 AT 5:00 A.M., THE CAR STALLED IN THE MIDDLE OF A 2-LANE STATE ROAD. WHEN WE ATTEMPTED TO RESTART THE CAR, IT SPUTTERED A BIT AND THEN DIED. THE CAR WOULD NOT RESTART AND HAD TO BE PUSHED OFF THE ROAD. WE ARE GOING TO ASK THE DEALERSHIP TO INSPECT THE IGNITION COIL. *NM
NHTSA ODI #10170052
54,552 miles · Sep 28, 2006
Service Brakes, Hydraulic
FAULTY ABS LIGHT, FAULTY BRAKE LIGHT SENSOR ANNOYING BEEPING, 2002 VW PASSAT. *NM
NHTSA ODI #10169496
66,900 miles · Sep 19, 2006
Fuel System, Gasoline
A CHEMICAL SMELL PERMEATING MY ENTIRE HOUSE FOR 2 MONTHS. I HAD HOME GAS COMPANY COME OUT AND CHECK FOR A GAS LEAK,GAS COMPANY DID NOT FIND A GAS LEAK. THE SMELL WOULD BE WORSE SOME DAYS. A FRIEND FOUND MY TANK LEAKING . I TOOK MY CAR IN THE NEXT DAY, MONDAY P.M. TO HAVE IT LOOKED AT BARON VW. THEY SAID IT WAS A NIPPLE ON A HO…
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A CHEMICAL SMELL PERMEATING MY ENTIRE HOUSE FOR 2 MONTHS. I HAD HOME GAS COMPANY COME OUT AND CHECK FOR A GAS LEAK,GAS COMPANY DID NOT FIND A GAS LEAK. THE SMELL WOULD BE WORSE SOME DAYS. A FRIEND FOUND MY TANK LEAKING . I TOOK MY CAR IN THE NEXT DAY, MONDAY P.M. TO HAVE IT LOOKED AT BARON VW. THEY SAID IT WAS A NIPPLE ON A HOSE INSIDE THE TANK, AND THE WHOLE TANK HAD TO BE REPLACED. THIS IS A VERY EXPENSIVE REPAIR, THAT THEY ARE ESTIMATING TO BE TWO THOUSAND DOLLARS. I DO NOT BELIEVE THAT THIS JUST HAPPENED, WITH THE HOSE BEING INSIDE THE TANK, I THINK THIS IS A BAD PART. I HAVE FOUND OTHER INCIDENTS OF THIS ONLINE , FOR THIS PARTICULAR 2002 PASSAT, WITH FOUR MOTION. I THINK IT IS A DEFECT OF THE PART AND IT IS EXPENSIVE BECAUSE THE WHOLE DRIVE TRAIN MUST BE REMOVED TO REPLACE IT. I AM HOPING YOU WILL LOOK INTO THIS BECAUSE THAT IS A VERY DANGEROUS PROBLEM. I DON'T THINK SOME PEOPLE WOULD EVEN NOTICE THEIR TANKS LEAKING. IF MY CAR WAS NOT STORED IN MY GARAGE EVERYDAY I WOULD HAVE NEVER NOTICED IT. IT COULD HAVE BLOWN MY HOUSE UP WHEN I TURNED MY HEATER ON FOR THE WINTER WITH THE FUMES THAT WERE IN THIS HOUSE, NOT TO MENTION DRIVING WITH A LEAKING TANK, AND THE CHANCE OF STATIC OR A CIGARETTE BUTT GETTING TOSSED MY WAY. THE CAR HAS BEEN OUT OF MY GARAGE FOR 3 DAYS NOW AND THE ATTIC FAN HAS BEEN ON UNTIL LAST NIGHT AND MY HOUSE STILL STINKS. I AM AFRAID NOW TO TURN MY HOME FURNACE ON. PEOPLE WHO OWN THESE CARS SHOULD BE WARNED TO CHECK THEM FOR GAS LEAKS, ESPECIALLY IF THEY KEEP THEM IN THEIR GARAGE. I ALSO THINK ABOUT THE TIMES I HAD MY GRANDSON STRAPPED INTO A CHILD SEAT RIGHT THERE OVER THAT LEAKING TANK. THE REASON THE SMELL WAS IN MY HOUSE STRONGER SOME DAYS WAS BECAUSE I WOULD LEAVE THE CAR OUTSIDE SOMETIMES AND I HAD THE WINDOWS OPEN AND ATTIC FAN ON WOULD DRAW THE SMELL OUT. THE DAY I DISCOVERED IT WAS PARTICULARLY STRONG WAS BECAUSE I HAD PUT THE CAR BACK IN AND SHUT THE WINDOWS AND TURNED MY A/C BACK ON IN THE HOUSE. *JB
NHTSA ODI #10168655
40,000 miles · Sep 19, 2006
Engine And Engine CoolingPower TrainInjury
I HAD THE CHECK ENGINE LIGHT ON AND TOOK IT TO THE DEALER. HE SAID THERE WAS PROBLEM WITH COMBI VALVE, VACUUM HOSE AND SECONDARY AIR PUMP WHICH COSTS A TOTAL OF >1200$ IN TOTAL. LUCKILY, I HAD THE EXTENDED WARRANTY AND I HAVE TO PAY 700$. THE CAR IS 2002 VW PASSAT GLS (1.8) AND HAVE ONLY 40K ON IT. THIS IS THE SECOND MAJOR REPAI…
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I HAD THE CHECK ENGINE LIGHT ON AND TOOK IT TO THE DEALER. HE SAID THERE WAS PROBLEM WITH COMBI VALVE, VACUUM HOSE AND SECONDARY AIR PUMP WHICH COSTS A TOTAL OF >1200$ IN TOTAL. LUCKILY, I HAD THE EXTENDED WARRANTY AND I HAVE TO PAY 700$. THE CAR IS 2002 VW PASSAT GLS (1.8) AND HAVE ONLY 40K ON IT. THIS IS THE SECOND MAJOR REPAIR AND THE PREVIOUS ONE WAS SOME KIND OF CV JOINT ISSUE. ALL THIS PROBLEMS SEEMS TO BE A COMMON PROBLEM FOR ALL PASSAT OWNERS AND I WONDER WHY THERE IS NOT EVEN A RECALL FOR THIS. MAY BE THEY KNOW THIS PROBLEM AND WANT PEOPLE TO GO AND PAY MONEY. ONE THING IS SURE. THIS WILL BE MY FIRST AND LAST VW. I DON'T RECOMMEND ANY ONE TO BUY VW, BUT BETTER BUY CHEAP JAPANESE CARS LIKE MITSUBHISHI WHICH RUNS FOR YEARS AND YEARS WITHOUT ANY PROBLEM. *JB
NHTSA ODI #10168627
92,350 miles · Sep 7, 2006
Power TrainCrashInjury
2002 VOLKSWAGEN PASSAT WAGON / 92350 MILES PLACED IN "PARK" ON A SLIGHT INCLINE (PARKING BRAKE NOT USED). ENGINE WAS TURNED OFF AND THE KEYS WERE REMOVED. DRIVER STEPPED OUT OF THE CAR AND A FEW SECONDS LATER CAR STARTED ROLLING BACKWARDS WITH CHILDREN (AGES 3 AND 10 MO) IN THE CAR. DRIVER JUMPED IN CAR TO SET THE BRAKE, BUT…
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2002 VOLKSWAGEN PASSAT WAGON / 92350 MILES PLACED IN "PARK" ON A SLIGHT INCLINE (PARKING BRAKE NOT USED). ENGINE WAS TURNED OFF AND THE KEYS WERE REMOVED. DRIVER STEPPED OUT OF THE CAR AND A FEW SECONDS LATER CAR STARTED ROLLING BACKWARDS WITH CHILDREN (AGES 3 AND 10 MO) IN THE CAR. DRIVER JUMPED IN CAR TO SET THE BRAKE, BUT FELL ON STREET AS CAR ROLLED. CAR CROSSED STREET AND HEADED DOWN A STEEPER INCLINE HITTING BUSHES, CROSSING ANOTHER DRIVEWAY, AND FINALLY HITTING A ROCK WALL COMING TO A STOP. CHILDREN WERE OK. DRIVER HAD BRUISES / SCRATCHES FROM FALLING ON PAVEMENT. CAR SUSTAINED $3,400 IN DAMAGE. NEIGHBORS VERIFIED CAR WAS IN PARK, AND OWNER MANUAL STATES THAT KEYS CANNOT BE REMOVED WITHOUT THE CAR BEING IN PARK ( KEYS WERE OBSERVED BY SEVERAL NEIGHBORS TO BE OUT OF THE CAR). VOLKSWAGEN OF AMERICA ASKED ME TO GO TO A DEALER FOR PROBLEM DETERMINATION. DEALER TRIED PARKING THE CAR 5 TIMES ON UPHILL AND DOWNHILL INCLINES, AND PARK HELD. THEY ALSO CHECKED THE COMPUTER AND FOUND NO FAULTS. NO ATTEMPT WAS MADE TO CHECK THE INTERNALS OF THE TRANSMISSION, TO DETERMINE WHETHER THE INCLINE WAS THE SAME AS THE DRIVEWAY WHERE IT OCCURRED, OR TO DETERMINE WHETHER THERE WAS A REASON FOR AN INTERMITTENT PROBLEM. VW OF AMERICA STATED THAT THE DEALER HAD FOUND THE CAR WAS IN SPEC (WITH THE 5 HILL TESTS AND COMPUTER CHECK), AND NO FURTHER ACTION WOULD BE TAKEN. VW STATED THAT WE SHOULD ALSO HAVE BEEN USING THE PARKING BRAKE ANY TIME WE PARK (WE DO ON STEEPER HILLS, BUT NOT ON HILLS AS SLIGHT AS OUR DRIVEWAY). NOBODY HAS EXPLAINED WHY PARK FAILED EVEN THOUGH THE KEYS WERE OUT OF THE IGNITION (AND OBSERVED TO BE BY OTHERS) -- I CONCEDE THE PARKING BRAKE SHOULD ALWAYS BE USED OUT OF EXTREME CAUTION, BUT MOST PEOPLE DO NOT ON SLIGHT HILLS -- PARK SHOULD NOT FAIL IN ANY CASE. WE FEEL WE HAVE TO GET RID OF THE CAR ASAP BECAUSE THIS HAS NOT BEEN EXPLAINED / ADDRESSED. OTHER CARS (LIKE 2006 BMW) HAVE RECALLS ON THE PARKING PAWL, BUT VW WILL NOT INVESTIGATE FURTHER. *NM
NHTSA ODI #10167597
50,000 miles · Aug 30, 2006
Fuel System, Gasoline
2002 VW PASSAT, V6 4MOTION JUST TURNED OVER 50,000 MILES (WARRANTY EXPIRED) AND NOTICED THAT WHEN I FILLED THE GAS TANK, FOR SEVERAL DAYS UNTIL THE GAS LEVEL WENT DOWN, THERE WAS A VERY STRONG GAS ODOR IN THE CAR AND AROUND THE CAR. TOOK IT TO THE DEALER, WHO FIRST POINTED OUT THAT IT WAS TIME FOR ME TO PAY THE PASSAT DRIVER P…
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2002 VW PASSAT, V6 4MOTION JUST TURNED OVER 50,000 MILES (WARRANTY EXPIRED) AND NOTICED THAT WHEN I FILLED THE GAS TANK, FOR SEVERAL DAYS UNTIL THE GAS LEVEL WENT DOWN, THERE WAS A VERY STRONG GAS ODOR IN THE CAR AND AROUND THE CAR. TOOK IT TO THE DEALER, WHO FIRST POINTED OUT THAT IT WAS TIME FOR ME TO PAY THE PASSAT DRIVER PRIVILEGE TAX, A.K.A., $650 FOR STANDARD MAINTENANCE WORK. REGARDING THE GAS SMELL, AFTER THE MECHANICS ALLEGEDLY CHECKED THE CAR, THE SERVICE ADVISOR SPECULATED THAT IT WAS A LEAK IN ONE OF THE FUEL PUMP SEALS, WHICH ARE LOCATED UNDER THE BACK SEAT (WHERE THE STRONGEST SMELL WAS COMING FROM). HE SAID THAT HE HAD SEEN OTHER PASSATS AT AROUND MY SAME MILEAGE WITH THE SAME PROBLEM. THE TANK WAS ONLY FULL THOUGH, AND THE SMELL WAS NOT PRESENT, SO HE ASKED ME TO BRING THE CAR BACK ON ANOTHER DAY, WITH A FULL GAS TANK, SO THAT THE MECHANICS COULD SMELL IT. WHEN I SUGGESTED THAT IT MIGHT BE MORE DIFFICULT (AND DANGEROUS) TO EXAMINE A FULL GAS TANK, HE AGREED AND WHEN I BROUGHT THE CAR BACK A WEEK LATER FOR THE MECHANICS CHECK IT OUT, THAT'S WHEN THE SERVICE ADVISOR TOLD ME THAT THE GAS TANK WAS 'CRACKED' (NEAR THE TOP) ' AND THAT IT WOULD COST $2,000+ TO FIX IT. THIS IS OBVIOUSLY NOT CAUSED BY 'WEAR AND TEAR'- NOR IS IT A PROBLEM THAT I COULD HAVE CAUSED ABSENT SOME SORT OF IMPACT. I CALLED VW AMERICA TO ASK THEM TO PAY FOR THE REPAIR, AND AFTER THEY INVESTIGATED MY CLAIM, THEY TOLD ME THAT THE DEALERSHIP OFFERED TO PAY 1/2 THE COST OF THE REPAIR, ($1,000). WHEN I NEXT SPOKE WITH THE SERVICE ADVISOR AT THE DEALERSHIP, HE TOLD ME THAT VW HAD OFFERED TO PAY 1/2 THE COST OF THE REPAIR, OR WOULD GIVE ME A $1,000 CREDIT TOWARD A NEW CAR. MY INVESTIGATIONS HAVE LED ME TO THE CONCLUSION THAT THIS IS EITHER A DEFECT OF THE VW FUEL TANKS OR THE CRACK IS DUE TO CORROSION, WHICH SHOULD BE 100% COVERED UNDER THE 12 YEAR CORROSION WARRANTY. EITHER WAY, VW SHOULD BE HELD ACCOUNTABLE. *NM
NHTSA ODI #10167094
NHTSA investigations
9EA11002 · Engine Compartment Fire
Opened Jan 26, 2011 · Closed Feb 17, 2012
Status: closed (inferred from source dates) · Electrical System; Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Additional source detail variants (2)
Electrical System
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
PE10027 · Engine Compartment Fire
Opened Jul 26, 2010 · Closed Feb 7, 2011
Status: closed (inferred from source dates) · Electrical System; Engine And Engine Cooling
ODI has received 11 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 9 complaints of ignition coil failure that did not result in a fire.Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated.The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once.The scope of PE10-027 focused on Model Years (MY)2002-2003 Passat vehicles.Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles as well as other MY Passat vehicles.ODI needs to further investigate this issue.To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an Engineering Analysis, EA11-002.
Additional source detail variants (2)
Electrical System
ODI has received 11 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 9 complaints of ignition coil failure that did not result in a fire.Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated.The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once.The scope of PE10-027 focused on Model Years (MY)2002-2003 Passat vehicles.Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles as well as other MY Passat vehicles.ODI needs to further investigate this issue.To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an Engineering Analysis, EA11-002.
Engine And Engine Cooling
ODI has received 11 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 9 complaints of ignition coil failure that did not result in a fire.Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated.The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once.The scope of PE10-027 focused on Model Years (MY)2002-2003 Passat vehicles.Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles as well as other MY Passat vehicles.ODI needs to further investigate this issue.To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an Engineering Analysis, EA11-002.
PE08008 · Fuel Tank Leak
Opened Jan 31, 2008 · Closed May 30, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly; Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Additional source detail variants (4)
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
EA07014 · Passenger Engine Compartment Fires
Opened Sep 28, 2007 · Closed Jul 7, 2008
Status: closed (inferred from source dates) · Electrical System:ignition; Engine And Engine Cooling:exhaust System
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
Additional source detail variants (2)
Electrical System:ignition
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
Engine And Engine Cooling:exhaust System
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
PE07024 · Passenger/engine Compartment Fires
Opened May 10, 2007 · Closed Sep 28, 2007
Status: closed (inferred from source dates) · Electrical System:ignition
MANY OF THE FIRE REPORTS ALLEGE THAT THE VEHICLE FIRE WAS ATTRIBUTED TO IGNITION COIL FAILURE.VW PROVIDED ADDITIONAL DATA REGARDING ITS ANALYSIS OF VEHICLE FIRES AND A DETAILED DESCRIPTION OF THE THREE DIFFERENT ENGINES AND IGNITION SYSTEMS FOR THE SUBJECT VEHICLES.ODIFINDS THE NEED TO FURTHER INVESTIGATE THIS ISSUE.TO FACILITATE ACQUISITION AND ANALYSIS OF ADDITIONAL INFORMATION, THIS INVESTIGATIONHAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-014).
PE07018 · Water/ice In Brake Booster
Opened Apr 3, 2007 · Closed Sep 4, 2007
Status: closed (inferred from source dates) · Service Brakes, Hydraulic:power Assist:vacuum
DURING THIS INVESTIGATION, VOLKSWAGEN OF AMERICA (VW) IDENTIFIED A PROBLEM WITH WATER ACCUMULATION IN THE FRESH AIR PLENUM THAT COULD, IN CERTAIN CIRCUMSTANCES, RESULT IN REDUCED BRAKE POWER ASSIST IN MODEL YEAR (MY) 2002 PASSAT VEHICLES.VW INDICATED THAT PROBLEM IS CAUSED BY LEAVES AND OTHER DEBRIS CLOGGING THE PLENUM DRAINS, WHICH MAY RESULT IN WATER FILLING THE PLENUM TO THE LEVEL OF THE BRAKE BOOSTER AIR INTAKE.THE BOOSTER AIR INTAKE IS LOCATED IN THE FRESH AIR PLENUM IN THE MY 2002 PASSAT VEHICLES, BUT NOT IN THE MY 2001 OR 2003 VEHICLES WHICH DRAW BOOSTER AIR FROM THE CABIN.VW TESTING SHOWED THAT BRAKE ASSIST COULD BE REDUCED IF WATER ENTERS THE BOOSTER AND FREEZES.VW IS ADDRESSING THE PROBLEM WITH A SERVICE CAMPAIGN, WHICH BEGAN IN AUGUST 2007.THE FRESH AIR PLENUM IN THE SUBJECT VEHICLES IS AN ENCLOSED SPACE AT THE BASE OF THE WINDSHIELD FROM WHICH THE VEHICLE VENTILATION SYSTEM DRAWS THE FRESH AIR SUPPLY VIA A POLLEN FILTER.RAIN WATER THAT FLOWS OFF THE WINDSHIELD INTO THE PLENUM IS DRAINED THROUGH TWO VALVES LOCATED BELOW THE BATTERY AND BRAKE BOOSTER.STRAINERS AT THE BASE OF THE WINDSHIELD AND IN THE PANEL COVERING THE TOP OF THE PLENUM BLOCK LEAVES, PINE NEEDLES AND OTHER DEBRIS.OVER TIME, DEBRIS MAY ENTER THE PLENUM THROUGH OPENINGS IN THE PLENUM PANEL OR AROUND THE HOOD HINGES.IF CLOGGED DRAINS ALLOW APPROXIMATELY 3-4 GALLONS OF WATER TO ACCUMULATE IN THE PLENUM, THE WATER MAY ENTER THE BOOSTER THROUGH THE AIR INTAKE.WATER ACCUMULATION IN THE PLENUM MAY ALSO RESULT IN COMPLAINTS OF WET CARPETS IN THE VEHICLE INTERIOR IF THE WATER REACHES THE LEVEL OF THE FRESH AIR INTAKE/POLLEN FILTER. VW STATED THAT ITS TESTING SHOWED THAT BRAKE PERFORMANCE AND ACTUATING FORCE (I.E., PEDAL EFFORT) ARE NOT AFFECTED WHEN THE BOOSTER IS FILLED WITH THE MAXIMUM AMOUNT OF WATER POSSIBLE (UP TO THE HEIGHT OF THE BOOSTER ENGINE VACUUM CONNECTION, THROUGH WHICH WATER DRAWN INTO THE BOOSTER IS EVACUATED).VW'S TESTING SHOWED THAT BRAKE PERFORMANCE AND ACTUATING FORCE COULD BE AFFECTED BY WATER FREEZING IN THE BOOSTER.HOWEVER, WHEN TESTED WITH RELATIVELY LOW VOLUMES OF FROZEN WATER IN THE BOOSTER, VW SHOWED THAT THE EFFECTS WERE SIGNIFICANTLY LESS SEVERE THAN FOR CONDITIONS THAT RESULT IN A COMPLETE LOSS OF VACUUM ASSIST.WHILE VW INDICATED THAT THE EFFECTS WOULD BE MORE SEVERE WITH GREATER VOLUMES OF FROZEN WATER, IT MAINTAINED THAT THE CHANCES OF THIS OCCURRING WERE REMOTE AND WOULD BE READILY DISCERNABLE TO THE DRIVER UPON THE INITIAL BRAKE APPLICATION AFTER VEHICLE START-UP.ODI'S ANALYSIS OF COMPLAINTS AND WARRANTY DATA SHOWED DISPROPORTIONATE CONCENTRATIONS IN WINTER MONTHS AND IN NORTHERN STATES WITH COLDER WINTER CLIMATES. ODI IDENTIFIED THREE MINOR CRASHES RELATED TO THE ALLEGED DEFECT IN MY 2002 PASSAT VEHICLES.TWO OF THE CRASHES OCCURRED INGARAGES/DRIVEWAYS AND THE THIRD OCCURRED IN A DEALER SERVICE GARAGE.THERE WERE NO INJURIES ALLEGED IN THE CRASHES BUT A FOOT INJURY WAS ALLEGED IN A FOURTH INCIDENT WHERE EXCESSIVE BRAKE EFFORT REQUIRED DURING A HARD STOP. VOLKSWAGEN IS CONDUCTING A SERVICE CAMPAIGN TO REMEDY THIS CONDITION IN MY 2002 PASSAT AND AUDI A4 AND A6 VEHICLES.THE REMEDY PROCEDURE REQUIRES VW DEALERS TO INSPECT, CLEAN AND MODIFY THE AIR PLENUM DRAIN, AS WELL AS MODIFY THE SUNROOF DRAIN (IF EQUIPPED) AND INSTALL AN IMPROVED SEAL FOR THE POLLEN FILTER.IN ADDITION, VW HAS AGREED TO PROVIDE THE FOLLOWING INFORMATION TO ODI1. QUARTERLY COMPLETION REPORTS FOR ONE YEAR; AND 2. PROMPTLY REPORTING ALL CRASHES ATTRIBUTED TO THE ALLEGED DEFECT. THIS INVESTIGATION IS CLOSED BASED UPON THE ACTIONS TAKEN BY VW.THE CLOSING OF THIS INVESTIGATION DOES NOT C
DP05004 · Engine Stalling
Opened Aug 11, 2005 · Closed Dec 8, 2005
Status: closed (inferred from source dates) · Electrical System:ignition:module
BY LETTER RECEIVED ON JUNE 24, 2005, MR. RONALD M. STRICKLAND OF RALEIGH, NC, SUBMITTED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE THE PERFORMANCE OF THE IGNITION COIL PLUGS ON MODEL YEAR (MY) 2000-2003 VOLKSWAGEN JETTA, GOLF AND PASSAT SEDANS.THE PETITIONER ALLEGES THAT HE HAD EXPERIENCED MULTIPLE STALLING EVENTS AS A RESULT OF ONE OR MORE IGNITION COIL PLUGS MALFUNCTIONING ON HIS 2002 VW JETTA SEDAN.AS A RESULT OF THE ENGINE STALLING, THE PETITIONER EXPERIENCED A LOSS OF POWER STEERING AND INCREASED BRAKING EFFORTS WHEN HE PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD TO CONTROL THE VEHICLE.AFTER A FEW MINUTES PARKED ON THE SHOULDER HE WAS ABLE TO RESTART THE VEHICLE ALTHOUGH THE ENGINE OPERATED AT REDUCED POWER.VW ISSUED A CUSTOMER SATISFACTION CAMPAIGN (CSC) ON JANUARY 31, 2003 TO INSTRUCT THEIR DEALERSHIPS TO INSPECT THE VEHICLES FOR ANY MALFUNCTIONING IGNITION COIL PACKS AND TO REPLACE THEM AT NO COST TO THE CONSUMER.CONSUMERS WERE NOTIFIED TO BRING THEIR VEHICLES TO THEIR DEALERSHIPS VIA OWNER LETTERS MAILED OUT ON JUNE 6, 2003.WHILE VW INITIALLY INSTRUCTED THE DEALERSHIPS TO ONLY REPLACE THE MALFUNCTIONING IGNITION COIL PACKS, A REVISED CSC WAS ISSUED TO DEALERSHIPS IN DECEMBER 2003 AND JANUARY 2004, INSTRUCTING DEALERSHIPS TO REPLACE ALL IGNITION COIL PACKS REGARDLESS OF THEIR PERFORMANCE.A REMINDER TO THE DEALERSHIPS WAS SENT BY VW ON APRIL OF 2004.ALTHOUGH THE CONCERNS OF THE PETITIONER COULD THEORETICALLY CREATE A SAFETY PROBLEM, THE RISK IS VERY SMALL, DUE TO THE ENGINE STILL RUNNING ON EITHER 3, 5, OR 7 CYLINDERS.THERE ARE NO REPORTED CRASHES OR INJURIES DUE TO THE ALLEGED DEFECT.ONCE DRIVERS ARE AWARE OF THE PROBLEM (LOSS OF POWER DUE TO ONE OF THE IGNITION COIL PACKS MALFUNCTIONING), DRIVERS ARE ABLE TO TAKE PRECAUTIONARY AND COMPENSATORY MEASURES AND STILL MAINTAIN CONTROL OF THEIR VEHICLES.IN ADDITION, FOUR FIRES WERE REPORTED TO ODI.THESE WERE IGNITION COIL BURNOUTS WITH NO ADDITIONAL DAMAGE TO THE VEHICLE AND WERE LOCALIZED ON TOP OF THE ENGINE. DURING THE LAST 24 MONTHS THE NUMBER OF STALL AND DRIVABILITY COMPLAINTS REPORTED TO ODI HAS GREATLY DIMINISHED FROM A PEAK OF 195 IN JANUARY OF 2003 TO ONLY 3 IN AUGUST OF 2005.THIS COINCIDES WITH THE CSC RELEASED BY VW.A SAFETY-RELATED DEFECT TREND HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
EA03020 · Passenger Air Bag Lid Failure
Opened Oct 7, 2003 · Closed Apr 23, 2004
Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal
THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.
Additional source detail variants (2)
Air Bags:frontal
THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.
Air Bags
THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.
PE03021 · Passenger Sir Door Mounting Stud Failure
Opened May 23, 2003 · Closed Oct 7, 2003
Status: closed (inferred from source dates) · Air Bags:frontal
ODI OPENED A PRELIMINARY EVALUATION (PE03-021) BASED ON TWO REPORTS OF FAILED BOLT STUDS THAT ATTACH THE PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) DOOR COVER TO THE INSTRUMENT PANEL (IP) ON THE VOLKSWAGEN (VW) PASSAT (MODEL YEARS 2000, 2002).VW HAS INDICATED TO ODI THAT IT HAS NO ADDITIONAL REPORTS.VW IMPLEMENTED A PROCESS CHANGE ON MARCH 1, 2002.THIS PROCESS CHANGE CONSISTED OF CHANGING THE BOLT APPLICATION THAT FASTENS THE PSIR DOOR TO THE IP FROM A WELD ON APPLICATION TO A PRESS ON APPLICATION.VW ALSO CHANGED THE MATERIAL OF THE BOLT.VW STATED THAT THE CHANGES WERE MADE TO EASE PRODUCTION BY ELIMINATING A WELDING PROCESS.ODI HAS UPGRADED ITS INVESTIGATION TO ENGINEERING ANALYSIS (EA03-020).
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