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2004 Volkswagen Passat

Owner reports · Recalls · Investigations

More warning signs than most Passat years

Owner complaints for the 2004 Volkswagen Passat are substantially higher than the model-year median of 110.

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When problems were reported

Mileage at the reported incident

217 reports with mileage · 62 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine And Engine Cooling. Review the 59 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 38 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Seats. Review the 34 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports25 fire reports23 injury reports

Engine And Engine Cooling complaints

59 reports
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160,000 miles · Feb 7, 2011
Engine And Engine Cooling

2004 VOLKSWAGEN PASSAT 1.8L TURBO. OIL SLUDGE CLASS ACTION. MY CAR HAD THE STOP ENGINE WARNING COME ON THE OTHER DAY AFTER THE REQUIRED OIL CHANGE. SINCE I AM THE SECOND OWNER OF THIS CAR I CAN NOT PROVE THE OIL CHANGES WHERE DONE AS VW RECOMMENDS. I HAVE ONLY OWNED THE CAR FOR A FEW MONTHS. SADLY I AM LOOKING AT A TOTAL ENGINE …

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2004 VOLKSWAGEN PASSAT 1.8L TURBO. OIL SLUDGE CLASS ACTION. MY CAR HAD THE STOP ENGINE WARNING COME ON THE OTHER DAY AFTER THE REQUIRED OIL CHANGE. SINCE I AM THE SECOND OWNER OF THIS CAR I CAN NOT PROVE THE OIL CHANGES WHERE DONE AS VW RECOMMENDS. I HAVE ONLY OWNED THE CAR FOR A FEW MONTHS. SADLY I AM LOOKING AT A TOTAL ENGINE CHANGE WITH NO HELP FROM THE CLASS ACTION SUIT OR VW. I HAVE OWNED A VW ON AND OFF FOR 15 YEARS. THIS WILL BE MY LAST IF THEY DON'T MAKE GOOD ON THE RECALL. *LN

NHTSA ODI #10380962

59,000 miles · Jan 13, 2011
Engine And Engine Cooling

MY 2004 VOLKSWAGEN PASSAT IS PART OF THE "VW OIL SLUDGE SETTLEMENT". I HAVE DONE ALL SCHEDULED OIL CHANGES, MAINTENANCE, ETC. I HAVE ALL RECEIPTS. I HAD TO REPLACE THE ENGINE COILS, THE UNDERBODY HEAT, ETC. NOV. 20TH 2010 I TOOK THE CAR IN BECAUSE A PERFORMANCE LIGHT RELATED TO THE ENGINE CAME ON. I DID NOT KNOW AT THE TIME THE …

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MY 2004 VOLKSWAGEN PASSAT IS PART OF THE "VW OIL SLUDGE SETTLEMENT". I HAVE DONE ALL SCHEDULED OIL CHANGES, MAINTENANCE, ETC. I HAVE ALL RECEIPTS. I HAD TO REPLACE THE ENGINE COILS, THE UNDERBODY HEAT, ETC. NOV. 20TH 2010 I TOOK THE CAR IN BECAUSE A PERFORMANCE LIGHT RELATED TO THE ENGINE CAME ON. I DID NOT KNOW AT THE TIME THE WARRANTY OF THE VEHICLE HAD BEEN EXTENDED. I HAD TO PAY $ 654.11 FOR REPAIRS AND SPENT 4.5 HOURS AT THE DEALER, VW SOUTH SERVICE, WAITING FOR MY CAR. NOW, I HAVE TO TAKE IT BACK IN FOR THE SAME LIGHT COMING ON AS IN NOVEMBER. I HAVE 2 YEARS TO PAY FOR THE CAR APPROXIMATELY $ 8000.00. A CAR THAT IS KNOWN HAS MAJOR ISSUES WITH OIL SLUDGE AND THE ENGINE. I CANNOT AFFORD TO CONTINUE TO PAY VOLKSWAGEN FOR A CAR THAT IS GOING TO GIVE ME HEADACHES IN THE NEXT 2 YEARS, A LEMON. AND WILL CONTINUOUSLY CAUSE ME TO MISS WORK. I HAVE THE SETTLEMENT LETTER AND A FILE WITH ALL RECEIPTS. VIN# [XXX] - 2004 PASSAT GLS 1.8T INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10376474

84,300 miles · Oct 20, 2010
Engine And Engine Cooling

THE OWNER'S MANUAL STATES THAT THE ENGINE COOLANT IS NOT TO BE REPLACED. HOWEVER, I NOW HAVE A HEATER CORE THAT IS CLOGGED AND THAT CAUSES NO HEAT IN THE PASSENGER COMPARTMENT OF THE CAR. THE INSTRUCTIONS GIVEN TO CONSUMERS IN THE VOLKSWAGEN OWNER'S MANUAL IS IN ERROR AND LEADS TO EXPENSIVE REPAIR COSTS. *TR

NHTSA ODI #10361409

Mileage unknown · Aug 26, 2010
Engine And Engine Cooling

2004 VOLKSWAGEN PASSAT. CONSUMER EXPRESSES DISCONTENT WITH VW REGARDING DEFECTIVE ENGINES *TGW THE CONSUMER STATED VW HAS ACKNOWLEDGED THAT THE ENGINE'S WERE DEFECTIVE. *JB

NHTSA ODI #10352128

35,000 miles · Aug 17, 2010
Engine And Engine Cooling

"OIL SLUDGE" RELATED REPAIRS ON '98-04 MODEL YEAR VW PASSAT EQUIPPED WITH 1.8L TURBO ENGINES. WAS NOT NOTIFIED UNTIL ENGINE LIGHT CAME ON MARCH 2010. LETTER FROM VW OF AMERICA DID NOT PRESCRIBE 3000 MILE OIL CHANGE, BUT WHEN CONTACTED, SAID IN ORDER FOR "EXTENDED WARRANTY TO BE ENFORCED" VEHICLE MUST HAVE 3000 MILE OIL CHANGE.…

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"OIL SLUDGE" RELATED REPAIRS ON '98-04 MODEL YEAR VW PASSAT EQUIPPED WITH 1.8L TURBO ENGINES. WAS NOT NOTIFIED UNTIL ENGINE LIGHT CAME ON MARCH 2010. LETTER FROM VW OF AMERICA DID NOT PRESCRIBE 3000 MILE OIL CHANGE, BUT WHEN CONTACTED, SAID IN ORDER FOR "EXTENDED WARRANTY TO BE ENFORCED" VEHICLE MUST HAVE 3000 MILE OIL CHANGE. LETTER FROM VW SUBSEQUENTLY FAXED OVER ON 3/22/10 DOES NOT STATE RULES REGULATING OIL CHANGE OR SUBSEQUENT LIMITATIONS ON "EXTENDED WARRANTY". MY 04 VW PASSAT WITH 35K MILES HAD TO HAVE A NEW ENGINE, AND HAD I SEEN THE AUGUST '04 LETTER PRIOR TO 03/10 WOULD HAVE GOTTEN RID OF CAR AS SOON AS I READ LETTER. THE ENGINE IS CLEARLY DEFECTIVE, AND VW HAS AN OBLIGATION TO INFORM ALL VW OWNERS OF THESE VEHICLES TO INFORM THEM OF THIS DEFORMITY. I BOUGHT THE CAR NEW IN 2004 AND NEVER SAW A COPY OF THIS LETTER UNTIL MY ENGINE FAILED. THE LETTER STATES 5000 MILE OIL CHANGE INTERVALS, BUT WHEN I PRESENTED PROOF TO GUNTHER VW OF COCONUT CREEK FLORIDA, THAT MY CAR WAS IN COMPLIANCE, THEY STATED THAT IT HAD TO BE 3000 MILE INTERVALS. THERE ARE OVER 197000 WEBSITES, AND BLOGS DEALING WITH THE VW 1.8 TURBO, BUT NO ONE HAS ADDRESSED THIS PROBLEM, AND PEOPLE CONTINUE TO BUY THESE CARS OFF USED CAR LOTS, UNAWARE THAT THEY ARE BUYING A CAR WITH LIMITED EXPECTATIONS, AND POSSIBLE ENGINE REPLACEMENT. PLEASE FEEL FREE TO CONTACT ME AT [XXX]. SO THAT WE CAN DISCUSS SAVING SOMEONE'S LIFE BEFORE THIS CAR'S ENGINE FAILURE IN HEAVY TRAFFIC. YOU HAVE OFFICIALLY BEEN NOTIFIED OF THE DANGERS OF THIS ENGINE. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10350155

75,000 miles · Apr 18, 2010
Engine And Engine Cooling

OIL SLUDGE IS CLOGGING OIL PICK UP AND STOP/OIL LIGHT IS GOING ON. STARVING ENGINE OF OIL. FULL SYNTHETIC OIL HAS ALWAYS BEEN USED. *TR

NHTSA ODI #10326260

35,000 miles · Apr 11, 2010
Engine And Engine Cooling

I OWN A 2004 VW PASSAT WITH 35000 MILES. THE CAR IS LIKE NEW, EXCEPT THE STOP ENGINE LIGHT CAME ON. TOOK IT TO A LOCAL MECHANIC, AND THEY DID NOT ADDRESS THE PROBLEM. TOOK IT TO GUNTHER VW IN COCONUT CREEK FLORIDA, FOR A DIAGNOSTIC. I WAS TOLD TO GO HOME AND THEY WOULD CALL ME WITH THE RESULTS. THEY LEFT A MESSAGE THAT THE …

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I OWN A 2004 VW PASSAT WITH 35000 MILES. THE CAR IS LIKE NEW, EXCEPT THE STOP ENGINE LIGHT CAME ON. TOOK IT TO A LOCAL MECHANIC, AND THEY DID NOT ADDRESS THE PROBLEM. TOOK IT TO GUNTHER VW IN COCONUT CREEK FLORIDA, FOR A DIAGNOSTIC. I WAS TOLD TO GO HOME AND THEY WOULD CALL ME WITH THE RESULTS. THEY LEFT A MESSAGE THAT THE CAR NEEDED A NEW ENGINE, AND TO COME AND GET MY CAR. I CALLED AND ASKED WHAT WERE MY OPTIONS AND THEY SAID THE CAR NEEDED A NEW ENGINE FOR $8600. I CALLED VW CORPORATE, THEY SAID THAT THERE WAS A LETTER SENT IN 2004 TO THE OWNERS OF CARS WITH THE 1.8 TURBO, I HAD NEVER SEEN THIS LETTER. IT WAS FAXED TO ME, I WAS STUNNED AT THE TONE OF THE LETTER, IF I HAD SEEN THIS LETTER I IMMEDIATELY WOULD HAVE GOTTEN RID OF THIS CAR. THERE ARE 197000 WEBSITES CONCERNING THIS ENGINE, AND PEOPLE ARE STILL BUYING THESE CARS WITHOUT BEING TOLD THEY ARE BUYING A CAR WITH A DEFECTIVE ENGINE. VW NOW STATES THAT THIS ENGINE NEEDS AN OIL CHANGE EVERY 3000MILES, AND IF YOU GO PAST THE 3000 MILE MARK, THEY ARE NOT RESPONSIBLE FOR THE ENGINES PERFORMANCE. THESE CARS SHOULD BE RECALLED BEFORE SOMEONE IS KILLED WHEN THEIR ENGINE STOPS IN TRAFFIC. *TR

NHTSA ODI #10324933

75,000 miles · Jan 15, 2010
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN PASSAT. ON OCTOBER 24, 2009 SHE NOTICED THAT THE VEHICLE HAD AN OIL LEAK. THE DEALER REPLACED THE OIL PAN AT THE OWNERS EXPENSE FOR $500. ON JANUARY 12, 2010, THE OIL FAILURE RECURRED; HOWEVER, THE DEALER REPLACED THE OIL TANK FOR $500. SHE STATED THAT THE FAILURES OCCURRED WHEN SHE DROVE OV…

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TL*THE CONTACT OWNS A 2004 VOLKSWAGEN PASSAT. ON OCTOBER 24, 2009 SHE NOTICED THAT THE VEHICLE HAD AN OIL LEAK. THE DEALER REPLACED THE OIL PAN AT THE OWNERS EXPENSE FOR $500. ON JANUARY 12, 2010, THE OIL FAILURE RECURRED; HOWEVER, THE DEALER REPLACED THE OIL TANK FOR $500. SHE STATED THAT THE FAILURES OCCURRED WHEN SHE DROVE OVER A SPEED BUMP AND A ROCK WHILE DRIVING APPROXIMATELY 15 MPH. THE MANUFACTURER STATED THAT THERE WERE NO RECALLS FOR THE OIL PAN; THEREFORE, THEY WOULD NOT ASSIST WITH THE REPAIR COST. THE FAILURE AND CURRENT MILEAGES WERE 75,000. *CN UPDATED 02/17/20

NHTSA ODI #10299885

80,499 miles · Jan 7, 2010
Engine And Engine Cooling

PURCHASED A USED 2004 VW PASSAT IN APRIL 09. DID NOT PURCHASE AN EXTENDED WARRANTY FOR THE VEHICLE, HOWEVER, SUCH WOULD NOT HAVE COVERED THIS ISSUE REGARDLESS. THE PASSAT HEATING/AIR CONDITIONING SYSTEM IS A CLIMATRONIC. THE VENTS AND AIRCONDITIONING OPERATED AS THEY SHOULD. AFTER PURCHASE, NOTICED ON COOL MORNINGS THAT VEHICLES…

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PURCHASED A USED 2004 VW PASSAT IN APRIL 09. DID NOT PURCHASE AN EXTENDED WARRANTY FOR THE VEHICLE, HOWEVER, SUCH WOULD NOT HAVE COVERED THIS ISSUE REGARDLESS. THE PASSAT HEATING/AIR CONDITIONING SYSTEM IS A CLIMATRONIC. THE VENTS AND AIRCONDITIONING OPERATED AS THEY SHOULD. AFTER PURCHASE, NOTICED ON COOL MORNINGS THAT VEHICLES HEAT WS NOT OPERATING CORRECTLY NECESSARY FOR DEFROSTING/DEFOGGING WINDSHIELD AND WINDOWS. TOOK VEHICLE BACK TO DEALERSHIP AND REQUESTED DIAGNOSTIC. DIAGNOSTIC WAS NO FLOW THROUGH HEATER CORE AND RECOMMENDATION WAS REPLACEMENT OF HEATER CORE IN ORDER TO RECEIVE HEAT. NO INDICATION OF ANY POSED DANGER OR THREAT WAS INDICATED BY DEALERSHIP AS TO THIS ISSUE. THREE MONTHS AFTER THE DIAGNOSIS, HAVING OPERATED THE VEHICLE WITH NO HEAT FOR 6 MONTHS, THE VEHICLE HAS NOW BEGUN TO LEAK MASSIVE AMOUNTS OF ANTIFREEZE/COOLANT, HOWEVER, THE COOLANT IS NOT LEAKING OUT OF THE CAR, I CANNOT SEE ANY COOLANT OR VERY LITTLE COOLANT ANYWHERE UNDERNEATH, THEREFORE I CAN ONLY ASSUME THAT THE ANTIFREEZE IS LEAKING INTO THE VEHICLE, POSSIBLY POSING A FIRE HAZARD AND RISK OF BEING BURNED SHOULD THE PRESSURE OF THE COOLANT SYSTEM BECOME TO GREAT AND THE VOLUME OF ANTIFREEZE IN MY VEHICLE IS UNKNOWN. I AM NOT OPERATING THE VEHICLE AT THIS TIME. I CONTACTED VW CUSTOMER CARE AND INFORMED THEM OF THIS PROBLEM, THE INDICATED MY VEHICLE IS TOO OLD AND HAS TOO MANY MILES ON IT FOR ANY GOODWILL REPLACEMENT. HOWEVER, THERE WAS A RECALL ON VW JETTAS FOR A SIMILAR ISSUE WITH THE HEATER CORE. *TR

NHTSA ODI #10298620

116,153 miles · Oct 17, 2009
Engine And Engine Cooling

WHILE DRIVING THE ENGINE LAMP CAME ON AND THE TEST MESSAGE INDICATED "EMISSION WORKSHOP". THE DEALERSHIP FOUND THE MASS AIR FLOW METER (P0101) TO BE FAULTY. IT WAS REPLACE BUT THE PROBLEM AND CODE RECURRED WITHIN 6 MILES. NEXT THE DEALERSHIP FOUND A CRACK IN THE TURBO AIR COOLER, IT WAS REPLACED BUT THE PROBLEM AND CODE RECUR…

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WHILE DRIVING THE ENGINE LAMP CAME ON AND THE TEST MESSAGE INDICATED "EMISSION WORKSHOP". THE DEALERSHIP FOUND THE MASS AIR FLOW METER (P0101) TO BE FAULTY. IT WAS REPLACE BUT THE PROBLEM AND CODE RECURRED WITHIN 6 MILES. NEXT THE DEALERSHIP FOUND A CRACK IN THE TURBO AIR COOLER, IT WAS REPLACED BUT THE PROBLEM AND CODE RECURRED WITHIN MILES. THE DEALERSHIP HAS HAD THE CAR FOR NEARLY 2 WEEKS WHEN THEY FOUND A SLIGHT AIR LEAK IN A TURBO HOSE. THE "O" RINGS WERE REPLACED AND IT MAY HAVE CORRECTED THE PROBLEM BUT I HAVE NOT HAD THE CAR SINCE THEY ARE STILL WORKING ON THE ENGINE SURGE PROBLEM. *TR

NHTSA ODI #10288798

Official recalls

3

08V156000 · Fuel System, Gasoline:delivery

Apr 7, 2008

VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN LEAK DUE TO FRACTURE.

Consequence & remedy

Consequence: A HEAT SHIELD THAT MAY CONTACT THE EXHAUST SYSTEM CAN RESULT IN A VEHICLE FIRE. IN ADDITION, A FUEL LEAK FROM A FUEL LINE OR FUEL TANK VENTILATION VALVE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN LEAD TO A VEHICLE FIRE.

Remedy: DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY SOFTWARE UPDATE. DEALERS WILL ALSO INSPECT AND ADJUST THE FUEL LINE ROUTING ON 1.8T VEHICLES AND THE FUEL TANK VENTILATION VALVE ON 4MOTION/ALL WHEEL DRIVE VEHICLES, AND REPLACE COMPONENTS IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON JUNE 13, 2008. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

07V063000 · Exterior Lighting:brake Lights:switch

Feb 20, 2007

ON CERTAIN PASSENGER, WAGON, AND CONVERTIBLE VEHICLES EQUIPPED WITH OR WITHOUT CRUISE CONTROL, A BRAKE LIGHT SWITCH MAY MALFUNCTION IF IT WAS INSTALLED INCORRECTLY.

Consequence & remedy

Consequence: THE BRAKE LIGHTS COULD BECOME INOPERATIVE, OR REMAIN ON. FAILURE TO PROVIDE THE PROPER SIGNAL WHEN BRAKING COULD LEAD TO A CRASH WITHOUT WARNING.

Remedy: DEALERS WILL INSTALL THE NEWLY DESIGNED BRAKE LIGHT SWITCH FREE OF CHARGE. THE RECALL BEGAN ON APRIL 27, 2007, AND WILL BE CONDUCTED IN SEVERAL STAGGERED MAILINGS THROUGH SEPTEMBER 21, 2007. VEHICLES WITHIN THE MAKE, MODEL, AND MODEL YEAR OF THIS POPULATION MAY BE INVOLVED IN EITHER THIS RECALL OR 06V-183, BUT NOT BOTH. THE REMEDY IS THE SAME FOR EACH RECALL. VOLKSWAGEN DEALERS WILL APPLY THE REMEDY BASED ON THE VIN NUMBER OF THE VEHICLE. OWNERS MAY CONTACT VW AT 1-800-822-8987.

04V586000 · Fuel System, Diesel

Dec 15, 2004

ON CERTAIN PASSENGER VEHICLES, THE HIGH PRESSURE DIESEL PUMPS WERE PRODUCED WITH AN IMPROPER FASTENER, WHICH COULD ALLOW DIESEL FUEL TO ESCAPE FROM THE PUMP.

Consequence & remedy

Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY LEAD TO A FIRE.

Remedy: DEALERS WILL REPLACE THE DIESEL PUMP. THE RECALL BEGAN ON FEBRUARY 8, 2005. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

3

EA11002 · Engine Compartment Fire

Opened Jan 26, 2011 · Closed Feb 17, 2012

Status: closed (inferred from source dates) · Electrical System; Engine And Engine Cooling

In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.

Additional source detail variants (2)

Electrical System

In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.

Engine And Engine Cooling

In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.

PE08008 · Fuel Tank Leak

Opened Jan 31, 2008 · Closed May 30, 2008

Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly; Fuel System, Other:storage:tank Assembly:pressure Relief Devices

VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.

Additional source detail variants (4)

Fuel System, Gasoline:storage:tank Assembly

VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.

Fuel System, Gasoline:storage:tank Assembly

VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.

Fuel System, Other:storage:tank Assembly:pressure Relief Devices

VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.

Fuel System, Other:storage:tank Assembly:pressure Relief Devices

VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.

EA07014 · Passenger Engine Compartment Fires

Opened Sep 28, 2007 · Closed Jul 7, 2008

Status: closed (inferred from source dates) · Electrical System:ignition; Engine And Engine Cooling:exhaust System

THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.

Additional source detail variants (2)

Electrical System:ignition

THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.

Engine And Engine Cooling:exhaust System

THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.