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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.

About this comparison →

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

Service Brakes, Hydraulic complaints

11 reports
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85,000 miles · Oct 5, 2013
Engine And Engine CoolingService Brakes, Hydraulic

I WAS DRIVING INSIDE TOWN APPROXIMATELY AT 35 MPH AND WAS STOPPING IN THE STOP LIGHT. WHEN I APPLIED THE BRAKE THE CAR WAS SHAKING AND CHECK ENGINE LIGHT STARTED FLASHING. AFTER THE STOP LIGHT TURNED GREEN I RELEASED BRAKE AND THE SHAKE WAS NOT THERE AND CHECK ENGINE LIGHT WAS GONE. I WENT FEW MILES TO PICK MY DAUGHTER AND AFTER…

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I WAS DRIVING INSIDE TOWN APPROXIMATELY AT 35 MPH AND WAS STOPPING IN THE STOP LIGHT. WHEN I APPLIED THE BRAKE THE CAR WAS SHAKING AND CHECK ENGINE LIGHT STARTED FLASHING. AFTER THE STOP LIGHT TURNED GREEN I RELEASED BRAKE AND THE SHAKE WAS NOT THERE AND CHECK ENGINE LIGHT WAS GONE. I WENT FEW MILES TO PICK MY DAUGHTER AND AFTER PICKING MY DAUGHTER AND LESS THAN A MILE ON ROAD THE CHECK ENGINE LIGHT CAME ON AGAIN AND THERE IS A SLIGHT VIBRATION OF THE VEHICLE WHEN THE ENGINE IS TURNED ON. I'M YET TO TAKE THE VEHICLE TO THE REPAIR SHOP. NOT SURE IF THERE IS ANY FACTORY RECALL FOR THIS PROBLEM. *TR

NHTSA ODI #10546821

59,000 miles · Nov 18, 2010
Air BagsService Brakes, HydraulicCrash

I WAS DRIVING THE CAR AROUND 40 MPH IN DOWNTOWN LOS ANGELES IN THE AFTERNOON AND I WAS THE ONLY OCCUPANT. THE VEHICLE IN FRONT OF ME SUDDENLY SLOWED DOWN. I PRESSED THE BRAKES HARD BUT THE CAR DID NOT STOP AND I TRIED TO SWERVE TO THE SHOULDER BUT THERE WAS NOT ENOUGH ROOM. I REAR-ENDED THE VEHICLE IN FRONT OF ME. I WAS PUZZLED…

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I WAS DRIVING THE CAR AROUND 40 MPH IN DOWNTOWN LOS ANGELES IN THE AFTERNOON AND I WAS THE ONLY OCCUPANT. THE VEHICLE IN FRONT OF ME SUDDENLY SLOWED DOWN. I PRESSED THE BRAKES HARD BUT THE CAR DID NOT STOP AND I TRIED TO SWERVE TO THE SHOULDER BUT THERE WAS NOT ENOUGH ROOM. I REAR-ENDED THE VEHICLE IN FRONT OF ME. I WAS PUZZLED AND BEWILDERED WHY THE CAR WAS NOT STOPPING EVEN THOUGH I WAS PRESSING ON THE BRAKES. I COULD SEE MYSELF APPROACHING THE VEHICLE IN FRONT OF ME AND WONDERING WHY I AM NOT STOPPING BUT AT THE SAME TIME TRYING TO SWERVE TOWARDS THE SHOULDER. THE AIRBAG ON THE DRIVER SIDE DID NOT DEPLOY BUT THE AIRBAG ON THE PASSENGER SIDE DEPLOYED EVEN THOUGH THERE WAS NO PASSENGER. *TR

NHTSA ODI #10366647

58,600 miles · Oct 11, 2008
Service Brakes, Hydraulic

I HAVE A 2004 PASSAT WAGON WITH 58,000 MILES. ABOUT 2 WEEKS AGO WE STARTED GETTING A "BRAKE FAULT" WARNING FOLLOWED BY A LARGE "STOP". IT LASTS FOR ABOUT 5 SECONDS AND THEN GOES AWAY. THIS ONLY HAPPENS IN THE MORNING, AND AFTER ABOUT 15 MINUTES OF DRIVING. AFTER THAT THERE WILL BE NO MORE WARNINGS UNTIL WE START THE CAR THE FOLL…

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I HAVE A 2004 PASSAT WAGON WITH 58,000 MILES. ABOUT 2 WEEKS AGO WE STARTED GETTING A "BRAKE FAULT" WARNING FOLLOWED BY A LARGE "STOP". IT LASTS FOR ABOUT 5 SECONDS AND THEN GOES AWAY. THIS ONLY HAPPENS IN THE MORNING, AND AFTER ABOUT 15 MINUTES OF DRIVING. AFTER THAT THERE WILL BE NO MORE WARNINGS UNTIL WE START THE CAR THE FOLLOWING MORNING. WE MAY GET ONE WARNING OR THREE DURING THE 15 MINUTES. WE TOOK THE CAR TO THE DEALER AND THEY SAID THERE WAS NOTHING IN THE CODES SHOWING A FAULT. THEY KEEP THE CAR OVER NIGHT, AND THE NEXT MORNING TOOK THE CAR FOR A DRIVE AND CONFIRMED THE "BRAKE FAULT". THEY TOLD US WE NEED REPLACE THE ABS MODULE AT A COST OF $900. OUR CAR ONLY HAS 58,000 MILES ON IT, AND IT WAS GARAGED MOST OF ITS LIFE. WE PICKED THE CAR UP FROM THE DEALER AND HAVE NOT FIXED THE PROBLEM YET. WE ARE JUST OUT OF WARRANTY, AND FEEL THIS SHOULD BE COVERED. TODD KNOEPPEL *TR

NHTSA ODI #10245166

Mileage unknown · Oct 18, 2007
Electronic Stability Control (esc)Service Brakes, Hydraulic

ABS LIGHT AND TRACTION CONTROL LIGHT STAY ON ALL THE TIME IN INSTRUMENT CLUSTER. *JB

NHTSA ODI #10206194

18,000 miles · Jun 19, 2007
Service Brakes, HydraulicCrashInjury

THE ABS HAS BEEN FAULTY FOR SIX MONTHS FROM TIME OF PURCHASE A S BRAND NEW. THE ABS LIT UP AND WILL STAY LIT UNTIL SERVICE DEPARTMENT RESET IT. THE BRAKE LIT UP AND GOT STUCK WITHOUT PRESSING ON BRAKE PEDAL. DASHBOARD LIGHTS MALFUNCTIONED, AND DID NOT COME ON THROUGH THIS FAILURE. VEHICLE SAT PARKED IN THE SERVICE DEPART…

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THE ABS HAS BEEN FAULTY FOR SIX MONTHS FROM TIME OF PURCHASE A S BRAND NEW. THE ABS LIT UP AND WILL STAY LIT UNTIL SERVICE DEPARTMENT RESET IT. THE BRAKE LIT UP AND GOT STUCK WITHOUT PRESSING ON BRAKE PEDAL. DASHBOARD LIGHTS MALFUNCTIONED, AND DID NOT COME ON THROUGH THIS FAILURE. VEHICLE SAT PARKED IN THE SERVICE DEPARTMENT OF DEALERSHIP FOR 15 MONTHS WITHOUT ANYONE INVESTIGATING THE PROBLEM. SWITCH HAS BEEN REPLACED 5 TIMES WITHIN 1.5 YEARS. THE ABS FAILED AND CAUSED AN ACCIDENT. *AK

NHTSA ODI #10193712

35,880 miles · Feb 26, 2007
Exterior LightingService Brakes, HydraulicCrashInjury

1. WHEN CAR IN FRONT OF THE PASSAT SLOWED, THE DRIVER APPLIED THE BRAKES AND THE ABS LIGHT AND ASR LIGHTS CAME ON BUT THE BRAKES DID NOT WORK. THE PASSAT WAS NOT GOING QUICKLY AND HAD SAFE STOPPING DISTANCE SO THE CAR HAD PLENTY OF TIME TO STOP. THE PASSAT DID NOT STOP, HITTING THE CAR AHEAD OF IT. 2. THE BRAKES FAILED, CAUSING…

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1. WHEN CAR IN FRONT OF THE PASSAT SLOWED, THE DRIVER APPLIED THE BRAKES AND THE ABS LIGHT AND ASR LIGHTS CAME ON BUT THE BRAKES DID NOT WORK. THE PASSAT WAS NOT GOING QUICKLY AND HAD SAFE STOPPING DISTANCE SO THE CAR HAD PLENTY OF TIME TO STOP. THE PASSAT DID NOT STOP, HITTING THE CAR AHEAD OF IT. 2. THE BRAKES FAILED, CAUSING THE PASSAT TO REAR-END THE CAR IN FRONT OF IT. THE DRIVER OF THE OTHER CAR SUSTAINED WHIPLASH INJURIES AND 600 USD TO HIS CAR. HE IS IN TREATMENT WITH THE COST OF TREATMENT UNDETERMINED AT THIS TIME. THE PASSAT SUSTAINED 3000 USD IN DAMAGE. THE DRIVER OF THE PASSAT WAS NOT INJURED, WAS TICKETED, LOST HALF A DAY'S WAGES IN COURT, AND DOES NOT TRUST HIS VEHICLE. 3. THE CAR WAS TAKEN TO THE VW DEALERSHIP, WHERE IT WAS DETERMINED THAT A BRAKE LIGHT SWITCH WAS DETERMINED TO BE ELECTRICALLY FAULTY. MALFUNCTIONS WERE STORED IN THE ABS CONTROL MODULE. THE BRAKE LIGHT SWITCH GAVE AN IMPLAUSIBLE SIGNAL, SPORADIC. THE BRAKE LIGHT SWITCH WAS DIAGNOSED AND REPLACED. THE FAULT MEMORY OF THE ABS CONTROL MODULE WAS ERASED AND RESET. THE DRIVER OF THE PASSAT CONTACTED VW ASKING ABOUT THE FAULT(S) AND EXPRESSING HIS DOUBT IN THE SAFETY AND RELIABILITY OF THE VEHICLE. THE DRIVER OF THE PASSAT FELT VW'S DEFECTIVE PARTS CAUSED THE ACCIDENT AND VW SHOULD COVER THE COST. VW'S ANSWER IS THAT THE DEFECTIVE PARTS COULD NOT HAVE CAUSED THE ACCIDENT. TONIGHT'S PAPER HAS ISSUED INFORMATION ABOUT A RECALL OF THIS PART HOWEVER, IT DOES NOT INCLUDE INFORMATION ABOUT PASSATS IN THIS RECALL. PASSATS HAVE THIS PROBLEM, TOO. WE DID NOT KNOW ABOUT YOUR ORGANIZATION OR WE WOULD HAVE CONTACTED YOU MONTHS AGO. *JB

NHTSA ODI #10183592

22,000 miles · Apr 10, 2005
Service Brakes, Hydraulic

AT THE 20000 MAINTENANCE INSPECTION THERE WAS NO OBSERVATION DONE BY THE DEALER. AT ABOUT 22K THE BRAKE PROBLEM WARNING LIGHT CAME ON AND THEN OFF. I TOOK THE CAR AT THE DEALER AND THEY FOUND THAT THE BACK BRAKE PADS ARE ALMOST COMPLETELY WORN OFF AND THEY NEED TO BE REPLACED AND THE BRAKE FLUID NEEDS TO BE FLUSHED. THE ESTIMAT…

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AT THE 20000 MAINTENANCE INSPECTION THERE WAS NO OBSERVATION DONE BY THE DEALER. AT ABOUT 22K THE BRAKE PROBLEM WARNING LIGHT CAME ON AND THEN OFF. I TOOK THE CAR AT THE DEALER AND THEY FOUND THAT THE BACK BRAKE PADS ARE ALMOST COMPLETELY WORN OFF AND THEY NEED TO BE REPLACED AND THE BRAKE FLUID NEEDS TO BE FLUSHED. THE ESTIMATED COST WAS MORE THAN 350$. I ASKED THEM TO GIVE ME AN EXPLANATION ON HOW THE BRAKES GOT WORN IN THE 2K BETWEEN THE 20K AND 22K SINCE THEY DID NOT TELL US ANYTHING ABOUT ANY BRAKES BEING WORN AT THE 20 MAINTENANCE INSPECTION. THEY HAD NO ANSWER ON THIS. I FINALLY DECIDED TO REPLACE THE BACK BRAKE PADS BECAUSE THE CAR WAS SHAKING ON BRAKING AND I FELT UNSAFE DRIVING IT. I DID NOT TRUST THE DEALER ANY MORE SO I DECIDED TO TAKE THE CAR TO A THIRD PARTY SHOP I TRUSTED, AND I HAD TO PAY 138$ TO REPLACE THE BACK BRAKE PADS.*AK

NHTSA ODI #10116696

16,000 miles · Dec 29, 2004
Electrical SystemService Brakes, Hydraulic

I HAVE A BRAND NEW 2004 VW PASSAT TDI WAGON THAT HAS NO TAIL LIGHTS. SIGNALS WORK, BRAKE LIGHTS WORK BUT, LICENSE PLATE LIGHT AND REAR PARKING/DRIVING LIGHTS DON'T WORK. CAR HAS NO BURNED OUT BULBS OR FUSES. MY CONCERN IS IF THE CAR HAS WIRING HARNESS PROBLEMS, IS THIS SOMETHING THAT OTHERS HAVE HAPPENING. ALSO ON A RAINY DAY …

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I HAVE A BRAND NEW 2004 VW PASSAT TDI WAGON THAT HAS NO TAIL LIGHTS. SIGNALS WORK, BRAKE LIGHTS WORK BUT, LICENSE PLATE LIGHT AND REAR PARKING/DRIVING LIGHTS DON'T WORK. CAR HAS NO BURNED OUT BULBS OR FUSES. MY CONCERN IS IF THE CAR HAS WIRING HARNESS PROBLEMS, IS THIS SOMETHING THAT OTHERS HAVE HAPPENING. ALSO ON A RAINY DAY THE ANTI LOCK BRAKE AND ELECTRONIC STABILITY PROGRAM IN THE SAME CAR FAILED BUT, WHEN THE CAR WAS PARKED AND RESTARTED THE COMPUTER RESET AND PROBLEM DISAPPEARED. IS THIS GOING TO BE A PROBLEM? *NM

NHTSA ODI #10104742

Mileage unknown · Dec 20, 2004
Service Brakes, Hydraulic

MY 2004 VW PASSAT HAD 13,823 WHEN THE REAR BRAKE PADS COMPLETELY WORE OUT. THE FRONT HAVE ONLY WORN OUT 8% TO THIS DAY (12/20/04). FIRST, THE CAR PULSATED WHEN THE BRAKES WERE APPLIED. SO, I PERSONALLY WENT TO THE DEALER TO FIND OUT WHAT THE PROBLEM WAS; WHICH WAS NO HELP. I WAS TOLD THERE WAS NOTHING WORNG. LATER, TO NO SUPRIS…

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MY 2004 VW PASSAT HAD 13,823 WHEN THE REAR BRAKE PADS COMPLETELY WORE OUT. THE FRONT HAVE ONLY WORN OUT 8% TO THIS DAY (12/20/04). FIRST, THE CAR PULSATED WHEN THE BRAKES WERE APPLIED. SO, I PERSONALLY WENT TO THE DEALER TO FIND OUT WHAT THE PROBLEM WAS; WHICH WAS NO HELP. I WAS TOLD THERE WAS NOTHING WORNG. LATER, TO NO SUPRISE OF MINE; THERE WAS. THE BRAKE LAMPS TURNED ON AND DIDNT GO OFF. EVEN WITH THE CAR IN PARK AND TURNED OFF. WITH THIS, I WENT TO THE DEALER WHO TOLD ME MY REAR BRAKE PADS WERE WORN. AT THE DEALERS, THE REAR ROTORS WERE REPLACED FOR FREE, BUT THE PADS WERE NOT. THIS IS SIMPLY DISRESPECTFUL, AS I AM NOT A CRAZY DRIVER AND HAD TO PAY $220 TO REPLACE DEFECTIVE BRAKE PADS. *AK

NHTSA ODI #10104174

2,500 miles · Jul 30, 2004
Service Brakes, HydraulicVehicle Speed Control

REPORTED WHEN SLOWING DOWN TO 5-10MPH CARE HESITATED AND THEN JERKED AS IF SOMEONE HIT FROM BEHIND, ALSO WHEN BRAKING TO STOP,CAR LURCHES FORWARD. VW DEALERSHIP REPLACED BRAKES AND ROTORS AND DID SOFTWARE UPDATE AFTER 3 TIMES IN SHOP. NOW CAR HESITATES WHEN EITHER SLOWING DOWN OR FROM STOP THEN KICKS IN ALL OF A SUDDEN,WILL BE C…

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REPORTED WHEN SLOWING DOWN TO 5-10MPH CARE HESITATED AND THEN JERKED AS IF SOMEONE HIT FROM BEHIND, ALSO WHEN BRAKING TO STOP,CAR LURCHES FORWARD. VW DEALERSHIP REPLACED BRAKES AND ROTORS AND DID SOFTWARE UPDATE AFTER 3 TIMES IN SHOP. NOW CAR HESITATES WHEN EITHER SLOWING DOWN OR FROM STOP THEN KICKS IN ALL OF A SUDDEN,WILL BE CALLING REGIONAL TECHNICIAN TO REPORT, STILL FEEL SLIGHT JERK AT SLOW SPEEDS. ALL HAPPENS WHEN ENGINE HOT OR COLD.*AK

NHTSA ODI #10083031

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.