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2004 Volkswagen Touareg

Owner reports · Recalls · Investigations

More warning signs than most Touareg years

Owner complaints for the 2004 Volkswagen Touareg are substantially higher than the model-year median of 27.5.

About this comparison →

When problems were reported

Mileage at the reported incident

165 reports with mileage · 66 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.

  • Power Train. Review the 50 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Tires. Review the 36 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 reports5 fire reports6 injury reports

Electrical System complaints

49 reports
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100,000 miles · Jul 5, 2012
Electrical SystemSteering

I WENT TO START THE CAR IN MY DRIVEWAY AND A RED WARNING ICON APPEARED ON THE INSTRUMENT PANEL. I LOOKED IT UP IN THE OWNERS MANUAL WHICH STATED THE ICON INDICATED A STEERING SYSTEM FAILURE. FURTHER, THE IGNITION KEY THEN STUCK IN THE IGNITION SWITCH/LOCK AND COULD NOT BE REMOVED. AS A RESULT THE TRUCK'S TRANSMISSION GEAR SEL…

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I WENT TO START THE CAR IN MY DRIVEWAY AND A RED WARNING ICON APPEARED ON THE INSTRUMENT PANEL. I LOOKED IT UP IN THE OWNERS MANUAL WHICH STATED THE ICON INDICATED A STEERING SYSTEM FAILURE. FURTHER, THE IGNITION KEY THEN STUCK IN THE IGNITION SWITCH/LOCK AND COULD NOT BE REMOVED. AS A RESULT THE TRUCK'S TRANSMISSION GEAR SELECTOR COULD NOT BE TAKEN OUT OF THE "PARK" DETENT. THIS RESULTED IN MY NOT BEING ABLE TO GET THE TRUCK TO A POSITION WHERE A TOW TRUCK COULD ACCESS THE CAR UNTIL THE SNOW MELTED TWO MONTHS LATER. THE VW AUTHORIZED REPAIR CENTER DIAGNOSED THE PROBLEM AS A FAILURE IN THE STEERING COLUMN. FURTHER, THEY STATED THAT THIS IS A COMMON FAILURE MODE FOR THIS MODEL AND THEY BELIEVED A RECALL OR CAMPAIGN WAS IMMINENT. THIS IS A SERIOUS DESIGN FLAW. IF IT HAD FAILED WHILE BEING DRIVEN THE RESULTS COULD HAVE BEEN CATASTROPHIC. ALSO VW MARKETS THIS TRUCK AS SUITABLE FOR OFF ROAD TRAVEL IN REMOTE PLACES, IF IT FAILED WHILE I WAS IN A REMOTE AREA, I COULD HAVE BEEN STRANDED AND PLACED IN GRAVE PERIL SINCE I WOULD NOT BEEN ABLE TO ROLL THE TRUCK TO AN AREA SUITABLE FOR RECOVERY OR FLAT TOW IT IF NECESSARY. *TR

NHTSA ODI #10464286

91,000 miles · Feb 21, 2011
Electrical SystemFuel System, Gasoline

CONSTANT REPAIR OF 2004 VW TOUAREG: THIS VEHICLE HAS BEEN CERTIFIED IN ALL STATES OF THE UNION AS BEING A CERTIFIED LEMON. WHEN I PURCHASED THE VEHICLE I HAD NO IDEA OF THIS. I HAVE HAD TO REPLACE A FAN SENSOR WHICH IS A CERTIFIED VW DEFECT, BUT I HAD TO PAY FOR THE COST, REPAIR AND LABOR IN THE AMOUNT OF $550 AND FURTHER, TH…

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CONSTANT REPAIR OF 2004 VW TOUAREG: THIS VEHICLE HAS BEEN CERTIFIED IN ALL STATES OF THE UNION AS BEING A CERTIFIED LEMON. WHEN I PURCHASED THE VEHICLE I HAD NO IDEA OF THIS. I HAVE HAD TO REPLACE A FAN SENSOR WHICH IS A CERTIFIED VW DEFECT, BUT I HAD TO PAY FOR THE COST, REPAIR AND LABOR IN THE AMOUNT OF $550 AND FURTHER, THE VEHICLE LEFT ME STRANDED BECAUSE THE FAULTY SENSOR ALLOWED A FAN TO KEEP BLOWING THEREBY DRAINING MY BATTERY COMPLETELY. REAR WINDSHIELD WIPER DISINTEGRATED DURING HEAVY RAIN AND COST 65 TO REPAIR ALTHOUGH THE PIECE LOOKS LIKE SOMETHING A CHILD PUT TOGETHER. FRONT WINDSHIELD WIPER FLEW OFF OF CAR WHILE RAINING, CAUSING ME TO PULL OVER AND BE STRANDED ONCE AGAIN. I GOT STRANDED AGAIN BECAUSE THE VW ENGINE COILS BURNT OUT WITHOUT NOTICE LEAVING ME STRANDED IN BLIZZARD CONDITIONS IN CHICAGO. I HAD TO GET A NEW BATTERY BUT WAS CHARGED $250 FOR THE BATTERY AND INSTALLATION BECAUSE VW CHOSE TO PUT THE BATTERY UNDER THE FRONT DRIVER'S SEAT. NOT THREE WEEKS HAVE PASSED AND I HAVEN'T EVEN DRIVEN THE VEHICLE BUT BOTH FUEL PUMPS AND THE FLANGE MODULE HAVE GONE OUT. I HAD TO PAY $1500 FOR LABOR, PARTS, SHOP AND REPAIRS. VEHICLE HAS 91,000 AND BRAKES AND ROTORS HAVE GONE OUT AGAIN FOR THE 3RD TIME. RIGHT DOOR OPENS WHEN DRIVING ALTHOUGH THE VEHICLE IS LOCKED, WHICH IS ANOTHER CERTIFIED DEFECT. VEHICLE LUNGES FORWARD FROM A STOPPED POSITION AND THEN HESITATES WHEN TRYING TO SPEED UP ON THE HIGHWAY. *TR

NHTSA ODI #10383882

75,285 miles · Aug 5, 2010
Electrical SystemPower TrainStructure

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THE GEAR SHIFT SELECTOR WOULD NOT MOVE OUT OF PARK AND HE WAS UNABLE TO REMOVE THE KEY FROM THE IGNITION. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER. WHILE THE VEHICLE WAS BEING TOWED, THE ENTIRE CONSOLE AND WARNING LIGHTS ILLUMINATED. IN ADDITION, THE CONTAC…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THE GEAR SHIFT SELECTOR WOULD NOT MOVE OUT OF PARK AND HE WAS UNABLE TO REMOVE THE KEY FROM THE IGNITION. THE VEHICLE WAS TOWED TO AN AUTHORIZED DEALER. WHILE THE VEHICLE WAS BEING TOWED, THE ENTIRE CONSOLE AND WARNING LIGHTS ILLUMINATED. IN ADDITION, THE CONTACT STATED WATER WAS ENTERING THE VEHICLE AND SETTLING IN THE TRUNK NEAR THE SPARE TIRE. THE DEALER REMOVED THE SHIFTER CABLE AND REPLACED THE HARNESS, A WIRE AND THE SHIFTER COLUMN. THE FAILURE MILEAGE WAS 75,285 AND THE CURRENT MILEAGE WAS 76,065. UPDATED 11/02/10. *LJ THE CONSUMER STATED THE TRUNK WOULD NOT OPEN PROPERLY. THE TIRE SENSORS WOULD COME ON. THE IGNITION SWITCH WAS DEFECTIVE AND HAD TO BE REPLACED. UPDATED 11/04/10

NHTSA ODI #10347465

95,000 miles · Jun 4, 2010
Air BagsElectrical SystemLatches/locks/linkages

2004 VW TOUAREG V-8 MANY PROBLEMS BUT 3 WORTH REPORTING: FOR NO APPARENT REASON PASSENGER DOOR COULD NOT BE OPENED OR UNLATCHED BY USING ANY KNOWN MEANS INCLUDING THE INSIDE DOOR HANDLE OR OUTSIDE DOOR HANDLE, ELECTRIC LOCK ACTUATOR CLICKS AS IF THE DOOR IS UNLOCKED BUT THE DOOR CAN NOT BE OPENED OR UNLATCHED. VEHICLE HAD TO…

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2004 VW TOUAREG V-8 MANY PROBLEMS BUT 3 WORTH REPORTING: FOR NO APPARENT REASON PASSENGER DOOR COULD NOT BE OPENED OR UNLATCHED BY USING ANY KNOWN MEANS INCLUDING THE INSIDE DOOR HANDLE OR OUTSIDE DOOR HANDLE, ELECTRIC LOCK ACTUATOR CLICKS AS IF THE DOOR IS UNLOCKED BUT THE DOOR CAN NOT BE OPENED OR UNLATCHED. VEHICLE HAD TO BE BROUGHT TO VW DEALERSHIP AND WORKED ON BY DESTROYING THE DOOR HANDLE TO OPEN THE DOOR AND PERHAPS CUTTING A WHOLE IN THE BODY PANNEL AT THE COST OF 2 HOURS OF DIAGNOSTICS, 8 HOURS OF LABOR TO OPEN DOOR AND PROBABLY 2 OR 3 ADDITIONAL HOURS OF REPLACING DOOR HANDLE IF BODY OF DOOR IS NOT BENT, PLUS PARTS VEHICLE HAS MANY ELECTRICAL GLITCHES INCLUDING BUT NOT LIMITED TO INTERMITTENT MALFUNCTION OF AIR BAG IGNITERS....ONCE AGAIN HAVING THE POTENTIAL TO CAUSE SERIOUS HARM OCCUPANTS GIVEN THE RIGHT CIRCUMSTANCES THIS IS A POTENTIAL DANGEROUS SITUATION AND HAS MADE ME LOSE ALL FAIH IN THIS MANUFACTURER. VEHICLE LUNGES FORWARD WHEN STOPPED AT TRAFIC LIGHTS AND BEGINNING TO PROCCEED ON A GREEN. *TR

NHTSA ODI #10334661

19,549 miles · Feb 5, 2010
Electrical SystemLatches/locks/linkagesSteering

UNEXPECTED AND SUDDEN ELECTRICAL MALFUNCTION OF THE STEERING COLUMN LOCK CAUSING THE VEHICLE TO SHUT DOWN, UNABLE TO START OR MOVE SHIFTER LEVER OUT OF GEAR. *TR

NHTSA ODI #10306349

62,000 miles · Jan 15, 2010
Electrical System

STRANDED WITH A DEAD BATTERY ON MULTIPLE OCCASIONS AS A RESULT OF A ELECTRICAL SYSTEM FAILURE WHICH VW ISSUED A TECHNICAL SERVICE BULLETIN ON AND FAILED TO NOTIFY THE CONSUMER THAT THERE WAS AN ISSUE WHILE UNDER WARRANTY. *TR UPDATED 01/25/10 *BF UPDATED 01/26/10.*JB

NHTSA ODI #10299865

Mileage unknown · Dec 22, 2008
Electrical SystemEngine And Engine CoolingPower Train

I HAVE HAD MY 2004 VW TOUAREG SINCE JUNE 2006 AND HAVE HAD PROBLEM AFTER PROBLEM WITH THE VEHICLE. THE CATALYTIC CONVERTER WENT OUT WITHIN 6 WEEKS OF BUYING THE CAR, THE DRIVE SHAFT HAD TO BE REPLACED, THE AIR CONDITIONING COMPRESSOR HAD TO BE REPLACED, THE BRAKES HAVE HAD TO BE REPLACED AND I AM GETTING ANOTHER "CHECK BRAKE PA…

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I HAVE HAD MY 2004 VW TOUAREG SINCE JUNE 2006 AND HAVE HAD PROBLEM AFTER PROBLEM WITH THE VEHICLE. THE CATALYTIC CONVERTER WENT OUT WITHIN 6 WEEKS OF BUYING THE CAR, THE DRIVE SHAFT HAD TO BE REPLACED, THE AIR CONDITIONING COMPRESSOR HAD TO BE REPLACED, THE BRAKES HAVE HAD TO BE REPLACED AND I AM GETTING ANOTHER "CHECK BRAKE PADS" ERROR AGAIN, THE TIRE MONITORING SYSTEM CONTINUALLY TELLS ME I HAVE A FLAT, THE RADIO AMPLIFIER WAS MAKING A LOUD CRACKING SO THE DEALERSHIP REPLACED A FUSE AND BLEW THE 2 BACK SPEAKERS (WHICH THEY WOULD NOT FIX, HEWLETT VW IN GEORGETOWN, TEXAS), THE AUTO DIFFERENTIAL IS GOING OUT. THERE SEEMS TO BE NO END IN SIGHT FOR REPAIRS. *TR

NHTSA ODI #10252545

44,000 miles · Aug 15, 2008
Electrical SystemEngine And Engine CoolingPower TrainFire

MULTIPLE ENGINE LIGHT FAILURES FOR OVER 4 YEARS. ENGINE LIGHT CAME ON AND ENGINE SHUT DOWN IMMEDIATELY WHILE WIFE WAS ON THE FREEWAY. VERY DANGEROUS...ESSENTIALLY NO WARNING. HAVE REPLACED WIRING HARNESS IN THE VEHICLE AND HAVE HAD IT IN THE SHOP FOR ELECTRICAL ISSUES MANY TIMES. UNSAFE HANDLING AND ACCELERATION...CAR JUMPS …

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MULTIPLE ENGINE LIGHT FAILURES FOR OVER 4 YEARS. ENGINE LIGHT CAME ON AND ENGINE SHUT DOWN IMMEDIATELY WHILE WIFE WAS ON THE FREEWAY. VERY DANGEROUS...ESSENTIALLY NO WARNING. HAVE REPLACED WIRING HARNESS IN THE VEHICLE AND HAVE HAD IT IN THE SHOP FOR ELECTRICAL ISSUES MANY TIMES. UNSAFE HANDLING AND ACCELERATION...CAR JUMPS FORWARD AT STOPS WHILE IT IS DOWNSHIFTING. THINK THE TRANSMISSION, TIRES AND BRAKES SHOULD BE TESTED. THINK YOU WILL FIND THEY ARE DEFECTIVE. ENGINE BLEW UP AT 44,000 MILES. VERY DANGEROUS CAR..AND YOU WILL FIND OTHER TOUAREGS WITH SIMILAR ISSUES. SHOULD BE RECALLED. *TR

NHTSA ODI #10238426

34,000 miles · Oct 15, 2007
Electrical SystemPower Train

THE ESP LIGHT CAME ON STEADY AND THE LIGHTS AROUND THE DIFFERENTIAL SWITCH CAME ON FLASHING. THEN THE VEHICLE LOST ELECTRICAL POWER AND WOULD NOT START. I HAD IT TOWED INTO THE DEALER AND THE SERVICE PEOPLE INDICATED THERE WERE NUMEROUS RECALLS ON THIS VEHICLE THAT CAUSED THIS PROBLEM. I WAS NEVER NOTIFIED OF THESE RECALLS. *TR

NHTSA ODI #10205718

100 miles · Mar 30, 2007
Electrical SystemExterior LightingService Brakes, Hydraulic

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE WARNING TONE OF THE TIRE PRESSURE MONITORING SYSTEM SOUNDS INTERMITTENTLY. IN ADDITION, THE HEADLIGHTS FAILED, AND THE VEHICLE PULLED TO THE RIGHT SPORADICALLY AND WITHOUT WARNING. THE DEALER WAS UNABLE TO DIAGNOSE THE CAUSE OF FAILURE. THE CONTACT POSSESSED THE REPAIR IN…

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TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE WARNING TONE OF THE TIRE PRESSURE MONITORING SYSTEM SOUNDS INTERMITTENTLY. IN ADDITION, THE HEADLIGHTS FAILED, AND THE VEHICLE PULLED TO THE RIGHT SPORADICALLY AND WITHOUT WARNING. THE DEALER WAS UNABLE TO DIAGNOSE THE CAUSE OF FAILURE. THE CONTACT POSSESSED THE REPAIR INVOICES. THE FAILURE MILEAGE BEGAN AT 100. *AK THE CONSUMER STATED THE FAILURES CONTINUE, SHE HAS HAD MULTIPLE PROBLEMS WITH THIS VEHICLE BRAKE ROTORS REPLACE AT 15,000 MILES, BRAKE PADS HAD TO BE REPLACED AT 18,000 MILES, TWO TIRES REPLACE AT 16,000 MILES, TPS LIGHTS CONTINUE TO GO ON AND OFF BEEN FIXED, FOUR NEW TIRES AT 30,000 MILES. THE CONSUMER STATES THAT THERE HAVE BEEN 9 RECALLS AND TPS LIGHTS STILL IN FAILURE. UPDATE 05/04/07*TR

NHTSA ODI #10186546

Official recalls

4

17V583000 · Fuel System, Gasoline:delivery:fuel Pump

Sep 20, 2017

Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2004-2007 Touareg vehicles. These gasoline-powered vehicles have a fuel filter flange that may crack, allowing fuel to leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy: Volkswagen will notify owners, and dealers will inspect the fuel filter flange for cracks, replacing the flange if cracks are found. If no cracks are found, a protective cover will be installed onto the filter flange. These repairs will be performed free of charge. The recall began March 9, 2018. Owners may contact Volkswagen customer service at 1-800-893-5298. Volkswagen's number for this recall is 20Ai.

04V592000 · Seat Belts

Dec 15, 2004

CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." ALL THREE REAR SEAT POSITIONS AND THE FRONT PASSENGER POSITION ARE EQUIPPED WITH SEAT BELT RETRACTORS THAT HAVE A LOCKING FEATURE WHICH CONVERTS THE RETRACTOR FROM AN EMERGENCY LOCKING RETRACTOR (ELR) MODE TO AN AUTOMATIC LOCKING RETRACTOR (ALR) MODE FOR THE PURPOSES OF CHILD RESTRAINT INSTALLATION. THE BELT MAY DEACTIVATE THE ALR MODE WITH CERTAIN CHILD RESTRAINTS.

Consequence & remedy

Consequence: WHEN INVOLVED IN A CRASH, THE CHILD RESTRAINTS MAY NOT BE PROPERLY SECURED, INCREASING THE RISK OF INJURIES OR DEATH.

Remedy: DEALERS WILL PERMANENTLY INSTALL A 'CLIP' IN EACH OF THE TWO REAR OUTBOARD SEAT BELTS. THE CLIPS WILL PREVENT UNWANTED DEACTIVATION OF THE ALR MODE WITH CHILD SEAT INSTALLATIONS. THE RECALL BEGAN ON APRIL 11, 2005. OWNERS SHOULD CONTACT VW AT 1-800-822-8987.

04V233000 · Seat Belts:rear/other

May 19, 2004

ON CERTAIN SPORT UTILITY VEHICLES, THE REAR SEAT BELT LATCH ATTACHMENT BOLT MAY HAVE BEEN INSUFFICIENTLY RIVETED.

Consequence & remedy

Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE BELT BUCKLE. OWNER NOTIFICATION BEGAN ON JUNE 21, 2004. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

03V266000 · Electrical System:wiring

Jul 25, 2003

ON CERTAIN SPORT UTILITY VEHICLES, THE TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING HARNESS MAY HAVE BEEN IMPROPERLY ROUTED DURING ASSEMBLY. AN IMPROPERLY ROUTED TPMS WIRING HARNESS MAY CONTACT THE PARKING BRAKE CABLE SPRING.

Consequence & remedy

Consequence: IF THIS HAPPENS, THE TPMS WIRING CIRCUIT COULD BE INTERRUPTED, RESULTING IN AN INOPERATIVE TPMS, AND CAUSING A SHORT-TO-GROUND CONDITION THAT COULD POTENTIALLY RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE TPMS WIRING HARNESS ROUTING AND, IF NECESSARY, CORRECT THE WIRING HARNESS ROUTING. OWNER NOTIFICATION BEGAN AUGUST 18, 2003. OWNERS SHOULD CONTACT VWOA AT 1-800-893-5298.

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

2

PE06022 · Srs Warning Light Illumination

Opened Jun 19, 2006 · Closed Oct 30, 2006

Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.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.

Additional source detail variants (2)

Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.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.

Air Bags

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.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.

PE05042 · Exterior Door Handle Malfunction

Opened Aug 11, 2005 · Closed Dec 21, 2005

Status: closed (inferred from source dates) · Latches/locks/linkages:doors:latch

VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB) DATED JUNE 10, 2005, DESCRIBING A CONDITION OF EXTERIOR DOOR HANDLE STICKS IN THE OPENED POSITION AFTER THE DOOR IS OPENED.VW DESCRIBED THE CAUSE OF THE PROBLEM TO BE A POTENTIAL FOR INCREASED FRICTION BETWEEN THE DOOR HANDLE AND THE LOCK CYLINDER HOUSING . . . BECAUSE SOME GUIDE NUBS THAT WERE MOLDED INTO THE PLASTIC DOOR HANDLE . . . WERE SLIGHTLY HIGHER THAN SPECIFIED.IN ADDITION TO THE TSB, VW HAS INTRODUCED PRODUCTION CHANGES (LUBRICATION, DELETION OF THE GUIDE NUBS, INTRODUCTION OF A LOW FRICTION GUIDE SURFACE ON THE LOCK CYLINDER HOUSING) TO ADDRESS THE PROBLEM.VW REPORTS THAT THE FAILURE OCCURS PREDOMINANTLY IN THE VERY EARLY LIFE STAGE OF THE VEHICLE.ODI EXAMINATION OF VW'S WARRANTY DATA SHOWS FEWER CLAIMS AS THE VEHICLE AGES.THE ONE INJURY RESULTED WHEN THE UNLATCHED DOOR HIT THE OCCUPANT'S HAND.A SAFETY 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.ODI WILL CONTINUE TO MONITOR COMPLAINTS ANDRESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.