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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

Engine And Engine Cooling complaints

22 reports
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300 miles · Apr 9, 2006
Engine And Engine CoolingPower TrainService Brakes, HydraulicCrash

I BROUGHT A VOLKSWAGEN TOUAREG. THIS VEHICLE HAS A LOT PROBLEMS WITH THE BRAKE AND ENGINE. SO I FILED A LEMON REQUEST. LAST MONTH, VW ASKED ME TO DROP THIS VEHICLE TO VW DEALER TO INVESTIGATE THE BRAKE PROBLEM. ON MARCH 23, THE VW EXPERT TEST DROVE MY TOUAREG AND HAD AN ACCIDENT BECAUSE THE BRAKES FAILED. THERE IS A POLICE REPO…

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I BROUGHT A VOLKSWAGEN TOUAREG. THIS VEHICLE HAS A LOT PROBLEMS WITH THE BRAKE AND ENGINE. SO I FILED A LEMON REQUEST. LAST MONTH, VW ASKED ME TO DROP THIS VEHICLE TO VW DEALER TO INVESTIGATE THE BRAKE PROBLEM. ON MARCH 23, THE VW EXPERT TEST DROVE MY TOUAREG AND HAD AN ACCIDENT BECAUSE THE BRAKES FAILED. THERE IS A POLICE REPORT. *NM THE REAR WIPER MADE A CLICKING NOISE. UPDATED 05/04/06. *JB THE CHECK ENGINE LIGHT ILLUMINATED. THE DEALER REPLACED THE ENGINE CONTROL MODULE. THE TRANSMISSION CONTROL MODULE WAS UPDATED. UPDATED 06/01/06. *JB

NHTSA ODI #10154917

Mileage unknown · Jan 9, 2006
Engine And Engine CoolingTiresVisibility

2004 VOLKSWAGEN TOUAREG LOSS POWER OWN 3 OCCASIONS AT 780 MILES. WINDSHIELD WIPERS DID NOT WORK IN THE INTERMITTENT MODE, TIRE PRESSURING MONITORING SYSTEM MALFUNCTIONED. *TS ***NO ANSWER REQUIRED*** THE TIRE PRESSURING MONITORING SYSTEM WAS GIVING A FALSE READING AS IF THERE WAS A PROBLEM WITH THE TIRES. *JB

NHTSA ODI #10148659

Mileage unknown · Oct 26, 2005
Engine And Engine CoolingLatches/locks/linkagesPower TrainInjury

OUR 2004 VW TOUAREG V-8 HAS THE FOLLOWING PROBLEMS DESPITE FIVE TRIPS TO THE DEALER: I) HESITATION DURING ACCELERATION; II) PULLS HARD TO THE RIGHT; AND III) SHIFTS ROUGHLY AT LOW SPEEDS. PAST PROBLEMS INCLUDE: IV) THE LATCH ON THE REAR DOOR BROKE, SUCH THAT IT CAME CRASHING DOWN ON MY WIFE'S HEAD; V) THE REAR SEAT BELT LATCH…

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OUR 2004 VW TOUAREG V-8 HAS THE FOLLOWING PROBLEMS DESPITE FIVE TRIPS TO THE DEALER: I) HESITATION DURING ACCELERATION; II) PULLS HARD TO THE RIGHT; AND III) SHIFTS ROUGHLY AT LOW SPEEDS. PAST PROBLEMS INCLUDE: IV) THE LATCH ON THE REAR DOOR BROKE, SUCH THAT IT CAME CRASHING DOWN ON MY WIFE'S HEAD; V) THE REAR SEAT BELT LATCH WOULDN'T WORK; VI) THE CAR SHUDDERED BADLY WHEN YOU TRIED TO MAKE A TURN AT LOW SPEEDS (E.G., WHILE PARKING) AND VII) THE FLAT TIRE INDICATOR WENT ON EVEN THOUGH THE TIRE WAS NEITHER FLAT NOR LOW. WE HAVE AN ARBITRATION SCHEDULED FOR 11/9/05 UNDER CALIFORNIA'S LEMON LAW. *NM

NHTSA ODI #10140862

2,000 miles · Aug 11, 2005
Engine And Engine Cooling

2004 TOUAREG V6 ENGINE HAS BEEN A TORMENT, WITH 40 DIFFERENT PROBLEMS! BUT TWO OF THE PROBLEMS COULD BE CONSIDERED SAFETY CONCERNS! ERADICATE BRAKING WITH LURCHING AND ACCELERATION HESITATION BOTH OF WHICH SET UP AN UNPREDICTABLE DRIVING STYLE! BOTH OF THESE PROBLEMS ARE MAGNIFIED WHEN ATTEMPTING A LEFT TURN. THE DRIVER C…

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2004 TOUAREG V6 ENGINE HAS BEEN A TORMENT, WITH 40 DIFFERENT PROBLEMS! BUT TWO OF THE PROBLEMS COULD BE CONSIDERED SAFETY CONCERNS! ERADICATE BRAKING WITH LURCHING AND ACCELERATION HESITATION BOTH OF WHICH SET UP AN UNPREDICTABLE DRIVING STYLE! BOTH OF THESE PROBLEMS ARE MAGNIFIED WHEN ATTEMPTING A LEFT TURN. THE DRIVER CAN NOT DEPEND ON A ASSURED PERFORMANCE AT CRITICAL TIMES . A DRIVER MUST HAVE CONFIDENCE THAT HIS OR HER VEHICLE WILL PERFORM WITH ASSURANCE AT ALL TIMES !*JB

NHTSA ODI #10132454

20 miles · Nov 16, 2004
Engine And Engine Cooling

WHEN PULLING OUT INTO TRAFFIC FROM A STOP VEHICLE INTERMITENTLY HESITATES FOR A FEW SECONDS. IT SEEMS AS THOUGH THE ENGINE IS NOT RESPONDING TO THE ELECTRONIC THROTTLE OR THE TRANSMISSION IS SLIPPING. THIS IS A DANGEROUS PROBLEM WHEN PULLING INOT TRAFFIC FROM A SIDE STREET OR MAKING ALEFT TURN INTO ONCOMING TRAFFIC. I WAS ALMOST…

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WHEN PULLING OUT INTO TRAFFIC FROM A STOP VEHICLE INTERMITENTLY HESITATES FOR A FEW SECONDS. IT SEEMS AS THOUGH THE ENGINE IS NOT RESPONDING TO THE ELECTRONIC THROTTLE OR THE TRANSMISSION IS SLIPPING. THIS IS A DANGEROUS PROBLEM WHEN PULLING INOT TRAFFIC FROM A SIDE STREET OR MAKING ALEFT TURN INTO ONCOMING TRAFFIC. I WAS ALMOST REA-ENDED THE OTHER DAY. I ALSO FEEL THAT IF I MAKE A LEFT TURN INTO ONGOING TRAFFIC WITH A NORMAL MARGIN OF SAFETY, THE VEHICLE COULD HESTITATE AND I COULD BE HIT HEAD-ON OR BROADSIDED. IT IS A DANGEROUS PROBLEM. I HAVE RETURNED THE VEHICLE TO THE DEALER TWICE. THE FIRST TIME THEY SAID THEY LOADED IN NEW ECU FIRMWARE AND NEW TCU FIRMWARE. IT DIDN'T FIX THE PROBLEM. I RETURNED THE VEHICLE TO THE SAME DEALER AND THEY INDICATED THAT THE VOLKSWAGON FACTORY ENGINEERS ARE WORKING ON A NEW FIRMWARE RELEASE AND SHOULD HAVE IT OUT THE FIRST PART OF DECEMBER 2004. THEY SAID THEY WOULD CALL ME TO INSTALL THE NEW FIRMWARE WHEN AVAILABLE.*AK

NHTSA ODI #10100038

90 miles · Oct 15, 2004
Engine And Engine CoolingFuel System, Gasoline

WHEN MAKING RIGHT OR LEFT TURNS THE VEHICLE'S ENGINE HESITATED. THE CONSUMER WAS CONCERNED THAT THE FAILURE WOULD RESULT IN AN ACCIDENT. *AK *NM

NHTSA ODI #10092034

Mileage unknown · Oct 7, 2004
Air BagsEngine And Engine CoolingPower Train

WHILE DRIVING VEHICLE HESITATED. CONSUMER PRESSED DOWN ON THE ACCELERATOR PEDAL AND VEHICLE MOVED INTERMITTENTLY ON ITS OWN. SRS LIGHT APPEARED ON THE DASHBOARD AND REMAINED ON. CONSUMER DROVE VEHICLE TO THE DEALER FOR INSPECTION, AND MECHANIC PLACED THE VEHICLE ON A DIAGNOSTIC MACHINE. THE MECHANIC DETERMINED THAT THE SE…

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WHILE DRIVING VEHICLE HESITATED. CONSUMER PRESSED DOWN ON THE ACCELERATOR PEDAL AND VEHICLE MOVED INTERMITTENTLY ON ITS OWN. SRS LIGHT APPEARED ON THE DASHBOARD AND REMAINED ON. CONSUMER DROVE VEHICLE TO THE DEALER FOR INSPECTION, AND MECHANIC PLACED THE VEHICLE ON A DIAGNOSTIC MACHINE. THE MECHANIC DETERMINED THAT THE SENSOR SHAFT FOR TRANSMISSION AND ENGINE NEEDED TO BE REPLACED. THIS PROBLEM WAS A DESIGN FLAW DEFECT. CONSUMER INFORMED THE MECHANIC THIS PROBLEM WAS NOT ACCEPTABLE AND HAD NOT BEEN RESOLVED. *AK

NHTSA ODI #10095461

19,165 miles · Sep 13, 2004
Engine And Engine Cooling

CONSUMER COMPLAINED ABOUT INTERMITTENT STALLING. WHEN DRIVING ON THE HIGHWAY AT APPROXIMATELY 60 MPH VEHICLE STALLED AS IF THE MOTOR SHUT DOWN. WHEN THIS OCCURRED VEHICLE LOST POWER. HAS TOOK VEHICLE TO DEALER, AND CONTACTED MANUFACTURER. YET NONE OF THEM SEEMED TO KNOW HOW TO RESOLVE THE PROBLEM. *AK

NHTSA ODI #10091949

Mileage unknown · Jul 6, 2004
Engine And Engine Cooling

WHEN TRYING TO ACCELERATE ON OCCASION THE CAR WILL STALL AND THE ACCELERATOR WILL NOT PRODUCE ANY ACTION. I WAS IN AN INTERSECTION TRYING TO MERGE INTO TRAFFIC AND GOT INTO THE INTERSECTION AND TRIED TO ACCELERATE AND COULD NOT. VERY SCARY. THE CAR HAS DONE IT REPEATEDLY UNDER LESS THREATENING CIRCUMSTANCES. *JB

NHTSA ODI #10080472

Mileage unknown · Mar 10, 2004
Engine And Engine Cooling

WHILE DRIVING AT HIGHWAY SPEEDS VEHICLE STALLED, FORCING THE CONSUMER TO PULL OFF THE ROAD. CONSUMER TOOK THE VEHICLE TO THE DEALERSHIP TO BE INSPECTED, AND MECHANIC COULD NOT DUPLICATE THE PROBLEM. *AK

NHTSA ODI #10061792

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.