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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

Fuel/propulsion System complaints

23 reports
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Mileage unknown · Nov 9, 2025
Fuel/propulsion System

I have contacted Volkswagen about my recall over a month ago the man claimed he ordered the parts and would be in contact but has never contacted me ever since and since then my vehicle has completely stopped working and the gas smell is at a very dangerous level

NHTSA ODI #11698472

Mileage unknown · Sep 4, 2025
Fuel/propulsion System

The flange for the fuel does not leak from that i can see couse if it was leaking it would be on the ground.

NHTSA ODI #11685014

1 miles · Aug 9, 2020
Fuel/propulsion System

SUV IS NOT GETTING GAS TO ENGINE

NHTSA ODI #11344166

85,000 miles · Dec 4, 2019
Fuel/propulsion System

THERE IS A STRONG SMELL OF GASOLINE OUTSIDE OF THE CAR AFTER THE CAR HAS BEEN DRIVEN (OR WHILE IT'S DRIVING, BUT IT'S NOT OFTEN I'M OUTSIDE OF THE CAR WHILE IT'S RUNNING). THIS IS DUE TO THE PLASTIC HOUSING ON THE FUEL PUMP THAT HAS DEVELOPED A CRACK, AND IS LEAKING GASOLINE. THIS IS SIMILAR TO ANOTHER RECALL, 17V583000, WHICH…

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THERE IS A STRONG SMELL OF GASOLINE OUTSIDE OF THE CAR AFTER THE CAR HAS BEEN DRIVEN (OR WHILE IT'S DRIVING, BUT IT'S NOT OFTEN I'M OUTSIDE OF THE CAR WHILE IT'S RUNNING). THIS IS DUE TO THE PLASTIC HOUSING ON THE FUEL PUMP THAT HAS DEVELOPED A CRACK, AND IS LEAKING GASOLINE. THIS IS SIMILAR TO ANOTHER RECALL, 17V583000, WHICH IS FOR THE FUEL FILTER FLANGE, BUT VW IS SAYING THEY WILL NOT COVER IT UNDER THAT BECAUSE THIS IS THE HOUSING, NOT THE FLANGE. BUT IT'S THE SAME RESULT...

NHTSA ODI #11286924

Mileage unknown · Jul 8, 2019
Fuel/propulsion System

FUEL FLANK WAS SEALED BY THE DEALERSHIP. HOWEVER, THERE IS FUEL LEAKING.

NHTSA ODI #11230095

103,000 miles · Jul 8, 2019
Electronic Stability Control (esc)EngineFuel/propulsion System

I WAS DRIVING ON THE HIGHWAY @ 70MPR WHEN ALL OF A SUDDEN WITHOUT WARNING THE CAR STARTS ACTING SLUGGISH FOR A MIN THEN BACK TO NORMAL, AND RANDOMLY FOR THE NEXT HOUR OR SO DOES(I HAD A WAYS TO GO) THIS A FEW MORE TIMES. I GOT TO MY DESTINATION AND LET HER REST FOR THE NIGHT. THE NEXT MORNING IT WAS DOING FINE EXCEPT NOW THE EMI…

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I WAS DRIVING ON THE HIGHWAY @ 70MPR WHEN ALL OF A SUDDEN WITHOUT WARNING THE CAR STARTS ACTING SLUGGISH FOR A MIN THEN BACK TO NORMAL, AND RANDOMLY FOR THE NEXT HOUR OR SO DOES(I HAD A WAYS TO GO) THIS A FEW MORE TIMES. I GOT TO MY DESTINATION AND LET HER REST FOR THE NIGHT. THE NEXT MORNING IT WAS DOING FINE EXCEPT NOW THE EMISSION CONTROL LIGHT CAME ON AND STAYED ON. BY THIS TIME IT WAS TIME FOR THE 100,000 MILE MAINTENANCE TO BE DONE AND IT DID GREAT UNTIL ABOUT 6 MONTHS LATER I WAS DRIVING @ 35MPR WHEN IT STARTED LOOSING POWER, THO I ONLY LOST A LITTLE BIT OF POWER STEERING WAS FORCED TO COME TO A STOP, WHICH JUST HAPPEN TO BE A ONE WAY BRIDGE, BABY IN THE CAR AND HAD TO PUSH MYSELF THE REST OF THE WAY ACROSS IT. ONCE OFF THE BRIDGE I TURNED THE CAR OFF (IT STAYED ON TIL I DID THIS) LET IT REST A MINUTE AND IT STARTED UP FINE AND LET ME GO A FEW BLOCKS STILL SLUGGISH AND THEN LOST POWER AGAIN. I REPEATED THIS PROCESS FOR ABOUT 5 MILES OR SO WHEN I WAS FORCED TO PARK IT CUZ I DIDN'T WANT TO RISK CROSSING THE HIGHWAY AGAIN. HAD IT TOWED TO DEALERSHIP WHERE THEY DID THE FLANGE RECALL, THAT DIDNT' FIX THE PROBLEM SO HAD TO REPLACE BOTH FUEL PUMPS AND THAT WAS ROUGHLY @ 103,000. 8 MONTHS LATER IT HAPPENS AGAIN THIS TIME AROUND 107,000. DEALERSHIP TOOK 4 HOURS TO DIAGNOSE ONLY TO TELL ME I NEED THE FUEL TANK REPLACED BECAUSE SOMEHOW ALL THE WIRES, CONNECTORS, AND CAPS THAT HAVE TO DO WITH THE FUEL LINES/TANK/PUMPS ARE EITHER MISSING, CRACKED, OR DAMAGED SO I NEED A WIRING HARNESS AS WELL. THEY ARE QUOTING A ME $5000 FIX!!!

NHTSA ODI #11229973

168,835 miles · Jul 28, 2018
EngineFuel/propulsion SystemUnknown Or Other

THE TOUAREG MADE SOME RATTLING NOISE WHILE I WAS DRIVING AT 35 MPH. AS SOON I STOPPED AND MADE IT MY DESTINATION AND TURNED OFF THE CAR THE CAR WOULDN'T START UP. I TOOK IT TO THE DEALERSHIP AND THE DEALERSHIP COULDN'T FIGURE OUT WHY THE CAR WOULDN'T START. FINALLY, AFTER A WELL OVER A WEEK, THEY DETERMINED THAT I NEEDED TO REPL…

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THE TOUAREG MADE SOME RATTLING NOISE WHILE I WAS DRIVING AT 35 MPH. AS SOON I STOPPED AND MADE IT MY DESTINATION AND TURNED OFF THE CAR THE CAR WOULDN'T START UP. I TOOK IT TO THE DEALERSHIP AND THE DEALERSHIP COULDN'T FIGURE OUT WHY THE CAR WOULDN'T START. FINALLY, AFTER A WELL OVER A WEEK, THEY DETERMINED THAT I NEEDED TO REPLACE ALL SIX FUEL INJECTORS. THE FUEL INJECTORS GOT REPLACED NOW THE CAR TURNS ON BUT AS SOON AS YOU STEP ON THE GAS THE CAR DIES.

NHTSA ODI #11114294

93,000 miles · Jun 3, 2018
Fuel/propulsion System

I RECEIVED A LETTER FROM VOLKSWAGEN OF AMERICA, IN MARCH OF 2018, STATING THAT THERE IS A SAFETY RECALL 20AI-FUEL PUMP FLANGE FOR MY MAKE AND MODEL OF VEHICLE. I HAD ALREADY HAD THAT REPAIR DONE, DUE TO A SEVERE LEAK IN MY FUEL PUMP (GAS WAS POURING OUT OF THE BOTTOM OF THE VEHICLE AS AS FAST AS I WAS PUMPING THE GAS IN ON ON…

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I RECEIVED A LETTER FROM VOLKSWAGEN OF AMERICA, IN MARCH OF 2018, STATING THAT THERE IS A SAFETY RECALL 20AI-FUEL PUMP FLANGE FOR MY MAKE AND MODEL OF VEHICLE. I HAD ALREADY HAD THAT REPAIR DONE, DUE TO A SEVERE LEAK IN MY FUEL PUMP (GAS WAS POURING OUT OF THE BOTTOM OF THE VEHICLE AS AS FAST AS I WAS PUMPING THE GAS IN ON ONE OCCASION). I HAD TO HAVE MY VEHICLE TOWED TO A REPAIR FACILITY AND COULDN'T DRIVE IT UNTIL IT WAS REPAIRED. THEN, 3 YEARS LATER, I RECIEVED A RECALL ANNOUNCEMENT FROM VOLKSWAGEN FOR THE EXACT REPAIR THAT I HAD DONE FOR THE FAULTY FUEL PUMP FLANGE. I COMPLETED THE REIMBURSEMENT FORM AND SUBMITTED IT TO VOLKSWAGEN. MY REIMBURSEMENT WAS REJECTED BECAUSE MY REPAIR WAS MADE PRIOR TO THE RECALL BEING ISSUED. I WAS TOLD BY VOLKSWAGEN REPRESENTATIVES THAT THE NHTSA LIMITS RECALL REPAIRS AND REIMBURSEMENTS, AND IT'S THE RESPONSIBILITY OF THE NHTSA BECAUSE THEY SET THE TIMELINE.

NHTSA ODI #11099448

60,000 miles · May 1, 2018
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING APPROXIMATELY 40 MPH, AN ODOR OF FUMES WAS DETECTED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO COACHELLA VALLEY VOLKSWAGEN (79050 VARNER RD, INDIO, CA 92203, 760-200-4000) WHERE THE TECHNICIAN FOUND A FUEL LEAK AND REPLACED THE FILTER FLANGES. THE FAILURE RECURRED FOUR…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING APPROXIMATELY 40 MPH, AN ODOR OF FUMES WAS DETECTED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO COACHELLA VALLEY VOLKSWAGEN (79050 VARNER RD, INDIO, CA 92203, 760-200-4000) WHERE THE TECHNICIAN FOUND A FUEL LEAK AND REPLACED THE FILTER FLANGES. THE FAILURE RECURRED FOUR YEARS LATER. THE VEHICLE WAS TAKEN TO VOLKSWAGEN OF PALM SPRINGS (67909 E PALM CANYON DR., CATHEDRAL CITY, CA 92234, 855-996-5429) WHERE THE FILTER FLANGES WERE REPLACED AGAIN DUE TO A FUEL LEAK. THE CONTACT LATER RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V583000 (FUEL SYSTEM, GASOLINE). THE CONTACT CALLED THE MANUFACTURER, REPORTED THE FAILURES, AND DEMANDED REIMBURSEMENT. THE CONTACT STATED THAT THE MANUFACTURER DENIED THE REIMBURSEMENT, STATING THE REPAIRS WERE PERFORMED PRIOR TO THE RECALL. THE FAILURE MILEAGE WAS APPROXIMATELY 60,000.

NHTSA ODI #11091195

89,000 miles · Feb 12, 2018
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING VARIOUS SPEEDS, A STRONG FUEL ODOR EMITTED THROUGH THE VENTS OF THE VEHICLE. THE CONTACT ALSO STATED THAT THE FUEL GAUGE FAILED TO PROVIDE THE ACCURATE READING. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V583000 (FUEL SYSTEM, GASOLINE); HOWEVER, TH…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING VARIOUS SPEEDS, A STRONG FUEL ODOR EMITTED THROUGH THE VENTS OF THE VEHICLE. THE CONTACT ALSO STATED THAT THE FUEL GAUGE FAILED TO PROVIDE THE ACCURATE READING. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V583000 (FUEL SYSTEM, GASOLINE); HOWEVER, THE PART NEEDED FOR THE REPAIR WAS NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC TO DETERMINE THE CAUSE OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THE PART WAS NOT AVAILABLE FOR THE REPAIR. THE APPROXIMATE FAILURE MILEAGE WAS 89,000. VIN TOOL CONFIRMS PARTS NOT AVAILABLE.

NHTSA ODI #11072332

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.