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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.

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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

Structure complaints

8 reports
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Mileage unknown · Feb 3, 2014
Structure

ALL OF THE EXTERIOR DOOR HANDLES ARE EXTREMELY LOOSE AND ONE OF THEM I HAVE TO MAKE SURE THAT THE HANDLE GOES IN ALL THE WAY BECAUSE MY KIDS SIT IN THE BACK SEAT AND I'M AFRAID THAT THE DOOR MIGHT SWING OPEN ONE DAY AND AN ACCIDENT MAY OCCUR. ALSO THE DOOR HANDLES SOMETIMES DON'T OPEN ON THE FIRST PULL WHETHER ITS FROM THE INSID…

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ALL OF THE EXTERIOR DOOR HANDLES ARE EXTREMELY LOOSE AND ONE OF THEM I HAVE TO MAKE SURE THAT THE HANDLE GOES IN ALL THE WAY BECAUSE MY KIDS SIT IN THE BACK SEAT AND I'M AFRAID THAT THE DOOR MIGHT SWING OPEN ONE DAY AND AN ACCIDENT MAY OCCUR. ALSO THE DOOR HANDLES SOMETIMES DON'T OPEN ON THE FIRST PULL WHETHER ITS FROM THE INSIDE OR OUTSIDE. *TR

NHTSA ODI #10562619

90,000 miles · Aug 28, 2013
Structure

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THAT WHENEVER IT RAINED, SHE WOULD FIND STANDING WATER INSIDE THE VEHICLE. ON ONE OCCASION WHILE ATTEMPTING TO START THE IGNITION, SPARKS EMITTED FROM THE IGNITION. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT …

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THAT WHENEVER IT RAINED, SHE WOULD FIND STANDING WATER INSIDE THE VEHICLE. ON ONE OCCASION WHILE ATTEMPTING TO START THE IGNITION, SPARKS EMITTED FROM THE IGNITION. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT THE SUNROOF DRAINS WERE THE CAUSE OF THE FAILURE. IN ADDITION, THE ABS CONTROLLER HAD BECOME RUSTED AND CAUSED THE VEHICLE TO ENGAGE IN FOUR BY FOUR MODE PERMANENTLY. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 90,000.

NHTSA ODI #10537686

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

Mileage unknown · Mar 12, 2006
Electrical SystemEquipmentExterior Lighting

I TOOK DELIVERY OF MY 2004 VW TOUAREG ON 7-11-04. BY 9-9-04 IT WAS HAVING PROBLEMS. IT HAS BEEN IN 6 TIMES FOR ELECTRICAL PROBLEMS, 3 TIMES FOR THE AC, 3 TIMES FOR THE BATTERY, AND 1-2 TIMES FOR OTHER THINGS. TOMORROW, I WILL BE TAKING IT IN AGAIN FOR FURTHER A/C PROBLEMS, BRAKES THAT CATCH ON THEIR OWN WHILE IN DRIVE, INTERMITT…

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I TOOK DELIVERY OF MY 2004 VW TOUAREG ON 7-11-04. BY 9-9-04 IT WAS HAVING PROBLEMS. IT HAS BEEN IN 6 TIMES FOR ELECTRICAL PROBLEMS, 3 TIMES FOR THE AC, 3 TIMES FOR THE BATTERY, AND 1-2 TIMES FOR OTHER THINGS. TOMORROW, I WILL BE TAKING IT IN AGAIN FOR FURTHER A/C PROBLEMS, BRAKES THAT CATCH ON THEIR OWN WHILE IN DRIVE, INTERMITTENT FAULTY TRIGGERING OF TIRE PRESSURE MONITORING SYSTEM, AND A HOLE THAT I DISCOVERED ONLY DAY IN THE FIRE BLANKET UNDER THE HOOD. APPARENTLY THE ENGINE HEAT HAS BEEN BURNING A HOLE IN IT AND HAS BURNED AWAY A HOLE RIGHT THROUGH THE BLANKET TO THE HOOD ITSELF, BUT NOT THROUGH THE HOOD YET. THIS CAR HAS MEANT TIME LOST FROM WORK AND AN INORDINATE AMOUNT OF TIME SPENT IN THE SHOP AND PAYING FOR RENTAL CARS. THIS CAR IS A FIRE AND SAFETY HAZARD. FAIRFAX COUNTY CONSUMER PROTECTION (ROY SEGER) HAD CONTACTED VW AS THIS CAR FALLS UNDER THE LEMON LAW. VW RESPONDED THAT THEY WOULD NOT COMPLY, STATING THAT THEY HAD FIXED THE BATTERY. THEIR RESPONSE FAILED TO ACCOUNT FOR THE MULTITUDE OF OTHER PROBLEMS...AND NOW THIS. I HAVE NEVER FELT SO POWERLESS. IS THERE ANYTHING YOU CAN DO TO HELP?? *NM

NHTSA ODI #10152523

5,000 miles · Jan 31, 2006
Structure

TWICE IN 18 MONTHS THE ENTIRE FRONT GRILL OF OUR 2004 VOLKSWAGEN TOURAEG HAS FLOWN OFF THE CAR, CRASHED INTO THE WINDSHIELD, AND THEN BOUNCED OFF THE TOP OF THE CAR INTO ONCOMING TRAFFIC. IN BOTH CASES THE MOTORIST, AND IN ONE CASE MOTORCYCLIST HAD TO SWERVE TO AVOID BEING HIT. THE FIRST TIME IT HAPPENED WAS IN SUMMER 2004. W…

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TWICE IN 18 MONTHS THE ENTIRE FRONT GRILL OF OUR 2004 VOLKSWAGEN TOURAEG HAS FLOWN OFF THE CAR, CRASHED INTO THE WINDSHIELD, AND THEN BOUNCED OFF THE TOP OF THE CAR INTO ONCOMING TRAFFIC. IN BOTH CASES THE MOTORIST, AND IN ONE CASE MOTORCYCLIST HAD TO SWERVE TO AVOID BEING HIT. THE FIRST TIME IT HAPPENED WAS IN SUMMER 2004. WE HAD IT REPAIRED AND VW ASSURED US IT WAS A FREAK INCIDENT, BUT IT OCCURRED AGAIN LAST SATURDAY. BOTH TIMES IT OCCURRED WHEN DRIVING AT HIGHWAY SPEED, BUT CERTAINLY NOT EXCESSIVELY. IT HAPPENED ONCE WHEN I WAS DRIVING, AND ONCE TO MY HUSBAND. THERE WAS NO WARNING AT ALL. THE GRILL DID NOT APPEAR TO BE LOOSE OR MAKING ANY RATTLING NOISES. WE FEEL VERY LUCKY THAT SERIOUS INJURY WAS AVOIDED, BUT ARE CONCERNED THAT THIS IS A RECURRING DEFECT THAT WILL SOONER OR LATER LEAD TO INJURY OR DEATH TO THE PEOPLE DRIVING BEHIND US IN PARTICULAR. *NM

NHTSA ODI #10149099

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

Mileage unknown · Dec 17, 2003
Structure

WHILE TRAVELING WITH SUN ROOF OPEN VIBRATION INSIDE OF VEHICLE HURT CONSUMER'S EARS.*AK

NHTSA ODI #10051689

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.