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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

What owners actually said

231 reports
Mileage unknown · Apr 16, 2006
Tires

TIRES KEEP GETTING WORN OUT. *NM

NHTSA ODI #10155443

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

35,000 miles · Apr 1, 2006
Electrical System

CURRENTLY, VW HAS PUBLISHED TECHNICAL SERVICE BULLETIN 27-05-01 AND 27-05-03 FOR THE TOUAREG RELATED TO BAD GROUND CONNECTIONS AT THE BATTERY AND A FAULTY BATCH OF GROUND/POSITIVE WIRES THAT RUN FROM THE GENERATOR TO THE BATTERY. HOWEVER, VW WILL ONLY REPAIR THE VEHICLE IF THE CAR GOES COMPLETELY DEAD, LEAVING THE DRIVER AND OCC…

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CURRENTLY, VW HAS PUBLISHED TECHNICAL SERVICE BULLETIN 27-05-01 AND 27-05-03 FOR THE TOUAREG RELATED TO BAD GROUND CONNECTIONS AT THE BATTERY AND A FAULTY BATCH OF GROUND/POSITIVE WIRES THAT RUN FROM THE GENERATOR TO THE BATTERY. HOWEVER, VW WILL ONLY REPAIR THE VEHICLE IF THE CAR GOES COMPLETELY DEAD, LEAVING THE DRIVER AND OCCUPANTS AT THE MERCY OF THE ENVIRONMENT THEY ARE STRANDED IN. AS THIS IS A SUV, THE ENVIRONMENT COULD BE ONE THAT POSES A THREAT TO THE WELL BEING OF THE OCCUPANTS. I HAVE OPENED CASE # 60111160 WITH VWOA AND EXPRESSED MY CONCERNS TO DWIGHT HARRISON VW IN SNELLVILLE, GA AND HAVE RECEIVED THE SAME RESPONSE......THE CAR HAS TO HAVE AN EXISTING NO-START CONDITION TO QUALIFY. *NM

NHTSA ODI #10154328

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

18,000 miles · Feb 6, 2006
Electrical System

MY VEHICLE, A 2004 VW TOUAREG LOOSES POWER, THE VOLT METER DROPS TO ZERO AND THEN THE TURN SIGNALS STOP WORKING. ALL THE LIGHTS IN THE VEHICLE DIM AND IF YOU SWITCH THE VEHICLE OFF, IT WILL NOT START AGAIN. THE VEHICLE WAS DRIVE A FEW HOURS EARLIER, WITH NO PROBLEMS. THIS HAS BEEN A RE-OCCURRING PROBLEM WITH THE VEHICLE AT THE D…

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MY VEHICLE, A 2004 VW TOUAREG LOOSES POWER, THE VOLT METER DROPS TO ZERO AND THEN THE TURN SIGNALS STOP WORKING. ALL THE LIGHTS IN THE VEHICLE DIM AND IF YOU SWITCH THE VEHICLE OFF, IT WILL NOT START AGAIN. THE VEHICLE WAS DRIVE A FEW HOURS EARLIER, WITH NO PROBLEMS. THIS HAS BEEN A RE-OCCURRING PROBLEM WITH THE VEHICLE AT THE DEALERSHIP AT LEAST 5 OR MORE TIMES IN A 2 MONTH PERIOD. *JB

NHTSA ODI #10149541

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 · Jan 29, 2006
Power TrainSuspensionTires

ALIGNMENT: SINCE ITS PURCHASE THE CAR WAS NOT PROPERLY ALIGNED. I TOOK IT TO THE DEALER SEVERAL TIMES, AT THE 5,000 MILES, 10,000 MILES, AND 20,000 MILES SERVICES. IT WAS NOT FIXED AT ALL. THE REPAIR SHEET STATED THAT CAR WAS FIXED TO THE MANUFACTURER'S STANDARDS. AT THE 20,000 MILES SERVICE I REQUESTED THE CAR TO REPAIRED BEFOR…

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ALIGNMENT: SINCE ITS PURCHASE THE CAR WAS NOT PROPERLY ALIGNED. I TOOK IT TO THE DEALER SEVERAL TIMES, AT THE 5,000 MILES, 10,000 MILES, AND 20,000 MILES SERVICES. IT WAS NOT FIXED AT ALL. THE REPAIR SHEET STATED THAT CAR WAS FIXED TO THE MANUFACTURER'S STANDARDS. AT THE 20,000 MILES SERVICE I REQUESTED THE CAR TO REPAIRED BEFORE I TAKE IT BACK. THE DEALER TOLD ME THAT DUE TO THE UNEVEN TIRES THERE WAS NO WAY FOR THEM TO REPAIR THE ALIGNMENT, AND THAT THE ONLY WAY TO FIX IT PROPERLY WAS TO REPLACE THE TIRES FIRST. I REPLACED THE TIRES AND BROUGHT THE CAR BACK. THE DEALER HAD THE CAR IN THE SHOP FOR THREE DAYS THE FIRST TIME. WHEN I TESTED THE CAR AFTER THE FIRST TIME IT WAS NOT FIXED. I TOOK IT BACK AND HAD A DISPUTE WITH THE TECHNICIAN. WHEN OTHER TECHNICIANS TESTED THE CAR THE DEALER DECIDED TO KEEP FOR REPAIR. THE CAR WAS AT THE SHOP FOR TWO DAYS. WHEN IT WAS FINALLY DONE, THE CAR HAD THE SAME PROBLEM. COMPUTER SYSTEM: LIGHTS AND SIGNALS PERIODICALLY STOP WORKING. GAS SENSOR PERIODICALLY STOPS WORKING FOR DAYS. CD PLAYER. PERIODICALLY SKIPS AND DOES NOT WORK. TRANSMISSION: PERIODIC JERKING WHEN SHIFTING TO LOWER SPEEDS. SCREECHING SOUND COMES FROM THE FRONT RIGHT SIDE AFTER 20 -30 MINUTES OF DRIVING. TIRES WERE WORN OUT AFTER 10,000 MILES.*AK

NHTSA ODI #10148958

Mileage unknown · Jan 26, 2006
Vehicle Speed Control

VEHICLE HAS AN INCONSISTENT LACK OF THROTTLE RESPONSE. WHEN PRESSING ACCLERATOR YOU MAY GET A RESPONSE, A DELAYED RESPONSE OR NOTHING. PULLING FROM STOP SIGN WITH A SAFE DISTANCE OF ONCOMOING TRAFFIC VEHICLE HESITATED ALMOST CAUSING COLLISION. HAVE BEEN ALMOST REAR ENDED WHEN VEHICLE DID NOT RESPOND TO THROTTLE AT STOP LIGHT.H…

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VEHICLE HAS AN INCONSISTENT LACK OF THROTTLE RESPONSE. WHEN PRESSING ACCLERATOR YOU MAY GET A RESPONSE, A DELAYED RESPONSE OR NOTHING. PULLING FROM STOP SIGN WITH A SAFE DISTANCE OF ONCOMOING TRAFFIC VEHICLE HESITATED ALMOST CAUSING COLLISION. HAVE BEEN ALMOST REAR ENDED WHEN VEHICLE DID NOT RESPOND TO THROTTLE AT STOP LIGHT.HAS BEEN TO DEALER 3 TIMES WITH NO RESOLUTION.*AK

NHTSA ODI #10148797

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

4,000 miles · Dec 22, 2005
Power Train

SEVERAL TRANSMISSION FAILURES WHERE THE ENGINE WOULD LOSE POWER AND WOULDN'T SHIFT. *JB

NHTSA ODI #10145952

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.