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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
115,000 miles · Jan 26, 2015
Electrical SystemElectronic Stability Control (esc)Steering

I RECENTLY PURCHASED A 2004 VW TUAREG IN JULY 1ST OF 2014. IMMEDIATELY UPON PURCHASING THE VEHICLE I BEGAN RECEIVING A PARKING BRAKE ALARM WHEN I TURNED ON THE VEHICLE. THE ALARM WOULD PERSIST UNTIL I PUSHED DOWN ON THE PARKING BRAKE. I WOULD ALSO RECEIVE AN OCCASIONAL ALARM FOR THE TIRE PRESSURE MONITORING SYSTEM. THEN, ON DECE…

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I RECENTLY PURCHASED A 2004 VW TUAREG IN JULY 1ST OF 2014. IMMEDIATELY UPON PURCHASING THE VEHICLE I BEGAN RECEIVING A PARKING BRAKE ALARM WHEN I TURNED ON THE VEHICLE. THE ALARM WOULD PERSIST UNTIL I PUSHED DOWN ON THE PARKING BRAKE. I WOULD ALSO RECEIVE AN OCCASIONAL ALARM FOR THE TIRE PRESSURE MONITORING SYSTEM. THEN, ON DECEMBER 15, 2014 THE VEHICLE REFUSED TO TURN ON AT ALL. THE DASHBOARD DISPLAY HAD A FLASHING STEERING WHEEL. I HAD THE VEHICLE TOWED TO A VOLKSWAGEN DEALERSHIP WHERE THE TECHNICIANS LOOKED IT OVER AND TOLD ME THAT THE CAUSE OF THE PROBLEM IS THAT TWO CABLES TOUCHED AND SHORTED OUT THE SYSTEM. AFTER 3 WEEKS OF HOLDING THE VEHICLE, THE COST OF REPAIR WAS QUOTED AT AROUND $3,500 TO REPLACE SOME MODULES. I WAS ALSO INFORMED THAT THIS MIGHT BE A RECALL ISSUE AS MANY OTHER 2004 VW TUAREGS HAVE HAD SIMILAR PROBLEMS. *TR

NHTSA ODI #10679060

93,000 miles · Dec 21, 2014
Electrical SystemSteering

CAME OUT TO 2004 V8 TOUAREG,AND IT WOULD NOT START. MRI READS STEERING DEFECTIVE WORKSHOP. AFTER SOME RESEARCH I DISCOVERED THAT THIS IS A COMMON DEFECT IN TOUAREGS AND ONE WHICH VW REFUSES TO TAKE RESPONSIBILITY OF.IT RENDERS THE VEHICLE PARALYZED AND DUE TO IT BEING ALL WHEEL DRIVE, REQUIRES SPECIAL EQUIPMENT TO EVEN TOW IT. …

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CAME OUT TO 2004 V8 TOUAREG,AND IT WOULD NOT START. MRI READS STEERING DEFECTIVE WORKSHOP. AFTER SOME RESEARCH I DISCOVERED THAT THIS IS A COMMON DEFECT IN TOUAREGS AND ONE WHICH VW REFUSES TO TAKE RESPONSIBILITY OF.IT RENDERS THE VEHICLE PARALYZED AND DUE TO IT BEING ALL WHEEL DRIVE, REQUIRES SPECIAL EQUIPMENT TO EVEN TOW IT. I AM FURIOUS. THIS IS A KNOWN, DANGEROUS ISSUE AND NO RECALL FOR IT - SHAME ON YOU VW. WHAT IF I WAS WITH MY YOUNG CHILDREN? THERE IS NO WARNING FOR THIS FAILURE. ALL IS FINE AND THEN WHAM, IT WILL NOT START, TURN OVER, SHIFT INTO NEUTRAL, ETC. YOU ARE 100% PARALYZED WHERE YOU ARE - BE IT AT A GAS PUMP OR A REMOTE DIRT ROAD. *TR

NHTSA ODI #10667491

90,000 miles · Oct 27, 2014
EnginePower Train

CAR STALLS, SKIPS GEARS, JERKS, WHEN COMING FROM A FULL STOP TO ACCELERATING JERKS AND PULL REALLY HARD GOING INTO 1ST AND 2ND GEAR,, TOOK IT TO THE DEALER AFTER PAYING 800 DOLLAR THEY COULD FIND ANYTHING WRONG,, AND THAT WAS VW DEALER.... I'VE BEEN SEEIN ALOT OF THE SAME COMPLAINTS FOR THIS SPECIFIC MODEL AND YEAR, CAN SOME P…

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CAR STALLS, SKIPS GEARS, JERKS, WHEN COMING FROM A FULL STOP TO ACCELERATING JERKS AND PULL REALLY HARD GOING INTO 1ST AND 2ND GEAR,, TOOK IT TO THE DEALER AFTER PAYING 800 DOLLAR THEY COULD FIND ANYTHING WRONG,, AND THAT WAS VW DEALER.... I'VE BEEN SEEIN ALOT OF THE SAME COMPLAINTS FOR THIS SPECIFIC MODEL AND YEAR, CAN SOME PLEASE LET ME KNOW IF VOLKSWAGEN IS NOT GOING TO TAKE RESPONSIBILITY FOR THIS ISSUE ATLEAST TELL ME WHAT COULD BE WRONG, SO I CAN FIX IT AND GET RID OF THIS STUPID CAR. IM BETTER OFF WITH AN AMERICAN CAR... *TR

NHTSA ODI #10650277

101,202 miles · Sep 9, 2014
Air Bags

BOTH RIGHT AND LEFT SIDE FRONT AIRBAG WIRING HARNESSES REQUIRED REPAIR WITHIN 600 MILES OF FIRST INCIDENT TO CORRECT PRIOR REPAIRS TO REPLACE HARNESS CONNECTORS WITH SPLICED WIRE UNDER VOLUNTARY SERVICE PACK "RECALL". BOTH REPAIRS WERE TRIGGERED BY AIRBAG FAULT LIGHT ON DASH. YOU HAD DONE AN INVESTIGATION IN 2006 ON THIS. VW WOU…

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BOTH RIGHT AND LEFT SIDE FRONT AIRBAG WIRING HARNESSES REQUIRED REPAIR WITHIN 600 MILES OF FIRST INCIDENT TO CORRECT PRIOR REPAIRS TO REPLACE HARNESS CONNECTORS WITH SPLICED WIRE UNDER VOLUNTARY SERVICE PACK "RECALL". BOTH REPAIRS WERE TRIGGERED BY AIRBAG FAULT LIGHT ON DASH. YOU HAD DONE AN INVESTIGATION IN 2006 ON THIS. VW WOULD NOT COVER THE REPAIRS BECAUSE I WAS "OUT OF WARRANTY". IT COST ME $600 TO FIX THE PROBLEM AND I HAVE NO ASSURANCE FROM THE DEALER IT WON'T OCCUR AGAIN OR THAT I WILL NEED NEW HARNESSES OR AIRBAG MODULES. *TR

NHTSA ODI #10631849

67,000 miles · Aug 28, 2014
Visibility/wiper

I WAS DRIVING ON 101 SOUTH FROM SANTA ROSA TOWARDS SAN FRANCISCO AND WHEN IN THE NOVATO AREA THE REARVIEW MIRROR CAME OFF DANGLING FROM THE HEADLINER BY THE WIRING HARNESS RIGHT ON MY FACE. THE DANGLING REARVIEW MIRROR BLOCKED MY VIEW OF THE ROAD AND THIS BIG DISTRACTION NEARLY CAUSED AN ACCIDENT. THIS IS CLEARLY A SAFETY I…

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I WAS DRIVING ON 101 SOUTH FROM SANTA ROSA TOWARDS SAN FRANCISCO AND WHEN IN THE NOVATO AREA THE REARVIEW MIRROR CAME OFF DANGLING FROM THE HEADLINER BY THE WIRING HARNESS RIGHT ON MY FACE. THE DANGLING REARVIEW MIRROR BLOCKED MY VIEW OF THE ROAD AND THIS BIG DISTRACTION NEARLY CAUSED AN ACCIDENT. THIS IS CLEARLY A SAFETY ISSUE, REARVIEW MIRRORS SHOULD NOT JUST RANDOMLY FALL OFF. I STRONGLY BELIEVE THAT VOLKSWAGEN OUGHT TO HAVE A RECALL FOR THIS DEFECTIVE MIRROR AND PERFORM A REPAIR AT VW'S EXPENSE. MY AAA CERTIFIED MECHANIC QUOTED ME IN EXCESS OF $700.00 TO RE-GLUE THE REARVIEW MIRROR TO THE WINDSHIELD. *TR

NHTSA ODI #10629233

112 miles · Jul 30, 2014
Electronic Stability Control (esc)Steering

WOULDN'T START SO HAD IT TOWED TO NORTHLAND VOLKSWAGEN. THERE THEY TESTED AND SAID I NEEDED STEERING COLUMN REPLACED AND WIRING DONE . NOT SURE BUT HAVE NEVER HAD PROBLEMS WITH COLUMN NOT PERFORMING CORRECTLY BUT I DON'T HAVE A CLUE ABOUT WIRING INSIDE ONE. THE REPAIRS ARE 2538.08 AND 1567.77 IS FOR THE COLUMN. *TR

NHTSA ODI #10617762

75,000 miles · Apr 27, 2014
Exterior Lighting

THIS IS A PROBLEM IMPACTING A LARGE PERCENTAGE OF 2005-2006 VW TOUAREGS WITH HID HEADLIGHTS. WIRE IN HEADLAMP ASSEMBLY IS TO SMALL FOR LOAD. THE INSULATION DECAYS DUE TO HEAT AND RESULTS IN A SHORT WHICH WILL BLOW THE FUSE FOR AFFECTED HEADLIGHT. USUALLY OCCURS WHEN SWITCHING ON HIGH BEAMS OR HITTING A LARGE BUMP. WHILE THERE…

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THIS IS A PROBLEM IMPACTING A LARGE PERCENTAGE OF 2005-2006 VW TOUAREGS WITH HID HEADLIGHTS. WIRE IN HEADLAMP ASSEMBLY IS TO SMALL FOR LOAD. THE INSULATION DECAYS DUE TO HEAT AND RESULTS IN A SHORT WHICH WILL BLOW THE FUSE FOR AFFECTED HEADLIGHT. USUALLY OCCURS WHEN SWITCHING ON HIGH BEAMS OR HITTING A LARGE BUMP. WHILE THERE IS AN INEXPENSIVE DIY FIX, OUTLINED IN BELOW LINK, VW IS TELLING OWNERS THEY NEED TO SPEND $950 PER HEADLAMP TO REPLACE THE ASSEMBLY. HTTP://WWW.CLUBTOUAREG.COM/FORUMS/F43/TOUAREG-DEAD-XENON-FIX-CODE-01344-A-103130.HTML. *TR

NHTSA ODI #10585130

55,000 miles · Apr 23, 2014
Exterior Lighting

WHILE DRIVING AT NIGHT ON THE GARDEN STATE PARKWAY AT 65MPH ALL OF THE LIGHTS, BOTH EXTERIOR AND INTERIOR, WENT OUT FOR ABOUT 7 SECONDS. THIS HAD HAPPENED ONCE BEFORE DURING DAYLIGHT HOURS. THE CAR DOES NOT STALL, BUT IS COMPLETELY DARK. I ADVISED VOLKSWAGEN OF AMERICA OF THIS PROBLEM BY LETTER DATED APRIL 17, 2014. ON TUESDAY A…

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WHILE DRIVING AT NIGHT ON THE GARDEN STATE PARKWAY AT 65MPH ALL OF THE LIGHTS, BOTH EXTERIOR AND INTERIOR, WENT OUT FOR ABOUT 7 SECONDS. THIS HAD HAPPENED ONCE BEFORE DURING DAYLIGHT HOURS. THE CAR DOES NOT STALL, BUT IS COMPLETELY DARK. I ADVISED VOLKSWAGEN OF AMERICA OF THIS PROBLEM BY LETTER DATED APRIL 17, 2014. ON TUESDAY APRIL 22, 2014 A REPRESENTATIVE OF VOLKSWAGEN CALLED ME AND ADVISED THAT SINCE THE VEHICLE WAS "OUT OF WARRANTY" THEY WOULD NOT INSPECT THE VEHICLE TO ANALYZE/DETERMINE THE CAUSE OF THE PROBLEM. I WAS SURPRISED BY THIS INDIFFERENCE TO A SERIOUS SAFETY PROBLEM SINCE THE 2004 TOUAREG IS NOTORIOUS FOR PROBLEMS WITH ITS ELECTRICAL SYSTEM, INCLUDING REPORTS OF STALLING. THE LOCAL DEALER INSPECTED PARTS OF THE ELECTRICAL SYSTEM AND COULD NOT DETERMINE THE CAUSE OF THE PROBLEM. *TR

NHTSA ODI #10584464

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

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.