IllustrationTL* THE CONTACT OWNS A 2004 AUDI A4. AFTER STARTING THE VEHICLE, THE DRIVER SIDE AIR BAG LIGHT REMAINED ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 87,000.
2004 Audi A4
Owner reports · Recalls · Investigations
More warning signs than most A4 years
Owner complaints for the 2004 Audi A4 are substantially higher than the model-year median of 76.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all A4 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
250–25K
4125–50K
5150–75K
2975–100K
16100–150K
6150K+
168 reports with mileage · 21 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.
- Fuel System, Gasoline. Review the 46 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Air Bags. Review the 26 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. Review the 18 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
8 crash reports3 fire reports5 injury reports
Air Bags complaints
26 reportsTL* THE CONTACT OWNS A 2004 AUDI A4. WHILE THE VEHICLE WAS IDLING, THE DRIVER SIDE AIR BAG AND TWO OF THE CURTAIN SIDE AIR BAGS DEPLOYED INADVERTENTLY. THE VEHICLE WAS TOWED TO A DEALER WHO STATED THAT THE AIR BAGS NEEDED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE …
Read full complaint
TL* THE CONTACT OWNS A 2004 AUDI A4. WHILE THE VEHICLE WAS IDLING, THE DRIVER SIDE AIR BAG AND TWO OF THE CURTAIN SIDE AIR BAGS DEPLOYED INADVERTENTLY. THE VEHICLE WAS TOWED TO A DEALER WHO STATED THAT THE AIR BAGS NEEDED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 164,000.
TL* THE CONTACT OWNS A 2004 AUDI A4. THE CONTACT STATED THAT THE VEHICLE WAS SHIFTED INTO NEUTRAL AND THE PARKING BRAKE WAS APPLIED WHEN THE DRIVER'S SIDE CURTAIN AIR BAGS DEPLOYED ERRONEOUSLY AND WITHOUT WARNING. THE AIR BAG INSIDE THE DRIVER'S SEAT ALSO DEPLOYED AND BECAME DETACHED FROM THE FRAME. THE VEHICLE WAS NOT BEEN INSP…
Read full complaint
TL* THE CONTACT OWNS A 2004 AUDI A4. THE CONTACT STATED THAT THE VEHICLE WAS SHIFTED INTO NEUTRAL AND THE PARKING BRAKE WAS APPLIED WHEN THE DRIVER'S SIDE CURTAIN AIR BAGS DEPLOYED ERRONEOUSLY AND WITHOUT WARNING. THE AIR BAG INSIDE THE DRIVER'S SEAT ALSO DEPLOYED AND BECAME DETACHED FROM THE FRAME. THE VEHICLE WAS NOT BEEN INSPECTED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE INCIDENT. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.
I PURCHASED A 2004 AUDI A4 1.8T ALL WHEEL DRIVE IN OCTOBER 2010. CARFAX SAYS NO ACCIDENTS, FLOODING, ETC. AIRBAG LIGHT CAME ON SO I TOOK IT TO AUDI OF SCHAUMBURG, IL WHO SAID THE HARNESS UNDER THE SEAT NEEDED TO BE REPLACED AND CHARGED $507.77. THIS IS THE DRIVER'S SEAT. SEVERAL MONTHS LATER THE AIR BAG LIGHT CAME ON AGA…
Read full complaint
I PURCHASED A 2004 AUDI A4 1.8T ALL WHEEL DRIVE IN OCTOBER 2010. CARFAX SAYS NO ACCIDENTS, FLOODING, ETC. AIRBAG LIGHT CAME ON SO I TOOK IT TO AUDI OF SCHAUMBURG, IL WHO SAID THE HARNESS UNDER THE SEAT NEEDED TO BE REPLACED AND CHARGED $507.77. THIS IS THE DRIVER'S SEAT. SEVERAL MONTHS LATER THE AIR BAG LIGHT CAME ON AGAIN. TOOK IT TO AUDI EXCHANGE IN HIGHLAND PARK, IL AND THEY SAID IT WAS RECOMMENDED THAT THE AIR BAG BE REPLACED. HOWEVER, AUDI DOES NOT GUARANTEE THAT THIS FIXES THE PROBLEM. THE COST IS $900 TO REPLACE THE AIRBAG BUT THE SERVICE MANAGER WAS GOING TO TRY TO GIVE ME SOME SORT OF DISCOUNT. PICKING THE CAR UP AGAIN TODAY. THIS IS A SAFETY ISSUE AND AUDI SHOULD RECALL THE CARS AND FIX IT FOR FREE. IF AIRBAGS AREN'T GOING TO DEPLOY THEN WHY HAVE THEM? WHY PAY MONEY FOR SAFETY FEATURES THAT DON'T WORK? *TR
MY HUSBAND AND I OWN A 2004 AUDI A4 CABRIO AND TOOK IT IN FOR A VOLUNTARY EMISSIONS SERVICE ACTION FOR AN IGNITION COIL REPLACEMENT ON FEB 4, 2010. AT THAT TIME, THE DASHBOARD LIGHT FOR THE DRIVER SIDE AIRBAG WAS ON CONSTANTLY AND WOULD NOT GO OFF SO WE ASKED THE SERVICE DEPARTMENT TO LOOK INTO IT. THEY TOLD US WE NEEDED A NEW …
Read full complaint
MY HUSBAND AND I OWN A 2004 AUDI A4 CABRIO AND TOOK IT IN FOR A VOLUNTARY EMISSIONS SERVICE ACTION FOR AN IGNITION COIL REPLACEMENT ON FEB 4, 2010. AT THAT TIME, THE DASHBOARD LIGHT FOR THE DRIVER SIDE AIRBAG WAS ON CONSTANTLY AND WOULD NOT GO OFF SO WE ASKED THE SERVICE DEPARTMENT TO LOOK INTO IT. THEY TOLD US WE NEEDED A NEW AIRBAG AND REPLACED IT AT A COST OF $746.14. WE HAD NOT BEEN IN A COLLISION AND HAD NOT TAMPERED WITH THE AIRBAG EITHER. *TR
PASSENGER SIDE AIRBAG LIGHT COMES ON DUE TO PASSENGER SEAT HARNESS ISSUES. THERE IS A TECHNICAL SERVICE BULLETIN HOWEVER AUDI WILL NOT REPAIR THIS ISSUE. *TR
I WAS IN A HEAD ON COLLISION PRIMARILY ON THE DRIVERS SIDE AND THE PASSENGER SIDE AIR BAG DEPLOYED AND THE DRIVERS SIDE DID NO. *TR
TL*THE CONTACTS OWNS A 2004 AUDI A4. THE CONTACT STATED THAT THE VEHICLE WAS REAR ENDED; HOWEVER, HE WAS NOT PRESENT AT THE TIME OF THE CRASH. AT THE TIME, THE FRONT PASSENGER SIDE AIR BAG DEPLOYED, BUT THE DRIVER'S SIDE AIR BAG DID NOT. AS A RESULT, THE DRIVER WAS INJURED AS WELL AS THE PASSENGER IN THE OTHER VEHICLE. A POL…
Read full complaint
TL*THE CONTACTS OWNS A 2004 AUDI A4. THE CONTACT STATED THAT THE VEHICLE WAS REAR ENDED; HOWEVER, HE WAS NOT PRESENT AT THE TIME OF THE CRASH. AT THE TIME, THE FRONT PASSENGER SIDE AIR BAG DEPLOYED, BUT THE DRIVER'S SIDE AIR BAG DID NOT. AS A RESULT, THE DRIVER WAS INJURED AS WELL AS THE PASSENGER IN THE OTHER VEHICLE. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO THE DEALER AND THE CAUSE OF THE FAILURE HAS NOT YET BEEN DETERMINED. THE CONTACT WAS UNSURE IF THE VEHICLE WAS DESTROYED. THE CURRENT AND FAILURE MILEAGES WERE 70,000.
TL*THE CONTACT OWNS A 2004 AUDI A4. WHILE TURNING A CORNER AT 45 MPH, THE CONTACT HAD TO APPLY THE BRAKES IMMEDIATELY TO AVOID STRIKING ANOTHER VEHICLE. AS A RESULT, HE REAR ENDED ANOTHER VEHICLE. THE PASSENGER SIDE AIR BAG FAILED TO DEPLOY. THERE WERE NO INJURIES. PRIOR TO THE FAILURE, THE CONTACT NOTICED FAILURE WITH THE …
Read full complaint
TL*THE CONTACT OWNS A 2004 AUDI A4. WHILE TURNING A CORNER AT 45 MPH, THE CONTACT HAD TO APPLY THE BRAKES IMMEDIATELY TO AVOID STRIKING ANOTHER VEHICLE. AS A RESULT, HE REAR ENDED ANOTHER VEHICLE. THE PASSENGER SIDE AIR BAG FAILED TO DEPLOY. THERE WERE NO INJURIES. PRIOR TO THE FAILURE, THE CONTACT NOTICED FAILURE WITH THE VEHICLE'S ELECTRICAL SYSTEM. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE 56,000.
I HAVE RECENTLY PURCHASED MY 2004 AUDI A4 AND THE AIRBAG LIGHT HAS RECENTLY IGNITED AFTER MY CAR HAS PASSED THE 50,000 MILE WARRANTY PERIOD. DEALERSHIP CLAIMS I NEED TO PAY 300 OUT OF POCKET TO COVER. I BELIEVE THIS TO BE A MANUFACTURE PROBLEM AS I HAVE NOT GOT INTO ANY ACCIDENTS OR ACTIONS WHICH MAY HAVE RESULTED IN THE AIRBAG …
Read full complaint
I HAVE RECENTLY PURCHASED MY 2004 AUDI A4 AND THE AIRBAG LIGHT HAS RECENTLY IGNITED AFTER MY CAR HAS PASSED THE 50,000 MILE WARRANTY PERIOD. DEALERSHIP CLAIMS I NEED TO PAY 300 OUT OF POCKET TO COVER. I BELIEVE THIS TO BE A MANUFACTURE PROBLEM AS I HAVE NOT GOT INTO ANY ACCIDENTS OR ACTIONS WHICH MAY HAVE RESULTED IN THE AIRBAG GOING OFF. *TR
Official recalls
216V382000 · Air Bags:frontal:passenger Side:inflator Module
Jun 1, 2016
Volkswagen Group of America, Inc. (Volkswagen) is recalling certain model year 2004-2008 Audi A4, and 2005-2011 Audi A6 vehicles originally sold, or ever registered, in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Volkswagen is recalling certain model year 2004-2008 Audi A4, and 2005-2008 Audi A6 vehicles originally sold, or ever registered, in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B." Lastly, unless included in "Zone A" or "Zone B" above, Volkswagen is recalling model year 2004 Audi A4 vehicles originally sold, or registered, in Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming. These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Audi will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. Owner notification letters were mailed April 28, 2017. Owners may contact Audi customer service at 1-800-822-2834.
05V096000 · Exterior Lighting:headlights
Mar 15, 2005
ON CERTAIN PASSENGER VEHICLES, THERE IS A POSSIBILITY OF XENON HEADLAMP COATING DEGRADATION OVER TIME. THE LUMINOUS TRANSMITTANCE OF THE HEADLAMP MAY DECREASE OVER A PERIOD OF TIME.
Consequence & remedy
Consequence: THIS CONDITION COULD AFFECT A DRIVER'S FIELD OF VIEW, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE LEFT AND RIGHT XENON HEADLAMP REFLECTORS FREE OF CHARGE. THE RECALL BEGAN ON APRIL 11, 2005. OWNERS MAY CONTACT AUDI AT 1-800-822-2834.
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
1PE08027 · Engine Stalling - Fuel Pump Failure
Opened Apr 14, 2008 · Closed Aug 6, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
IN RESPONSE TO ODI'S INFORMATION REQUEST FOR PE08-027, VOLKSWAGEN AG (VW) STATED THAT IT BELIEVES THAT THE POSSIBLE CAUSAL OR CONTRIBUTORY FACTORS OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES COULD RESULT FROM EXCESSIVE ACCUMULATION OF FOREIGN MATERIALS IN THE FUEL FILTER.IN RARE CASES, THE FUEL FILTER COULD BECOME CLOGGED, WHICH CAN CAUSE INCREASED PRESSURE ON THE PUMP.VW INDICATED THAT ENGINE STALLS RESULTING FROM THIS CONDITION ARE RARE AND WOULD BE PRECEDED BY SYMPTOMS SUCH AS REDUCED ENGINE POWER, NOISE OR HESITATION.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA DETERMINED THAT THE RATE OF ENGINE STALL INCIDENTS RESULTING FROM FUEL PUMP FAILURE IS LOW AT APPROXIMATELY 0.2 PERCENT AFTER THREE YEARS IN SERVICE. ON JANUARY 17, 2006, VW SUBMITTED A DEFECT INFORMATION REPORT TO ODI CONCERNING A SAFETY RECALL TO ADDRESS A DEFECT IN THE FUEL PUMPS OF APPROXIMATELY 74,000 MODEL YEAR (MY) 2003 VOLKSWAGEN PASSAT (47,000), AUDI A4 (20,000) AND AUDI A6 (7,000) VEHICLES BUILT FROM SEPTEMBER 2002 THROUGH MARCH 2003 (NHTSA RECALL NO. 06V-017, VW RECALL NOS. M7 FOR PASSAT AND JL FOR AUDI A4 AND A6).ACCORDING TO VW, A SUB-SUPPLIER EXPERIENCED AN UNKNOWN CHANGE IN THE MATERIAL COMPOSITION OF THE CARBON-BRUSH SET USED IN THE ELECTRIC MOTOR IN THE FUEL PUMP, WHICH COULD LEAD TO INCREASED WEAR OF THE CARBON-BRUSH SETS, WHICH IN TURN CAN LEAD TO AN INOPERATIVE FUEL PUMP AND, ULTIMATELY, STOPPAGE OF FUEL SUPPLY TO THE ENGINE.ON JULY 23, 2007, VW EXPANDED THE SCOPE OF THE RECALL TO INCLUDE VEHICLES MANUFACTURED FROM AUGUST 2002 THROUGH APRIL 2003, ADDING ANOTHER 34,358 VEHICLES TO THE ORIGINAL RECALL (24,801 VOLKSWAGEN PASSAT, 7,436 AUDI A4 AND 2,121 AUDI A6 VEHICLES).ODI ASSIGNED RECALL NO. 07V-375 TO THE AMENDED RECALL REPORT. THE MY 2004 AUDI A4 VEHICLES THAT ARE THE SUBJECT OF PE08-027 ARE NOT AFFECTED BY THE SUB-SUPPLIER ISSUE THAT PROMPTED 06V-017 AND 07V-375.PRODUCTION OF THE MY 2004 VEHICLES BEGAN FOUR MONTHS AFTER THE AMENDED PRODUCTION RANGE IDENTIFIED IN 07V-375.THE FUEL PUMP FAILURES IN THE MY 2004 VEHICLES HAVE DIFFERENT CAUSES THAN THE DEFECT IDENTIFIED IN THE PRIOR RECALL POPULATIONS AND HAVE OCCURRED AT MUCH LOWER FREQUENCIES. FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FIND BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
IN RESPONSE TO ODI'S INFORMATION REQUEST FOR PE08-027, VOLKSWAGEN AG (VW) STATED THAT IT BELIEVES THAT THE POSSIBLE CAUSAL OR CONTRIBUTORY FACTORS OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES COULD RESULT FROM EXCESSIVE ACCUMULATION OF FOREIGN MATERIALS IN THE FUEL FILTER.IN RARE CASES, THE FUEL FILTER COULD BECOME CLOGGED, WHICH CAN CAUSE INCREASED PRESSURE ON THE PUMP.VW INDICATED THAT ENGINE STALLS RESULTING FROM THIS CONDITION ARE RARE AND WOULD BE PRECEDED BY SYMPTOMS SUCH AS REDUCED ENGINE POWER, NOISE OR HESITATION.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA DETERMINED THAT THE RATE OF ENGINE STALL INCIDENTS RESULTING FROM FUEL PUMP FAILURE IS LOW AT APPROXIMATELY 0.2 PERCENT AFTER THREE YEARS IN SERVICE. ON JANUARY 17, 2006, VW SUBMITTED A DEFECT INFORMATION REPORT TO ODI CONCERNING A SAFETY RECALL TO ADDRESS A DEFECT IN THE FUEL PUMPS OF APPROXIMATELY 74,000 MODEL YEAR (MY) 2003 VOLKSWAGEN PASSAT (47,000), AUDI A4 (20,000) AND AUDI A6 (7,000) VEHICLES BUILT FROM SEPTEMBER 2002 THROUGH MARCH 2003 (NHTSA RECALL NO. 06V-017, VW RECALL NOS. M7 FOR PASSAT AND JL FOR AUDI A4 AND A6).ACCORDING TO VW, A SUB-SUPPLIER EXPERIENCED AN UNKNOWN CHANGE IN THE MATERIAL COMPOSITION OF THE CARBON-BRUSH SET USED IN THE ELECTRIC MOTOR IN THE FUEL PUMP, WHICH COULD LEAD TO INCREASED WEAR OF THE CARBON-BRUSH SETS, WHICH IN TURN CAN LEAD TO AN INOPERATIVE FUEL PUMP AND, ULTIMATELY, STOPPAGE OF FUEL SUPPLY TO THE ENGINE.ON JULY 23, 2007, VW EXPANDED THE SCOPE OF THE RECALL TO INCLUDE VEHICLES MANUFACTURED FROM AUGUST 2002 THROUGH APRIL 2003, ADDING ANOTHER 34,358 VEHICLES TO THE ORIGINAL RECALL (24,801 VOLKSWAGEN PASSAT, 7,436 AUDI A4 AND 2,121 AUDI A6 VEHICLES).ODI ASSIGNED RECALL NO. 07V-375 TO THE AMENDED RECALL REPORT. THE MY 2004 AUDI A4 VEHICLES THAT ARE THE SUBJECT OF PE08-027 ARE NOT AFFECTED BY THE SUB-SUPPLIER ISSUE THAT PROMPTED 06V-017 AND 07V-375.PRODUCTION OF THE MY 2004 VEHICLES BEGAN FOUR MONTHS AFTER THE AMENDED PRODUCTION RANGE IDENTIFIED IN 07V-375.THE FUEL PUMP FAILURES IN THE MY 2004 VEHICLES HAVE DIFFERENT CAUSES THAN THE DEFECT IDENTIFIED IN THE PRIOR RECALL POPULATIONS AND HAVE OCCURRED AT MUCH LOWER FREQUENCIES. FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FIND BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.
Fuel System, Gasoline:delivery
IN RESPONSE TO ODI'S INFORMATION REQUEST FOR PE08-027, VOLKSWAGEN AG (VW) STATED THAT IT BELIEVES THAT THE POSSIBLE CAUSAL OR CONTRIBUTORY FACTORS OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES COULD RESULT FROM EXCESSIVE ACCUMULATION OF FOREIGN MATERIALS IN THE FUEL FILTER.IN RARE CASES, THE FUEL FILTER COULD BECOME CLOGGED, WHICH CAN CAUSE INCREASED PRESSURE ON THE PUMP.VW INDICATED THAT ENGINE STALLS RESULTING FROM THIS CONDITION ARE RARE AND WOULD BE PRECEDED BY SYMPTOMS SUCH AS REDUCED ENGINE POWER, NOISE OR HESITATION.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA DETERMINED THAT THE RATE OF ENGINE STALL INCIDENTS RESULTING FROM FUEL PUMP FAILURE IS LOW AT APPROXIMATELY 0.2 PERCENT AFTER THREE YEARS IN SERVICE. ON JANUARY 17, 2006, VW SUBMITTED A DEFECT INFORMATION REPORT TO ODI CONCERNING A SAFETY RECALL TO ADDRESS A DEFECT IN THE FUEL PUMPS OF APPROXIMATELY 74,000 MODEL YEAR (MY) 2003 VOLKSWAGEN PASSAT (47,000), AUDI A4 (20,000) AND AUDI A6 (7,000) VEHICLES BUILT FROM SEPTEMBER 2002 THROUGH MARCH 2003 (NHTSA RECALL NO. 06V-017, VW RECALL NOS. M7 FOR PASSAT AND JL FOR AUDI A4 AND A6).ACCORDING TO VW, A SUB-SUPPLIER EXPERIENCED AN UNKNOWN CHANGE IN THE MATERIAL COMPOSITION OF THE CARBON-BRUSH SET USED IN THE ELECTRIC MOTOR IN THE FUEL PUMP, WHICH COULD LEAD TO INCREASED WEAR OF THE CARBON-BRUSH SETS, WHICH IN TURN CAN LEAD TO AN INOPERATIVE FUEL PUMP AND, ULTIMATELY, STOPPAGE OF FUEL SUPPLY TO THE ENGINE.ON JULY 23, 2007, VW EXPANDED THE SCOPE OF THE RECALL TO INCLUDE VEHICLES MANUFACTURED FROM AUGUST 2002 THROUGH APRIL 2003, ADDING ANOTHER 34,358 VEHICLES TO THE ORIGINAL RECALL (24,801 VOLKSWAGEN PASSAT, 7,436 AUDI A4 AND 2,121 AUDI A6 VEHICLES).ODI ASSIGNED RECALL NO. 07V-375 TO THE AMENDED RECALL REPORT. THE MY 2004 AUDI A4 VEHICLES THAT ARE THE SUBJECT OF PE08-027 ARE NOT AFFECTED BY THE SUB-SUPPLIER ISSUE THAT PROMPTED 06V-017 AND 07V-375.PRODUCTION OF THE MY 2004 VEHICLES BEGAN FOUR MONTHS AFTER THE AMENDED PRODUCTION RANGE IDENTIFIED IN 07V-375.THE FUEL PUMP FAILURES IN THE MY 2004 VEHICLES HAVE DIFFERENT CAUSES THAN THE DEFECT IDENTIFIED IN THE PRIOR RECALL POPULATIONS AND HAVE OCCURRED AT MUCH LOWER FREQUENCIES. FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FIND BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.
Fuel System, Gasoline
IN RESPONSE TO ODI'S INFORMATION REQUEST FOR PE08-027, VOLKSWAGEN AG (VW) STATED THAT IT BELIEVES THAT THE POSSIBLE CAUSAL OR CONTRIBUTORY FACTORS OF THE ALLEGED DEFECT IN THE SUBJECT VEHICLES COULD RESULT FROM EXCESSIVE ACCUMULATION OF FOREIGN MATERIALS IN THE FUEL FILTER.IN RARE CASES, THE FUEL FILTER COULD BECOME CLOGGED, WHICH CAN CAUSE INCREASED PRESSURE ON THE PUMP.VW INDICATED THAT ENGINE STALLS RESULTING FROM THIS CONDITION ARE RARE AND WOULD BE PRECEDED BY SYMPTOMS SUCH AS REDUCED ENGINE POWER, NOISE OR HESITATION.ODI'S ANALYSIS OF COMPLAINT AND WARRANTY DATA DETERMINED THAT THE RATE OF ENGINE STALL INCIDENTS RESULTING FROM FUEL PUMP FAILURE IS LOW AT APPROXIMATELY 0.2 PERCENT AFTER THREE YEARS IN SERVICE. ON JANUARY 17, 2006, VW SUBMITTED A DEFECT INFORMATION REPORT TO ODI CONCERNING A SAFETY RECALL TO ADDRESS A DEFECT IN THE FUEL PUMPS OF APPROXIMATELY 74,000 MODEL YEAR (MY) 2003 VOLKSWAGEN PASSAT (47,000), AUDI A4 (20,000) AND AUDI A6 (7,000) VEHICLES BUILT FROM SEPTEMBER 2002 THROUGH MARCH 2003 (NHTSA RECALL NO. 06V-017, VW RECALL NOS. M7 FOR PASSAT AND JL FOR AUDI A4 AND A6).ACCORDING TO VW, A SUB-SUPPLIER EXPERIENCED AN UNKNOWN CHANGE IN THE MATERIAL COMPOSITION OF THE CARBON-BRUSH SET USED IN THE ELECTRIC MOTOR IN THE FUEL PUMP, WHICH COULD LEAD TO INCREASED WEAR OF THE CARBON-BRUSH SETS, WHICH IN TURN CAN LEAD TO AN INOPERATIVE FUEL PUMP AND, ULTIMATELY, STOPPAGE OF FUEL SUPPLY TO THE ENGINE.ON JULY 23, 2007, VW EXPANDED THE SCOPE OF THE RECALL TO INCLUDE VEHICLES MANUFACTURED FROM AUGUST 2002 THROUGH APRIL 2003, ADDING ANOTHER 34,358 VEHICLES TO THE ORIGINAL RECALL (24,801 VOLKSWAGEN PASSAT, 7,436 AUDI A4 AND 2,121 AUDI A6 VEHICLES).ODI ASSIGNED RECALL NO. 07V-375 TO THE AMENDED RECALL REPORT. THE MY 2004 AUDI A4 VEHICLES THAT ARE THE SUBJECT OF PE08-027 ARE NOT AFFECTED BY THE SUB-SUPPLIER ISSUE THAT PROMPTED 06V-017 AND 07V-375.PRODUCTION OF THE MY 2004 VEHICLES BEGAN FOUR MONTHS AFTER THE AMENDED PRODUCTION RANGE IDENTIFIED IN 07V-375.THE FUEL PUMP FAILURES IN THE MY 2004 VEHICLES HAVE DIFFERENT CAUSES THAN THE DEFECT IDENTIFIED IN THE PRIOR RECALL POPULATIONS AND HAVE OCCURRED AT MUCH LOWER FREQUENCIES. FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FIND BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.