NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
94 reportsClear category filter58,000 miles · Mar 8, 2005
Engine And Engine Cooling
THE ENGINE CHECK-EMISSION LIGHT HAS COME ON FIVE TIMES. EACH TIME THE DEALER MADE A DIFFERENT REPAIR. 1) SECONDARY AIR PUMP 2) CHECK VALVE 3) MASS AIR FLOW SENSOR 4) INLET HOSE FOR BOOSTER VALVE 5)COMBI VALVE AND SECONDARY AIR PUMP. THE FIRST TIME THE SECONDARY AIR PUMP WAS REPLACED WAS AT 58000 MILES. THE SECOND TIME AT 7200…
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THE ENGINE CHECK-EMISSION LIGHT HAS COME ON FIVE TIMES. EACH TIME THE DEALER MADE A DIFFERENT REPAIR. 1) SECONDARY AIR PUMP 2) CHECK VALVE 3) MASS AIR FLOW SENSOR 4) INLET HOSE FOR BOOSTER VALVE 5)COMBI VALVE AND SECONDARY AIR PUMP. THE FIRST TIME THE SECONDARY AIR PUMP WAS REPLACED WAS AT 58000 MILES. THE SECOND TIME AT 72000 MILES, ONLY 14000 MILES LATER. THE DEALER SAID THE EMISSION SYSTEM IS POORLY DESIGNED.*AK
NHTSA ODI #10112712
55,000 miles · Mar 3, 2005
Engine And Engine Cooling
IF FOUND ON WWW.EPA.GOV A RECALL FOR EMISSION ON THE PASSAT 2.8L. MFR RECALL # WE/LK, EPA# 1694. THE EXACT DEFECT WAS FOUND ON MY PASSAT 1.8L. VACUUM SUPPLY WITHIN THE SECONDARY AIR SYSTEM IS LOST WHEN THE SECONDARY AIR VACUUM HOSES DISCONNECT FROM THE SYSTEM CONTROL VALVE. THE RUBBER VACUUM HOSE CONNECTORS SPLIT AND SEPARAT…
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IF FOUND ON WWW.EPA.GOV A RECALL FOR EMISSION ON THE PASSAT 2.8L. MFR RECALL # WE/LK, EPA# 1694. THE EXACT DEFECT WAS FOUND ON MY PASSAT 1.8L. VACUUM SUPPLY WITHIN THE SECONDARY AIR SYSTEM IS LOST WHEN THE SECONDARY AIR VACUUM HOSES DISCONNECT FROM THE SYSTEM CONTROL VALVE. THE RUBBER VACUUM HOSE CONNECTORS SPLIT AND SEPARATE FROM THE VACUUM CONNECTION THE VALVE DUE TO HEAT DISSIPATION IN THAT AREA. THE SECONDARY AIR HOSE PART# 058133817D. I TOOK MY VEHICLE IN AFTER THE CHECK ENGINE LIGHT WENT ON FOR THE EMISSION WORKSHOP. MY REPAIR WAS NOT COVERED DUE TO RECALL NOT COVERING MY VIN. *JB
NHTSA ODI #10112452
60,586 miles · Feb 11, 2005
Engine And Engine Cooling
THE CAR WAS MAKING A FUNNY NOISE AND THEN THE ENGINE STOPPED. WE HAD IT TOWED TO MINUTEMAN VW IN BEDFORD, MA AND THEY SAID THAT THE OIL PUMP HAD FAILED AND THAT BOTH THE OIL PUMP AND THE ENGINE WOULD HAVE TO BE REPLACED AT A COST OF $6,320.00. THE 2000 PASSAT HAS 60,586 MILES ON IT AND HAD BEEN IN FOR SERVICE AT 55,478 MILES. …
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THE CAR WAS MAKING A FUNNY NOISE AND THEN THE ENGINE STOPPED. WE HAD IT TOWED TO MINUTEMAN VW IN BEDFORD, MA AND THEY SAID THAT THE OIL PUMP HAD FAILED AND THAT BOTH THE OIL PUMP AND THE ENGINE WOULD HAVE TO BE REPLACED AT A COST OF $6,320.00. THE 2000 PASSAT HAS 60,586 MILES ON IT AND HAD BEEN IN FOR SERVICE AT 55,478 MILES. THE SERVICE DEPARTMENT TOLD US THAT IT SHOULD BE COVERED UNDER THE 10 YEAR/100,000 MILE POWER TRAIN WARRANTY, BUT WHEN THEY SUBMITTED OUR CLAIM TO VW THEY REFUSED TO COVER IT BECAUSE THEY SAID I NEEDED TO PROVIDE COPIES OF EVERY OIL CHANGE RECEIPT FOR THE PAST 4 1/2 YEARS. I WAS ABLE TO FIND 4 RECEIPTS, BUT I DO NOT SEE ANYWHERE IN THE OWNERS MANUAL WHERE IT CLEARLY AND EXPLICITLY STATES THAT WARRANTY REPAIRS WILL ONLY BE PERFORMED IF ALL RECEIPTS FOR ALL SERVICES PERFORMED ON THE CAR ARE PROVIDED. I NOTICED THAT THERE HAVE BEEN SEVERAL TECHNICAL SERVICE BULLETINS ISSUED ON THIS CAR WHICH RELATE TO ENGINE PROBLEMS AND WOULD LIKE THIS DEFECT TO BE CONSIDERED FOR A RECALL. THANK YOU. *JB
NHTSA ODI #10110325
66,823 miles · Jan 3, 2005
Engine And Engine Cooling
WHILE DRIVING AT ANY SPEED A KNOCKING NOISE WAS COMING FROM THE ENGINE COMPARTMENT. DEALERSHIP REPAIRED THE GAS RECIRCULATION VALVE (EGR VALVE). *AK
NHTSA ODI #10106637
75,250 miles · Dec 28, 2004
Engine And Engine Cooling
THE MASS AIR FLOW METER GAVE OUT ON MY 2000 VOLKSWAGEN PASSAT IN AUGUST 2003. A COUPLE OF MONTHS LATER, THE WARRANTY FOR THE PART WAS EXTENDED TO 70,000 MILES. I RECEIVED A REBATE FOR THE EXPENSE (FIVE MONTHS AFTER SUBMITTING IT). NOW, 16 MONTHS LATER, THE AIR FLOW METER FAILED AGAIN, AND MY CAR IS PAST THE 70,000 MILE WARRANTY…
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THE MASS AIR FLOW METER GAVE OUT ON MY 2000 VOLKSWAGEN PASSAT IN AUGUST 2003. A COUPLE OF MONTHS LATER, THE WARRANTY FOR THE PART WAS EXTENDED TO 70,000 MILES. I RECEIVED A REBATE FOR THE EXPENSE (FIVE MONTHS AFTER SUBMITTING IT). NOW, 16 MONTHS LATER, THE AIR FLOW METER FAILED AGAIN, AND MY CAR IS PAST THE 70,000 MILE WARRANTY PERIOD (BUT THE PART IS ONLY 20,000 MILES OLD). VOLKSWAGEN IS CLEARLY HAVING A SIGNIFICANT PROBLEM WITH THIS PART, WHICH HAS BEEN CONFIRMED BY TWO DIFFERENT VOLKWAGEN DEALERSHIPS. *JB
NHTSA ODI #10104665
60,000 miles · Dec 20, 2004
Engine And Engine Cooling
MY CHECK ENGINE LIGHT COMES ON EVERY 2 WEEKS, MY TRANSMISSION IS JERKING WHEN GEARING DOWN. THIS IS A NEW CAR AND IT SHOULD BE MORE DEPENDABLE. THEY RESET MY LIGHT AND THEN WE START OVER BECAUSE IT ALWAYS COMES BACK ON.*AK
NHTSA ODI #10104124
43,800 miles · Nov 12, 2004
Engine And Engine Cooling
FOR SECOND TIME, IN TWO MONTHS THE EMISSION CHECK LIGHT HAS COME ON. THIS IS ON MY VW PASSAT 2000, WHICH HAS 43,000 MILES. AFTER TAKING THE CAR TO DEALERSHIP, I WAS TOLD THAT THERE ARE FAULTY VACUUM HOSES AGAIN IN THE ENGINE THAT NEEDS TO BE REPLACED. I WAS TOLD BY DEALERSHIP THAT I SHOULD BE EXPECTING TO CHANGE THESE VAC…
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FOR SECOND TIME, IN TWO MONTHS THE EMISSION CHECK LIGHT HAS COME ON. THIS IS ON MY VW PASSAT 2000, WHICH HAS 43,000 MILES. AFTER TAKING THE CAR TO DEALERSHIP, I WAS TOLD THAT THERE ARE FAULTY VACUUM HOSES AGAIN IN THE ENGINE THAT NEEDS TO BE REPLACED. I WAS TOLD BY DEALERSHIP THAT I SHOULD BE EXPECTING TO CHANGE THESE VACUUM HOSES EVERY 40,000 MILES. THIS SOUNDS LIKE A MANUFACTURING DEFECT TO ME, AS I HAVE NEVER REPLACED THIS COMPONENT IN MY OTHER CARS, LET ALONE ON A REGULAR BASIS. I HAD REPLACED OTHER VACUUM HOSES A MONTH AGO. *JB
NHTSA ODI #10098769
80,000 miles · Oct 22, 2004
Engine And Engine CoolingEquipmentFire
1. BROUGHT 2000 PASSAT GLX TO DEALER TWICE TO FIX 'SMOKE COMING FROM ENGINE COMPARTMENT AND ACCOMPANYING BURNING SMELL.' DEALER CHARGED $430 TO REPLACE "IN/OUT TRANSMISSION COOLER LINES" THE FIRST TIME IN THE SHOP, AND "TIGHTENED THE CAMS" THE SECOND TIME. 2. LESS THAN 3 WEEKS AFTER THE SECOND SERVICE 'TIGHTENING THE CAMS', CA…
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1. BROUGHT 2000 PASSAT GLX TO DEALER TWICE TO FIX 'SMOKE COMING FROM ENGINE COMPARTMENT AND ACCOMPANYING BURNING SMELL.' DEALER CHARGED $430 TO REPLACE "IN/OUT TRANSMISSION COOLER LINES" THE FIRST TIME IN THE SHOP, AND "TIGHTENED THE CAMS" THE SECOND TIME. 2. LESS THAN 3 WEEKS AFTER THE SECOND SERVICE 'TIGHTENING THE CAMS', CAR CAUGHT FIRE WHILE TRAVELING NORTHBOUND ON I-95 AT MILE MARKER 8 IN NY. AFTER BEING NOTIFIED OF SMOKE COMING FROM THE CAR BY ANOTHER MOTORIST, WE PULLED OVER. SHORTLY THEREAFTER, THE ENTIRE CAR WAS ENGULFED IN FLAMES. 3. NOTHING WAS DONE TO CORRECT THE FAILURE AS THE CAR WAS TOTALED. INVESTIGATION MAY OR MAY NOT BE CONDUCTED BY INSURANCE COMPANY TO FIND THE CAUSE OF THE FIRE. *AK
NHTSA ODI #10096217
43,580 miles · Oct 14, 2004
Engine And Engine Cooling
AT 40,000 MILES, THE WATER PUMP BEARING FAILED. FOUTUNATELY, I STOPPED THE CAR IMMEDIATELY AND DID NOT INCUR FURTHER ENGINE DAMAGE. WAS ADVISED BY THE DEALER THAT WV "UNDER-ENGINEERED" THE WATER PUMP BEARING, RESULTING IN PREMATURE FAILURE.*AK
NHTSA ODI #10095750
Mileage unknown · Aug 25, 2004
Engine And Engine Cooling
WHILE DRIVING CHECK ENGINE LIGHT APPEARED ON THE DASHBOARD AND REMAINED ON. CONSUMER DROVE THE VEHICLE TO THE DEALER FOR INSPECTION, AND MECHANIC INFORMED CONSUMER THAT THE PROBLEM COULD NOT BE DUPLICATED. *AK
NHTSA ODI #10089791
NHTSA investigations
7EA07014 · Passenger Engine Compartment Fires
Opened Sep 28, 2007 · Closed Jul 7, 2008
Status: closed (inferred from source dates) · Electrical System:ignition; Engine And Engine Cooling:exhaust System
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
Additional source detail variants (2)
Electrical System:ignition
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
Engine And Engine Cooling:exhaust System
THE MANUFACTURER NOTIFIED NHTSA ON 04-APR-08 THAT A SAFETY RECALL ACTION WOULD BE INITIATED TO REMEDY THE ISSUE.IN JUNE 2008, THE MANUFACTURER ISSUED A TECHNICAL SERVICE BULLETIN (CODE 26E5/R5) REGARDING THE SPECIFIC PROCEDURES TO BE EMPLOYED IN THIS CAMPAIGN.VEHICLE OWNER NOTIFICATION LETTERS WERE SENT BEGINNING APPROXIMATELY JUNE 13, 2008.THE CAMPAIGN WAS ASSIGNED NHTSA NO. 08V-156.THIS RECALL AFFECTS ALL MY 1999-2005, 5TH GENERATION GASOLINE-POWERED PASSAT SEDANS AND STATION WAGONS.APPROXIMATELY 412,000 VEHICLES ARE AFFECTED.CORRECTIVE ACTION WILL CONSIST OF INSTALLING ADDITIONAL EXHAUST SYSTEM HEAT SHIELDING TO MITIGATE THE POTENTIAL THERMAL EFFECTS OF ENGINE IGNITION PROBLEMS.BASED ON THIS ACTION, THE SUBJECT EA HAS BEEN CLOSED.
PE07024 · Passenger/engine Compartment Fires
Opened May 10, 2007 · Closed Sep 28, 2007
Status: closed (inferred from source dates) · Electrical System:ignition
MANY OF THE FIRE REPORTS ALLEGE THAT THE VEHICLE FIRE WAS ATTRIBUTED TO IGNITION COIL FAILURE.VW PROVIDED ADDITIONAL DATA REGARDING ITS ANALYSIS OF VEHICLE FIRES AND A DETAILED DESCRIPTION OF THE THREE DIFFERENT ENGINES AND IGNITION SYSTEMS FOR THE SUBJECT VEHICLES.ODIFINDS THE NEED TO FURTHER INVESTIGATE THIS ISSUE.TO FACILITATE ACQUISITION AND ANALYSIS OF ADDITIONAL INFORMATION, THIS INVESTIGATIONHAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-014).
DP05004 · Engine Stalling
Opened Aug 11, 2005 · Closed Dec 8, 2005
Status: closed (inferred from source dates) · Electrical System:ignition:module
BY LETTER RECEIVED ON JUNE 24, 2005, MR. RONALD M. STRICKLAND OF RALEIGH, NC, SUBMITTED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE THE PERFORMANCE OF THE IGNITION COIL PLUGS ON MODEL YEAR (MY) 2000-2003 VOLKSWAGEN JETTA, GOLF AND PASSAT SEDANS.THE PETITIONER ALLEGES THAT HE HAD EXPERIENCED MULTIPLE STALLING EVENTS AS A RESULT OF ONE OR MORE IGNITION COIL PLUGS MALFUNCTIONING ON HIS 2002 VW JETTA SEDAN.AS A RESULT OF THE ENGINE STALLING, THE PETITIONER EXPERIENCED A LOSS OF POWER STEERING AND INCREASED BRAKING EFFORTS WHEN HE PULLED THE VEHICLE OVER TO THE SIDE OF THE ROAD TO CONTROL THE VEHICLE.AFTER A FEW MINUTES PARKED ON THE SHOULDER HE WAS ABLE TO RESTART THE VEHICLE ALTHOUGH THE ENGINE OPERATED AT REDUCED POWER.VW ISSUED A CUSTOMER SATISFACTION CAMPAIGN (CSC) ON JANUARY 31, 2003 TO INSTRUCT THEIR DEALERSHIPS TO INSPECT THE VEHICLES FOR ANY MALFUNCTIONING IGNITION COIL PACKS AND TO REPLACE THEM AT NO COST TO THE CONSUMER.CONSUMERS WERE NOTIFIED TO BRING THEIR VEHICLES TO THEIR DEALERSHIPS VIA OWNER LETTERS MAILED OUT ON JUNE 6, 2003.WHILE VW INITIALLY INSTRUCTED THE DEALERSHIPS TO ONLY REPLACE THE MALFUNCTIONING IGNITION COIL PACKS, A REVISED CSC WAS ISSUED TO DEALERSHIPS IN DECEMBER 2003 AND JANUARY 2004, INSTRUCTING DEALERSHIPS TO REPLACE ALL IGNITION COIL PACKS REGARDLESS OF THEIR PERFORMANCE.A REMINDER TO THE DEALERSHIPS WAS SENT BY VW ON APRIL OF 2004.ALTHOUGH THE CONCERNS OF THE PETITIONER COULD THEORETICALLY CREATE A SAFETY PROBLEM, THE RISK IS VERY SMALL, DUE TO THE ENGINE STILL RUNNING ON EITHER 3, 5, OR 7 CYLINDERS.THERE ARE NO REPORTED CRASHES OR INJURIES DUE TO THE ALLEGED DEFECT.ONCE DRIVERS ARE AWARE OF THE PROBLEM (LOSS OF POWER DUE TO ONE OF THE IGNITION COIL PACKS MALFUNCTIONING), DRIVERS ARE ABLE TO TAKE PRECAUTIONARY AND COMPENSATORY MEASURES AND STILL MAINTAIN CONTROL OF THEIR VEHICLES.IN ADDITION, FOUR FIRES WERE REPORTED TO ODI.THESE WERE IGNITION COIL BURNOUTS WITH NO ADDITIONAL DAMAGE TO THE VEHICLE AND WERE LOCALIZED ON TOP OF THE ENGINE. DURING THE LAST 24 MONTHS THE NUMBER OF STALL AND DRIVABILITY COMPLAINTS REPORTED TO ODI HAS GREATLY DIMINISHED FROM A PEAK OF 195 IN JANUARY OF 2003 TO ONLY 3 IN AUGUST OF 2005.THIS COINCIDES WITH THE CSC RELEASED BY VW.A SAFETY-RELATED 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.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.
EA03020 · Passenger Air Bag Lid Failure
Opened Oct 7, 2003 · Closed Apr 23, 2004
Status: closed (inferred from source dates) · Air Bags; Air Bags:frontal
THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.
Additional source detail variants (2)
Air Bags:frontal
THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.
Air Bags
THIS INVESTIGATION INVOLVES THE VOLKSWAGEN (VW) PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) LID UTILIZED IN MY 1998-2002 VW PASSAT.THE PSIR LID MAY DETACH FROM THE INSTRUMENT PANEL DURING AIR BAG DEPLOYMENT.THE OFFICE OF DEFECTS INVESTIGATION (ODI) OF THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION (NHTSA) OPENED THE PRELIMINARY EVALUATION ON MAY 23, 2003 TO DETERMINE WHETHER ALLEGED PSIR LID DETACHMENT PRESENTS AN UNREASONABLE SAFETY RISK TO PASSENGERS IN THE VEHICLE.ODI?S INVESTIGATION REVEALS THAT DETACHMENT OF THE PSIR LID DURING AIR BAG DEPLOYMENT MAY OCCUR FOR TWO REASONS: 1) THE SHAPE OF THE PSIR LID, AND THE LENGTH OF THE ATTACHING TETHER, MAY SNAG THE AIR BAG DURING DEPLOYMENT APPLYING ADDITIONAL PRESSURE ON BOLTS THAT FASTEN THE LID TO THE INSTRUMENT PANEL (IP); AND/OR 2) THE ORIGINAL PSIR LID DESIGN (SUBJECT VEHICLES) UTILIZED SIX GRADE 4.8 MM CARBON STEEL TACK WELD BOLTS WHICH MAY NOT BE AS STRONG AS THE NEW DESIGN PSIR LID CONSISTING OF SIX GRADE 8.8 MM CARBON STEEL PRESS BOLTS THAT ARE HEAT TREATED.ODI CONCLUDES THAT DETACHMENT OF THE PSIR LID IS A DEFECT BECAUSE THE LID SHOULD REMAIN ATTACHED TO THE IP AFTER DEPLOYMENT OF THE AIRBAG.HOWEVER, AFTER ANALYZING VW?S RESPONSES, AND TEST DATA COLLECTED BY VW AND FAURECIA, THE PSIR LID SUPPLIER, ODI BELIEVES THAT FURTHER INVESTIGATION WOULD NOT LIKELY IDENTIFY A SAFETY-RELATED DEFECT TREND BECAUSE A DETACHED PSIR LID AND PARTS DO NOT PROJECT TOWARDS A PASSENGER DURING DEPLOYMENT OF THE AIRBAG.THE TEST DATA SHOWS THAT THE AIRBAG PUSHES A DETACHED PSIR LID UPWARDS INTO THE WINDSHIELD DURING DEPLOYMENT, AND AWAY FROM THE PASSENGER COMPARTMENT.IT IS HIGHLY UNLIKELY THAT A PASSENGER WOULD CONTACT THE PSIR LID OR ASSOCIATED PARTS DURING AIR BAG DEPLOYMENT.THEREFORE THIS ENGINEERING ANALYSIS (EA 03-020) IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST. FOR A DETAILED DISCUSSION OF THE PSIR LID AND TESTING, SEE THE ATTACHED REPORT.
PE03021 · Passenger Sir Door Mounting Stud Failure
Opened May 23, 2003 · Closed Oct 7, 2003
Status: closed (inferred from source dates) · Air Bags:frontal
ODI OPENED A PRELIMINARY EVALUATION (PE03-021) BASED ON TWO REPORTS OF FAILED BOLT STUDS THAT ATTACH THE PASSENGER SUPPLEMENTAL INFLATABLE RESTRAINT (PSIR) DOOR COVER TO THE INSTRUMENT PANEL (IP) ON THE VOLKSWAGEN (VW) PASSAT (MODEL YEARS 2000, 2002).VW HAS INDICATED TO ODI THAT IT HAS NO ADDITIONAL REPORTS.VW IMPLEMENTED A PROCESS CHANGE ON MARCH 1, 2002.THIS PROCESS CHANGE CONSISTED OF CHANGING THE BOLT APPLICATION THAT FASTENS THE PSIR DOOR TO THE IP FROM A WELD ON APPLICATION TO A PRESS ON APPLICATION.VW ALSO CHANGED THE MATERIAL OF THE BOLT.VW STATED THAT THE CHANGES WERE MADE TO EASE PRODUCTION BY ELIMINATING A WELDING PROCESS.ODI HAS UPGRADED ITS INVESTIGATION TO ENGINEERING ANALYSIS (EA03-020).
EA00028 · Fuel Tank Puncture
Opened Dec 28, 2000 · Closed Jan 29, 2002
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
No summary supplied.
PE00033 · Fuel Tank Puncture
Opened Aug 10, 2000 · Closed Dec 28, 2000
Status: closed (inferred from source dates) · Vehicle Speed Control:linkages
THE OFFICE OF DEFECTS INVESTIGATION OPENED THIS INVESTIGATION ON AUGUST 10, 2000 BASED ON 9 REPORTS REGARDING PUNCTURED FUEL TANKS INVOLVING THE JETTA, PASSAT, AND CABRIO MODELS.THE REPORTS INDICATE ADDITIONAL REPORTS IN ITS RESPONSE TO THE PRELIMINARY EVALUATION.THIS INVESTIGATION HAS BEEN UPGRADED FOR FURTHER STUDY.
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