Service Brakes, Hydraulic. Review the 160 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Engine And Engine Cooling. Review the 94 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 43 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

11 crash reports25 fire reports10 injury reports

Engine And Engine Cooling complaints

94 reports

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43,000 miles · Jul 28, 2004

Engine And Engine Cooling

CONSUMER COMPLAINED THAT AT 43000 MILES CATALYTIC CONVERTER WAS REPLACED UNDER WARRANTY. CURRENTLY, AT 90,000 MILES ANOTHER ONE NEEDED TO BE REPLACED. DEALER WILL NOT REPLACE THE CATALYTIC CONVERTER FOR FREE.*AK

NHTSA ODI #10083689

33,503 miles · Jul 24, 2004

Engine And Engine Cooling

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ANALYSIS OF SYSTEM AFTER CHECK ENGINE LIGHT SHOWED ONE OF TWO OXYGEN SENSORS DEFECTIVE. ITEM WAS REPLACED. NO OTHER CODES INDICATED FURTHER PROBLEMS..TWO DAYS LATER, CHECK ENGINE LIGHT LIT AGAIN. SECOND OXYGEN SENSOR REPLACED. THREE DAYS LATER, CHECK ENGINE LIGHT ON AGAIN. . ANALYSIS DETERMINED AIR MASS METER DEFECTIVE AND WAS REPLACED. REPAIR COSTS = $841.25. VERY REPUTABLE REPAIR SHOP SAID THIS HAPPENS FREQUENLY TO VW'S??? VW WILL BE NOTIFIED AND ASKED TO COMPENSATE FOR REPAIRS. *AK

NHTSA ODI #10082597

72,500 miles · Jun 10, 2004

Engine And Engine CoolingVehicle Speed Control

ENGINE SPEED PULSATES AT IDLE WHEN AUTOMATIC TRANSMISSION IS IN GEAR AND BRAKES APPLIED. NO FAILURE OR WARNING LIGHTS DISPLAYED. TO PREVENT SURGING OF CAR WHILE STOPPED, TRANSMISSION MUST BE PUT IN NEUTRAL. ALSO HESITATES SIGNIFICANTLY DURING SOME ACCELERATIONS FROM STOP DUE TO CONDITION, AND IDLES ROUGH WHEN COLD. SAME FAUL…

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NHTSA ODI #10075127

28,000 miles · May 6, 2004

Engine And Engine Cooling

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I HAVE A 2000 VW PASSAT AND HAVE CARBON BUILD UP ON THE VALVES DUE FROM PREMIUM GAS USE AS REQUIRED IN MANUAL. 2 SEPERATE OCCASIONS I HAD TO PAY HUNDREDS TO REPAIR THIS RECURRING PROBLEM. THE DEALER SAYS THEY DON'T KNOW WHAT FUEL I SHOULD USE. VW HEADQUARTERS FIRST SAID A YEAR AGO TO STRICTLY USE PREMIUM. NOW THEY TELL ME TO USE REGULAR BUT THEY WILL NOT DO ANYTHING FOR ME. I HAD TO REPLACE A RE CIRCULATION VALVE AND VACUUMS. I BELEIVE THERE IS A CONSUMER ISSUE HERE THAT SOMEONE HAS TO ADDRESS BECAUSE I CANNOT GET ANYBODY TO AGREE WHICH FUEL TO USE. THEY SHOULD REPAIR MY PROBLEM FOR FREE.

NHTSA ODI #10068406

82,000 miles · Mar 26, 2004

Engine And Engine Cooling

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I HAVE A 2000 VW PASSAT GLS SEDAN (AUTOMATIC) 1.8T ENGINE. I HAVE TAKEN THE CAR TO SERVICE EVERY 5K MILES TO VW AND THEN TO A REPUTABLE MECHANIC (HAVE ALL THE SERVICE RECORDS). IT IS CURRENTLY AT 82,000 MILES. 2 MONTHS AGO THE CAR STALLED ON THE ROAD. THE OIL CHECK LIGHT HAD BEEN ON FOR AWHILE. I HAD CALLED VW REGARDING THE SENSOR LIGHT AND THEY SAID THAT IT IS ONLY A SENSOR PROBLEM, AND NOT WORRY ABOUT IT. AFTER INVESTIGATION, THE CAR IS IN NEED OF A NEW ENGINE. CAM SHAFTS 3 AND 4 WERE DRY AND NOT RECEIVING OIL. I SUBMITTED THE CAR TO VW TO CLAIM UNDER THE 10 YEAR/100K MILE POWERTRAIN WARRANTY. AFTER 2 MONTHS OF INVESTIGATIONS, VW USA HAS DENIED MY CLAIM AND STATES THAT THIS IS DUE TO POOR MAINTENANCE. THE MECHANIC SHOP I TAKE MY CAR TO IS VERY REPUTABLE. MY FAMILY AND FRIENDS HAVE AND CONTINUE TO GO TO THIS SHOP AND HAVE NEVER HAD A PROBLEM. I AM IN THE STAGES OF LEGAL ACTION AGAINST VW USA.*AK

NHTSA ODI #10063944

Mileage unknown · Mar 17, 2004

Engine And Engine Cooling

I HAVE HAD PERSISTENT EMISSION PROBLEMS WITH MY 2000 V6 VW PASSAT SINCE DATE OF PURCHASE. THE MAF/OXYGEN SENSORS HAVE BEEN REPLACED NUMEROUS TIMES AND NOW I HAVE AN EMISSIONS ISSUE AGAIN (NOW OUTSIDE OF WARRANTY) THAT TRACES BACK TO SOMETHING IN MY SECONDARY AIR SYSTEM (ERROR CODES 1411, 1423). THESE EMISSION PROBLEMS ARE REG…

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NHTSA ODI #10062401

44,578 miles · Jan 15, 2004

Engine And Engine Cooling

COMPLETE ENGINE FAILURE CHECK OIL PRESSURE LIGHT APPEARED AT 38000 MILES; BROUGHT TO VW DEALER - TOLD THAT THE SENSOR LIGHT WAS STUCK ON CAR IS TAKEN TO VW DEALER AT 40444 FOR 40000 MILE MAINTENANCE CHECK OIL PRESSURE LIGHT APPEARS AT 44578 MILES; CAR TAKEN TO ANOTHER DEALER AND DEALER CLAIMS ENGINE IS TOTAL LOSS.

NHTSA ODI #10069077

35,234 miles · Jan 6, 2004

Engine And Engine CoolingFuel System, Gasoline

WHEN THE VEHICLE STOPPED AT A STOP SIGN OR A TRAFFIC LIGHT, IT STALLED. *AK THE PROBLEM WAS DIAGNOSED AS A SECONDARY AIR INJECTOR VALVE. THE VEHICLE EXPERIENCED A ROUGH IDLE. THE VALVE WAS REPLACED, BUT THE VEHICLE STILL IDLED ROUGH. THE CHECK ENGINE LIGHT WAS INTERMITTENT PRIOR TO REPAIR. *SC *JB

NHTSA ODI #10046637

Mileage unknown · Dec 30, 2003

Engine And Engine Cooling

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4TH WINTER IN A ROW SINCE PURCHASING VEHICLE IT HAS EXPERIENCED A PROBLEM STARTING. EACH YEAR THE "DIAGNOSIS" HAS BEEN SOMEWHAT DIFFERENT...BUT MAINLY A "PROBLEM WITH CARBONIZATION BUILDUP". 4 TIMES IN 4 YEARS, RESULTING IN NEW PLUGS, OIL CHANGE, THIS YEAR A NEW BATTERY, "DECARBONIZATION PROCEDURE"....HUNDREDS AND HUNDREDS OF DOLLARS. HAVE USED ONLY THE FINEST FUEL (VW CLAIMED THIS WAS THE ROOT PROBLEM, POOR QUALITY FUEL) SINCE THE FIRST INCIDENT IN 2000. PROBLEM PERSISTS.

NHTSA ODI #10051370

20,000 miles · Nov 17, 2003

Electrical SystemEngine And Engine Cooling

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MY HUSBAND AND I PURCHASED A 2000 PASSAT WITH 927 MILES ON THE ODOMETER ON JULY 21, 2000 (ANCIRA, SAN ANTONIO, TX). THREE VISITS TO THE DEALER THREE FOR A FLUID LEAK (3/29/01, 2/13/02, 1/17/03). EACH TIME, WE WERE TOLD THAT NOTHING WAS WRONG. FOUR MONTHS AGO- "EMISSION CONTROL," "CHECK ENGINE" LIGHT CAME ON. ALSO THE FOLLOWING QUIT WORKING: POWER MIRRORS, THE TRAVEL COMPUTER, TEMPERATURE SENSOR WAS ERRATIC, FUEL DOOR QUIT AND THE FUEL MILEAGE GAUGE MALFUNCTIONED. MOST RECENTLY, THE CAR STARTED RUNNING ROUGH AND A CLEAR, VISCOUS FLUID APPEARED ON MY GARAGE FLOOR. THE CAR HAS 25,000 MILES. WE CHANGE THE OIL REGULARLY. IT HAD A 15,000-MILE CHECK-UP. WE TOOK THE CAR TO A REPUTABLE MECHANIC (MANDER AUTOMOTIVE IN HELOTES, TEXAS). THE OWNER OF MANDER (BOB MANDER) WAS VERY CONCERNED THAT THIS CAR HAD SO MANY ELECTRICAL AND COMPUTER PROBLEMS. ANCIRA INFORMED (MANDER) THAT THE CAR'S WARRANTY HAD EXPIRED BY 900 MILES (24,990) THAT VISIT (11/6/03). COMPUTER SCAN AND ANALYSIS SHOWED SEVERAL CODES RELATED TO MISFIRES AND RUNNING LEAN. ALSO: TRANSAXLE SEAL LEAK AND BATTERY FAILED THE LOAD TEST-WOULD NOT HOLD ACHARGE. MANDER FIXED: SEAL LEAK, REPLACED THE BATTERY, CHANGED THE OIL, REPLACED THE ACTUATOR (FUEL DOOR), REPAIRED VACUUM LEAKS, RESET THE T.E.H. COMPUTER AND CORRECTED THE FAULTY WIRING TO THE MIRRORS. WE SPENT $649. 24 HOURS LATER-"CHECK ENGINE" LIGHT RE-APPEARED. THE CAR BEGAN TO VIBRATE HARD. WE TOOK THE CAR BACK TO MR. MANDER (11/14/03). HE FOUND A DEFECTIVE OXYGEN SENSOR AND PROBLEM WITH THE COOLANT SENSOR- BOTH REPLACED. THAT TIME WE SPENT $358. MY HUSBAND AND I HAVE AN ESTABLISHED RELATIONSHIP WITH MANDER AUTOMOTIVE AND TRUST THEIR WORK AND ANALYSIS. THE "CHECK ENGINE" LIGHT AND "EMISSIONS CONTROL" LIGHT IS BACK ON. THE CAR IS RUNNING HARD, AGAIN. I HAVE CONTACTED VW (REFERENCE #30522917) AND MY HUSBAND WAS ADVISED TO TAKE THE CAR TO A DIFFERENT DEALER HERE IN SAN ANTONIO (ROD EAST). *LA

NHTSA ODI #10047080

Official recalls

08V156000 · Fuel System, Gasoline:delivery

Apr 7, 2008

VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN LEAK DUE TO FRACTURE.

Consequence & remedy

Consequence: A HEAT SHIELD THAT MAY CONTACT THE EXHAUST SYSTEM CAN RESULT IN A VEHICLE FIRE. IN ADDITION, A FUEL LEAK FROM A FUEL LINE OR FUEL TANK VENTILATION VALVE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN LEAD TO A VEHICLE FIRE.

Remedy: DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY SOFTWARE UPDATE. DEALERS WILL ALSO INSPECT AND ADJUST THE FUEL LINE ROUTING ON 1.8T VEHICLES AND THE FUEL TANK VENTILATION VALVE ON 4MOTION/ALL WHEEL DRIVE VEHICLES, AND REPLACE COMPONENTS IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON JUNE 13, 2008. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

02V026000 · Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap

Jan 25, 2002

ON SOME PASSENGER VEHICLES, THE FUEL TANK FILLER NECK CAN SUFFER ABRASION DAMAGE IF THE REAR TIRE GOES FLAT AND THE VEHICLE IS DRIVEN UNTIL THE TIRE DISINTEGRATES.

Consequence & remedy

Consequence: FUEL LEAKAGE CAN OCCUR INCREASING THE RISK OF A FIRE.

Remedy: DEALERS WILL FIT PASSAT VEHICLES WITH A NEW WHEEL HOUSE LINER THAT WILL BETTER PROTECT THE CAR'S FILLER NECK. JETTA VEHICLES WILL BE FITTED WITH A DIFFERENT METAL SHIELD DESIGNED TO ENHANCE ABRASION PROTECTION IN THE EVENT OF TIRE DISINTEGRATION. OWNER NOTIFICATION BEGAN JUNE 13, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

01V157000 · Fuel System, Gasoline:storage:tank Assembly

May 3, 2001

VEHICLE DESCRIPTION: PASSENGER VEHICLES. SULFUR IN FUEL INTERACTS WITH CERTAIN ADDITIVES FOUND IN WIDELY AVAILABLE GASOLINE CAUSING SULFUR TO BECOME DEPOSITED ON THE CONTACT POINTS OF THREE FUEL SENDING UNITS MOUNTED INSIDE THE FUEL TANK. THIS COULD CAUSE THE FUEL GAUGE TO READ FULL WHILE THE FUEL TANK MAY NOT IN FACT BE FULL OR COULD BE EMPTY.

Consequence & remedy

Consequence: RUNNING OUT OF FUEL WITHOUT WARNING WHILE THE FUEL GAUGE INDICATES THAT THERE IS SUFFICIENT FUEL IN THE TANK LEAD TO SAFETY PROBLEMS.

Remedy: DEALERS WILL REMOVE THE EXISTING FUEL LEVEL SENDING UNITS AND REPLACE THEM WITH FUEL LEVEL SENDING UNITS USING A NEW ALLOY COMPOSED OF GOLD, SILVER, AND A SMALL AMOUNT OF NICKEL, WHICH WILL NOT CHEMICALLY REACT WITH SULFUR. VW/AUDI WILL ALSO CALL BACK VEHICLES THAT WERE REPAIRED UNDER A PREVIOUS RECALL LAST JUNE IN ORDER TO INSTALL THE UPDATED FUEL SENDING UNITS NHTSA 00V137/AUDI LB). OWNER NOTIFICATION BEGAN MAY 1, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT AUDI AT 1-866-892-2834.

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

EA07014 · 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

Engine And Engine Cooling:exhaust System

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

Air Bags

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.