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

Clear category filter

22,975 miles · Oct 13, 2003

Engine And Engine Cooling

3 EMISSIONS SYSTEM FAILURES IN ONE YEAR. SECONDARY AIR PUMP REPLACED TWICE AND MASS AIR FLOW SENSOR REPLACED ONCE. CAR HAS LESS THAN 24000 MILES. *LA

NHTSA ODI #10041744

57,000 miles · Sep 9, 2003

Engine And Engine Cooling

Read full complaint

WHILE DRIVING AT MODERATE SPEEDS OF ABOUT 35 TO 45 MPH, CAR ENGINE LOST ALL POWER. ENGINE WAS STILL RUNNING AND ALL ACCESSORIES (LIGHTS, RADIO, ETC.) WERE ON, BUT PRESSING ON THE GAS PEDAL LEAD TO NO MOVEMENT BY THE CAR. EPC WARNING LIGHT CAME ON AT THE TIME OF POWER LOSS AS DID THE ASR WARNING LIGHT. STOPPING THE CAR AND TURNING IT OFF AND THEN BACK ON REMEDIED SITUATION, BUT IT RECURRED ON 9/2/2003 UNDER SAME CONDITIONS. DEALER ANALYSIS SHOWED A STICKING TURBO BOOSTER VALVE AND A BAD OXYGEN SENSOR (THIS IS THE 2ND O2 SENSOR TO BE REPLACED WITHIN A YEAR). DEALER HAD TO ORDER PARTS AND THEY WILL NOT BE IN UNTIL AT LEAST 9/9/2003. MEANWHILE, I HAVE TO DRIVE A 79 MILE ROUND TRIP COMMUTE DAILY IN TRAFFIC, AND FEAR THAT THIS WILL HAPPEN WHEN I AM AT 75 MPH ON THE INTERSTATE. THIS COULD LEAD TO A CRASH WITH POSSIBLE FATALITIES IF IT OCCURRED.*AK

NHTSA ODI #10037505

Mileage unknown · Sep 4, 2003

Engine And Engine Cooling

MASS AIR FLOW SENSOR NEEDED TO BE REPLACED 4 MONTHS AFTER HAVING THE SECONDARY AIR PUMP AND ACTUATOR VALVE ON THE BACK OF THE HEAD REPLACED.*AK

NHTSA ODI #10037228

24,600 miles · Sep 4, 2003

Engine And Engine Cooling

THE MALFUNCTION INDICATOR LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER ON 5/24/2003, AND THE TEMPERATURE SENSOR WAS REPLACED. SIX DAYS LATER LIGHT THE ILLUMINATED AGAIN.*AK THE VOLKSWAGEN HEADQUARTERS DID PAY FOR THE HOSE WHEN THE MALFUNCTION INDICATOR LIGHT ILLUMINATED AT APPROX. 24,000 MILES. *PH *JB

NHTSA ODI #10024264

31,796 miles · Apr 30, 2003

Engine And Engine Cooling

Read full complaint

I PURCHASED A NEW 2000 PASSAT IN FEB. OF 2000. ON NOV. 5, 2001 THE ENGINE LIGHT CAME ON, THE DASH DISPLAYED EMISSION WORKSHOP.THE SYSMPTOMS WERE A JOLTING WHEN PLACING THE CAR INTO ANY GEAR AND THE CAR LOSING POWER FOR SEVERAL SECONDS WHILE DRIVING.I TOOK IT IN AND FOUND OUT THE "ENGINE CONTROL MODULE" NEEDED REPLACMENT & THE "MASS AIR FLOW SENSOR" NEEDED TO BE REPLACED AND IT WAS FIXED AT NO CHARGE. THEN, ON DEC. 23, 2002 I HAD THE SAME SYMPTOMS AND TOOK IT IN AND HAD TOPAY $161.00 TO REPLACE THE "VACCUM LINE TO MANIFOLD". NOW YESTERDAY APRIL 28,2003 I HAD THE SAME SYMPTOMS AND FOUND OUT THE "MASS AIR FLOW SENSOR" NEEDS TO BE REPLACED FOR THE SEONCD TIME AND THE DEALER WILL ONLY PAY 50% AND THEY WILL STAND BEHIND THEIR DECISION BECAUSE THEY FEEL IT'S MORE THEN FAIR. THE DEALER HAS TOLD ME THAT IT IS VERY RARE FOR THIS PROBLEM TO HAPPEN. WELL IT HAS ALREADY HAPPENED 3 TIMES IN THE 3 YEARS I HAVE OWNED IT AND THEY ARE UNABLE TO GIVE ME AN ANSWER TO WHY THIS HAPPENS. I WOULD LIKE TO KNOW HOW MAY COMPLAINTS YOU HAVE RECEIVED ON CASE NUMBER:748685. I FEEL LIKE I PURCHASED A LEMON AND WILL BE DEALING WITH THIS SAME PROBLEM OVER AND OVER. I WILL NEVER PURCHASE OR RECOMMEND A VOLKSWAGEN TO ANYONE.

NHTSA ODI #10016778

Mileage unknown · Mar 3, 2003

Engine And Engine Cooling

THE VEHICLE STARTED TO MAKE A NOISE, AND THEN STALLED.*JB

NHTSA ODI #10009694

21,000 miles · Dec 29, 2002

Engine And Engine CoolingService Brakes, Hydraulic

Read full complaint

I DRIVE A 2000 VOLKSWAGON PASSAT GLX 4MOTION. I HAVE FELT THAT I GOT A BAD CAR SINCE VERY EARLY ON IN MY LEASE (I NOW HAVE 8 MONTHS LEFT). ON THIS PARTICULAR OCCAISION, I HAD A SEVERE OIL LEAK. THE DEALER INFORMED ME THAT THERE WAS A HOLE IN MY OIL PAN THAT MUST HAVE BEEN CAUSED BY A ROCK (I DON'T RECALL FEELING ANYTHING HIT THE CAR HARD ENOUGH TO PUT A HOLE IN ANYTHING). I WAS TOLD THAT THIS WAS NOT A WARRANTEED ITEM, RATHER NORMAL WEAR AND TEAR. I HAVE OWNED 5 OTHER CARS AND NEVER HAD THIS PROBLEM. I ALSO NOTICED THAT THE CAR WAS SHAKING WHEN THE BREAKS ARE APPLIED. I WAS TOLD BY THE DEALER THAT THIS IS DUE TO WARPED ROTORS. I ONLY HAVE 20,000 MILES ON THE VEHICLE AND HAVE NEVER HEARD OF ANY KIND OF BREAK PROBLEMS WITH THAT FEW MILES. I WAS ALSO TOLD THAT IS NOT COVERED BY WARRANTEE EITHER, AGAIN, NORMAL WEAR AND TEAR. THE OTHER 5 CARS THAT I OWNED EASILY HAD OVER 20,000 MILES ON THEM AND NEVER HAD A PROBLEM WITH BRAKE ROTORS. THIS SEEMS TO BE A TREND WITH THIS VEHICLE. EARLY ON IN MY LEASE, I HAD MULTIPLE PROBLEMS WITH MY CAR NOT STARTING. EACH TIME IT WAS DUE TO CARBON BUILDUP ON MY SPARK PLUGS. THE FIRST TIME IT HAPPENED THERE WAS ONLY 2,000 MILES ON THE CAR AND THE DEALER HAD THE NERVE TO TELL ME THAT SPARK PLUGS WERE STANDARD MAINTENENANCE ITEMS AND I MUST NOT BE TAKING CARE OF MY CAR PROPERLY. 2 YEARS LATER, THERE WAS AN EMISSION CONTROLS RECALL WHICH FIXED THIS PROBLEM, WHICH THE DEALER INITIALLY CALLED DRIVER ERROR, NOT A VEHICLE PROBLEM.

NHTSA ODI #10000417

Mileage unknown · Dec 19, 2002

Engine And Engine Cooling

THERE ARE FOUR OIL PACKETS LOCATED INTO HER VEHICLE. CAUSING THE VEHICLE TO STALL AND THE ENGINE LIGHT APPEAR ON THE DASHBOARD. PLEASE PROVIDE ADDITIONAL INFORMATION DEALER IS AWARE OF THE PROBLEM. TS

NHTSA ODI #10001228

Mileage unknown · Nov 22, 2002

Engine And Engine Cooling

Read full complaint

VEHICLE CHECK ENGINE LIGHT AND EMISSIONS WORKSHOP INDICATOR HAVE BEEN COMING ON 2-3 MINUTES AFTER START UP. VEHICLE TAKEN IN FOR 40,000 MILE SERVICE AND CHECK ENGINE LIGHT DIAGNOSTIC. VISIT # 1) REPLACED OXYGEN SENSOR ON EMISSIONS SYSTEM. CHECK ENGINE LIGHT BACK ON NEXT DAY. VISIT # 2)RESET CHECK ENGINE LIGHT. CHECK ENGINE LIGHT BACK ON NEXT DAY. SCHEDULED APPOINTMENT FOR FULL DIAGNOSTIC NEXT WEEK. VISIT #3) REPLACED VACUUM LINES, THOUGHT 40,000 MILE SERVICE WAS STRESSING OLDER PARTS. CHECK ENGINE LIGHT ON NEXT DAY. VISIT # 4) RESET CHECK ENGINE LIGHT. CHECK ENGINE LIGHT ON NEXT DAY. SCHEDULED ANOTHER FULL DIAGNOSTIC. VISIT # 5) ORDERED AND REPLACED SECONDARY AIR PUMP, LEFT VEHICLE OVERNIGHT. CHECK ENGINE LIGHT ON AT PICK UP. NO ALTERNATE TRANSPORTATION AVAILABLE, AGREED TO RETURN VEHICLE NEXT DAY. VISIT # 6) REPLACED RELAY FOR SECONDARY AIR PUMP. PLAN TO RETURN VEHICLE TO ME AFTER 3 MORE DAYS. HOPING 6TH REPAIR ATTEMPT IS SUCCESSFUL (11/22/02) DT

NHTSA ODI #770022

Mileage unknown · Nov 1, 2002

Engine And Engine Cooling

Read full complaint

ENGINE OCCASSIONALLY STALLS WHEN SHIFTING FROM A GEAR INTO NEUTRAL (FOR THE PURPOSE OF BRAKING). TODAY IT HAPPENED 3 TIMES STOPPING AT STOP LIGHTS, AND 2 TIMES IN PARKING LOTS. THIS HAS BEEN HAPPENING, OFTEN, ALL WEEK (ONCE AT HIGHWAY SPEEDS, SLOWING FOR AN EXIT RAMP - ENGINE STALLS, POWER STEERING AND BRAKING GOES OUT, NOT GOOD). THIS PROBLEM WAS 'FIXED' AT AROUND 40K MILES WHEN A 'WASTE SOLENOID GATE' AND A 'TURBO VALVE' WERE REPLACED AT THE DEALERSHIP OVER 3 SEPARATE VISITS. THE STALLING WAS GONE FOR ABOUT 6000 MILES, BUT NOW IT HAS RETURNED. THIS MAY BE CONNECTED WITH THE 'CHECK ENGINE LIGHT' WHICH WAS ON AT THAT TIME, AND HAS FLASHED ON RECENTLY. I'M PLANNING ON TAKING IT TO A LOCAL VW SHOP SOON TO GET THIER OPINION. DT

NHTSA ODI #769192

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.