NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
279 reports55,000 miles · Apr 29, 2009
Engine And Engine Cooling
I PURCHASED A USED 2004 VW PASSAT WITH 34K MILES IN SEPTEMBER 2007. THE CAR WAS RUNNING FILE AND HAS BEEN KEPT CURRENT WITH OIL CHANGES. ON APRIL 3, 2009, MY FIANCE WAS DRIVING US HOME FROM WORK AND A LOUD KNOCKING NOISE STARTED AND A MESSAGE DISPLAYED SAYING STOP! OIL PRESSURE LOW. THIS HAS NEVER HAPPENED BEFORE. WE WERE STILL …
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I PURCHASED A USED 2004 VW PASSAT WITH 34K MILES IN SEPTEMBER 2007. THE CAR WAS RUNNING FILE AND HAS BEEN KEPT CURRENT WITH OIL CHANGES. ON APRIL 3, 2009, MY FIANCE WAS DRIVING US HOME FROM WORK AND A LOUD KNOCKING NOISE STARTED AND A MESSAGE DISPLAYED SAYING STOP! OIL PRESSURE LOW. THIS HAS NEVER HAPPENED BEFORE. WE WERE STILL FAR FROM HOME SO WE PULLED OVER AND TOOK A LOOK UNDER THE HOOD. THE OIL WAS LOW FOR SOME REASON, ALTHOUGH IT WAS RECENTLY CHANGED, SO WE PURCHASED A QUART TO GET US HOME. WE CONTINUED TO DRIVE HOME AND STARTING LOSING POWER AS THIS KNOCKING NOISE CONTINUED. WE DID MAKE IT HOME. THE CAR WAS TOWED FROM OUR HOME TO A VW DEALER THE NEXT DAY. WE WERE TOLD THAT THE CRANK SHAFT WAS DAMAGED DUE TO OIL SLUDGE BUILD-UP IN THE ENGINE. BASICALLY, THE ENGINE WAS SHOT AND I NEEDED A NEW ONE, WHICH WOULD COST ABOUT $4K WITH ABOUT $2K IN LABOR. THE CAR ONLY HAS 55K MILES ON IT - HOW COULD THIS HAPPEN? WE THEN WENT ONLINE AND CONDUCTED A SEARCH. WE FOUND THAT THIS IS A WELL-KNOWN PROBLEM WITH 1.8 T ENGINES BETWEEN 2003-2005. I WAS MORTIFIED. I WAS NEVER GIVEN ANY INFORMATION FROM VW ABOUT THIS ISSUE, ALTHOUGH THE CAR WAS PURCHASED USED. THE DEALER TOLD US THAT VW EXTENDED THE POWERTRAIN WARRANTY FOR TO 8 YRS DUE TO THIS ISSUE BUT WE MUST PROVIDE OIL CHANGE RECEIPTS. WE HAD NONE, BECAUSE NOT ONLY DID WE NOT HAVE ONES FROM THE PREVIOUS OWNER, BUT MY FIANCE CHANGES MY OIL AND ALTHOUGH HE USED THE REQUIRED SYNTHETIC OIL, THE DEALER TOLD US THAT THERE ARE "APPROVED BRANDS" THAT MUST BE USED. WE WERE NEVER GIVEN THIS INFO BECAUSE THE OWNER MANUAL ONLY SAYS USE 5W40 OR IF NOT AVAILABLE, USE 5W30 OIL. SO, WE ARE LEFT WITH NOTHING. IT CAN COST ANYWHERE BETWEEN $4-8K TO FIX. THE COST TO GET A NEW OR USED ENGINE PLUS LABOR IS RIDICULOUS. I'M DRIVING MY OLD HONDA THAT HAS 231K MILES WHILE MY VW SITS AT THE SHOP WAITING TO BE FIXED. I FEAR THE BILL. I PLANNED TO PURCHASE A NEW VW IN A COUPLE YEARS, BUT NOW I WILL NEVER BUY A VW AGAIN AND WILL MAKE SURE MY STORY IS HEARD!! *TR
NHTSA ODI #10267205
Mileage unknown · Mar 27, 2009
Engine And Engine Cooling
I OWN A 2004 VW PASSAT TDI (DIESEL) WITH 64, 500 MILES ON IT. I DID NOT HAVE A FAILURE BUT I WAS SO CONCERNED ABOUT IT, THAT I HAD IT PRE- FIXED. THE PROBLEM IS THAT THE BALANCE SHAFTS IN THIS ENGINE ARE DRIVEN BY A CHAIN OFF THE MOTOR WHICH ALSO DRIVES THE OLL PUMP. THIS UNFORTUNATE DESIGN SUBJECTS THE CHAIN TO STRESSES IT …
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I OWN A 2004 VW PASSAT TDI (DIESEL) WITH 64, 500 MILES ON IT. I DID NOT HAVE A FAILURE BUT I WAS SO CONCERNED ABOUT IT, THAT I HAD IT PRE- FIXED. THE PROBLEM IS THAT THE BALANCE SHAFTS IN THIS ENGINE ARE DRIVEN BY A CHAIN OFF THE MOTOR WHICH ALSO DRIVES THE OLL PUMP. THIS UNFORTUNATE DESIGN SUBJECTS THE CHAIN TO STRESSES IT CAN'T WITHSTAND. ON VARIOUS TDI FORUMS, ESPECIALLY TDICLUB.COM, THERE HAVE BEEN A SIGNIFICANT NUMBER OF CHAIN FAILURES REPORTED. WHEN THE CHAIN DRIVING THE OIL PUMP FAILS,THE ENGINE IS STARVED OF ESSENTIAL LUBRICATION AND IF IT FAILS IT CAN CAUSE CATASTROPHIC ENGINE DAMAGE AND THE ENGINE COULD SEIZE UP WHICH WOULD BE LIFE-THREATENING. RECENTLY, VW IN EUROPE RECOGNIZED THE PROBLEM AND DESIGNED A REPAIR, WHICH CHANGES THE CHAIN DRIVEN OIL PUMP TO A GEAR DRIVEN OIL PUMP. THIS APPEARS TO BE A PERMANENT FIX TO THE ORIGINAL DESIGN DEFECT. SINCE, UNLIKE VW OF AMERICA, I AM UNWILLING TO PUT MY AND MY CHILD'S LIFE AT RISK, I RECENTLY PAID ALMOST $3000 TO HAVE THE BALANCE SHAFT MODULE REPLACED WITH THE GEAR DRIVEN ONE. MOST OF THE PEOPLE HAVING THIS PROBLEM ARE EXPERIENCING IT AFTER THE CAR IS OUT OF WARRANTY AND VW DONE NOTHING TO NOTIFY THE NEARLY 12, 000 OWNERS OF THESE VEHICLES. MOST OF THE PEOPLE DRIVING THESE VEHICLES HAVE NO IDEA THAT THEIR CAR IS A POTENTIAL TIME BOMB. IT IS NOT A MATTER OF IF, BUT WHEN, BECAUSE OF THE POOR DESIGN, THEY ALL WILL FAIL. I WAS FORTUNATE THAT THE PARTS WERE AVAILABLE; THERE HAS BEEN A SHORTAGE AND PEOPLE HAVE HAD TO WAIT SEVERAL WEEKS JUST FOR THE PARTS TO COME IN. IF THE PART FAILS AND DESTROYS THE ENGINE, THE COST FOR THAT REPAIR IS $8-10,000. THIS IS A SAFETY ISSUE THAT NEEDS TO BE ADDRESSED BY VW OF AMERICA AND WE NEED YOUR HELP. THANK YOU FOR YOUR CONSIDERATION. *TR THE MECHANIC INFORMED THE CONSUMER THE MODULE AND CHAIN DRIVE HAD NOT FAILED, BUT THEY WERE SHOWING SIGNS OF FATIGUE. UPDATED 04/15/09. *JB
NHTSA ODI #10263256
48,000 miles · Mar 13, 2009
Visibility
IN APRIL 2008 MY 2004 VW PASSAT SPONTANEOUSLY DEVELOPED A CRACK, GRADUALLY LENGTHENING, IN THE WINDSHIELD. I REPLACED IT WITH AN ORIGINAL EQUIPMENT WINDSHIELD, AND NOW, IN MARCH 2009, THE WINDSHIELD HAS AGAIN SPONTANEOUSLY DEVELOPED A LENGTHENING CRACK. IN NEITHER CASE WAS THERE ANY CHIP OR "DING" OR ANYTHING SUGGESTING ANY IMPA…
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IN APRIL 2008 MY 2004 VW PASSAT SPONTANEOUSLY DEVELOPED A CRACK, GRADUALLY LENGTHENING, IN THE WINDSHIELD. I REPLACED IT WITH AN ORIGINAL EQUIPMENT WINDSHIELD, AND NOW, IN MARCH 2009, THE WINDSHIELD HAS AGAIN SPONTANEOUSLY DEVELOPED A LENGTHENING CRACK. IN NEITHER CASE WAS THERE ANY CHIP OR "DING" OR ANYTHING SUGGESTING ANY IMPACT OF ANYTHING INTO THE WINDSHIELD. *TR
NHTSA ODI #10261759
109,789 miles · Mar 5, 2009
Engine And Engine Cooling
A POTENTIAL ISSUE HAS COME TO MY ATTENTION THAT SOME ENGINE PARTS RELATED TO THE BALANCE SHAFT ASSEMBLY AND THE ENGINE OIL PUMP SYSTEM DRIVE CAN FAIL AS EARLY AS 45,000 MILES. AND IF THE FAILURE OF SAID COMPONENTS DO FAIL, SEVERE ENGINE DAMAGE CAN EASILY OCCUR FORCING THE DRIVER, AT MINIMUM, TO PAY AN UNREASONABLE AND VERY COSTL…
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A POTENTIAL ISSUE HAS COME TO MY ATTENTION THAT SOME ENGINE PARTS RELATED TO THE BALANCE SHAFT ASSEMBLY AND THE ENGINE OIL PUMP SYSTEM DRIVE CAN FAIL AS EARLY AS 45,000 MILES. AND IF THE FAILURE OF SAID COMPONENTS DO FAIL, SEVERE ENGINE DAMAGE CAN EASILY OCCUR FORCING THE DRIVER, AT MINIMUM, TO PAY AN UNREASONABLE AND VERY COSTLY SERVICE BILL. IF A DRIVER EXPERIENCES A SUDDEN LOSS OF POWER FROM THE ENGINE DURING A TYPICAL HIGHWAY PASS OR MERGING ON A ROADWAY, THE COST WOULD BE UNFATHOMABLE PERTAINING TO THE LOSS OF LIFE, FAR SURPASSING THE COST OF A NEW ENGINE AND THE LABOR TO INSTALL THE ENGINE. VOLKSWAGEN HAS COME UP WITH A FIX BY CHANGING THE CHAIN TO A GEAR. THEY HAVE NOT ACKNOWLEDGED THIS PROBLEM AS YET, EVEN WITH MANY OF THESE VEHICLES HAVING FAILED. IT IS JUST A MATTER OF WHEN NOT IF THIS WILL HAPPEN TO EVERY 2004 PASSAT WITH THE BHW ENGINES. I WOULD LIKE TO KNOW WHAT STEPS VOLKSWAGEN OF AMERICA IS TAKING TO INFORM 2004 AND 2005 PASSAT TDI OWNERS OF THIS PROBLEM. GOOD CORPORATE CITIZENSHIP WOULD DICTATE A PROBLEM OF THIS SEVERITY SHOULD BE COMMUNICATED TO THE OWNERS AS SOON AS POSSIBLE. THESE ENGINE FAILURES COULD LEAVE MOTORISTS STRANDED UNDER DIRE CIRCUMSTANCES. *TR
NHTSA ODI #10260796
Mileage unknown · Mar 2, 2009
Engine And Engine Cooling
WHILE UNDER WARRANTY COMPLAINED TO DEALER OF NOISE FROM ENGINE AREA. DEALER COULD NOT DETERMINE WHERE NOISE WAS COMING FROM BUT SAID NOT TO WORRY PROBLEM WAS NOTED AND WOULD BE COVERED IF/WHEN SOMETHING FAILED. OUT OF WARRANTY NOW, DEALER STATES POWER STEERING PUMP NEEDS REPLACING, NOT COVERED UNDER WARRANTY. HAD THE POWER STEER…
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WHILE UNDER WARRANTY COMPLAINED TO DEALER OF NOISE FROM ENGINE AREA. DEALER COULD NOT DETERMINE WHERE NOISE WAS COMING FROM BUT SAID NOT TO WORRY PROBLEM WAS NOTED AND WOULD BE COVERED IF/WHEN SOMETHING FAILED. OUT OF WARRANTY NOW, DEALER STATES POWER STEERING PUMP NEEDS REPLACING, NOT COVERED UNDER WARRANTY. HAD THE POWER STEERING PUMP REPLACED, NOT BY DEALER BUT SEVERE WINE REMAINS. WAS TOLD IT IS PROBABLY AC PUMP. HAD BELT TENSIONER REPLACED ALSO WITH NO RESOLVE. NOISE IS A LOUD WINE, CONSTANT VARIES SLIGHTLY WHEN AC IS ON. HAVE HEARD SEVERAL OTHER PASSATS WITH SAME NOISE. NO FAILURE HAS OCCURRED AS OF YET. *TR
NHTSA ODI #10260499
112,000 miles · Mar 1, 2009
Engine And Engine Cooling
THE BALANCE SHAFT CHAIN DRIVE IN THE BOTTOM END OF OUR 2004 PASSAT TDI HAS STARTED TO MAKE NOISE. THEY WILL ALL FAIL. I AM A CAR ENTHUSIAST AND FROM WHAT I UNDERSTAND THROUGH THE PAINS OF MANY THAT HAVE ALREADY REPLACED THEIR FAILED OR FAILING CHAIN DRIVEN BALANCE ASSEMBLY, MANY BREAK APART COMPLETELY, AND CAUSE THE OIL PUMP TO …
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THE BALANCE SHAFT CHAIN DRIVE IN THE BOTTOM END OF OUR 2004 PASSAT TDI HAS STARTED TO MAKE NOISE. THEY WILL ALL FAIL. I AM A CAR ENTHUSIAST AND FROM WHAT I UNDERSTAND THROUGH THE PAINS OF MANY THAT HAVE ALREADY REPLACED THEIR FAILED OR FAILING CHAIN DRIVEN BALANCE ASSEMBLY, MANY BREAK APART COMPLETELY, AND CAUSE THE OIL PUMP TO QUIT TURNING AND THE ENGINE TO LOCK UP SUDDENLY. VW HAS COME UP WITH A FIX FOR THIS, TO RETROFIT A GEAR DRIVEN UNIT, BUT AS OF YET HAS NOT EVEN ACKNOWLEDGED THIS VERY SERIOUS PROBLEM THAT MORE TIMES THAN NOT MANIFESTS ITSELF IN THE 60 TO 80K MILE RANGE. THE COST TO REPAIR PROACTIVE IS ABOUT $2500, BUT IF THE ENGINE IS DAMAGED, THE COST IS ABOUT $9000. THIS IS A VERY SERIOUS SAFETY ISSUE, AND CAN CAUSE THE ENGINE TO SUDDENLY SEIZE WHILE UNDERWAY! CURRENTLY THERE IS NOT EVEN A WARNING OF ANY KIND FROM VW TO OWNERS OF THESE VEHICLES TO BE AWARE OF THIS ISSUE. IF NOT FOR AN INTERNET FORUM, FRED'S TDI CLUB.COM, I LIKE MANY OTHERS WHO STILL ARE, WOULD BE COMPLETELY OBLIVIOUS TO THIS SERIOUS AND POTENTIALLY CATASTROPHIC FAILURE. *TR
NHTSA ODI #10260338
96,000 miles · Feb 26, 2009
Engine And Engine Cooling
THE CHAIN ON THE OIL PUMP, BALANCE SHAFT ASSEMBLY FAILED AT 96,000 MILES. IT WAS DETECTED BY A MECHANIC BEFORE THE ENGINE SEIZED. THE ENTIRE OIL PUMP AND BALANCE SHAFT ASSEMBLY WAS REPLACED. HAD THE PROBLEM NOT BEEN DETECTED, AND THE CHAIN BROKE, THE ENGINE WOULD HAVE BEEN STARVED OF LUBRICATION AND FAILED. THIS IS THE DIESEL…
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THE CHAIN ON THE OIL PUMP, BALANCE SHAFT ASSEMBLY FAILED AT 96,000 MILES. IT WAS DETECTED BY A MECHANIC BEFORE THE ENGINE SEIZED. THE ENTIRE OIL PUMP AND BALANCE SHAFT ASSEMBLY WAS REPLACED. HAD THE PROBLEM NOT BEEN DETECTED, AND THE CHAIN BROKE, THE ENGINE WOULD HAVE BEEN STARVED OF LUBRICATION AND FAILED. THIS IS THE DIESEL PASSAT WITH THE BHW ENGINE. *TR
NHTSA ODI #10260032
68,000 miles · Feb 25, 2009
Engine And Engine Cooling
THE BALANCE SHAFT ASSEMBLY AND THE ENGINE OIL PUMP SYSTEM DRIVE WILL FAIL. FAILURE OF BALANCE SHAFT ASSEMBLY AND THE ENGINE OIL PUMP SYSTEM DRIVE CAN LEAD TO CATASTROPHIC ENGINE FAILURE WITH LOSS OF OIL PRESSURE, BROKEN OIL PAN, BROKEN FRONT ENGINE SEAL FLANGE, AND DAMAGED CRANKSHAFT. THIS CAN RESULT IN DAMAGE TO THE EXTENT THAT…
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THE BALANCE SHAFT ASSEMBLY AND THE ENGINE OIL PUMP SYSTEM DRIVE WILL FAIL. FAILURE OF BALANCE SHAFT ASSEMBLY AND THE ENGINE OIL PUMP SYSTEM DRIVE CAN LEAD TO CATASTROPHIC ENGINE FAILURE WITH LOSS OF OIL PRESSURE, BROKEN OIL PAN, BROKEN FRONT ENGINE SEAL FLANGE, AND DAMAGED CRANKSHAFT. THIS CAN RESULT IN DAMAGE TO THE EXTENT THAT THE ENGINE MUST BE REPLACED. IF THIS OCCURS WHILE THE VEHICLE IS IN TRAFFIC, IT CAN LEAD TO A COLLISION WITH INJURIES OR DEATHS. *TR
NHTSA ODI #10259892
82,387 miles · Feb 24, 2009
Engine And Engine Cooling
THE BALANCE SHAFT CHAIN DRIVE IN THE BOTTOM END OF OUR 2004 PASSAT STARTED TO MAKE NOISE. THEY WILL ALL FAIL. I AM A MECHANIC SPECIALIZING IN THESE CARS, AND HAVE CURRENTLY HAD TO REPAIR 27 OF THESE, INCLUDING MY OWN. MANY BREAK APART COMPLETELY, AND CAUSE THE OIL PUMP TO QUIT TURNING AND THE ENGINE TO LOCK UP SUDDENLY. I HA…
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THE BALANCE SHAFT CHAIN DRIVE IN THE BOTTOM END OF OUR 2004 PASSAT STARTED TO MAKE NOISE. THEY WILL ALL FAIL. I AM A MECHANIC SPECIALIZING IN THESE CARS, AND HAVE CURRENTLY HAD TO REPAIR 27 OF THESE, INCLUDING MY OWN. MANY BREAK APART COMPLETELY, AND CAUSE THE OIL PUMP TO QUIT TURNING AND THE ENGINE TO LOCK UP SUDDENLY. I HAVE ONE SUCH CAR HERE RIGHT NOW. VW HAS COME UP WITH A FIX FOR THIS, TO RETROFIT A GEAR DRIVEN UNIT, BUT AS OF YET HAS NOT EVEN ACKNOWLEDGED THIS VERY SERIOUS PROBLEM THAT MORE TIMES THAN NOT MANIFESTS ITSELF IN THE 60 TO 80K MILE RANGE. THE COST TO REPAIR PROACTIVELY IS ABOUT $2500, BUT OF THE ENGINE IS DAMAGED, THE COST IS ABOUT $9000. THIS IS A VERY SERIOUS SAFETY ISSUE, AND CAN CAUSE THE ENGINE TO SUDDENLY SEIZE WHILE UNDERWAY! *TR
NHTSA ODI #10259806
80,000 miles · Feb 24, 2009
Engine And Engine Cooling
IT HAS COME TO MY ATTENTION THROUGH THE B5 FORUMS AT WWW.TDICLUB.COM THAT ALL 2004-2005 VW PASSAT TDI ENGINES HAVE BEEN OUTFITTED WITH A FAULTY CHAIN DRIVEN OIL-PUMP (AKA BALANCE SHAFT) ASSEMBLY THAT HAS AN EXTREMELY HIGH RATE OF FAILURE. FAILURE OF THE OIL-PUMP ASSEMBLY HAS PROVEN TO CAUSE MULTI-THOUSAND DOLLAR REPAIR BILLS FOR…
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IT HAS COME TO MY ATTENTION THROUGH THE B5 FORUMS AT WWW.TDICLUB.COM THAT ALL 2004-2005 VW PASSAT TDI ENGINES HAVE BEEN OUTFITTED WITH A FAULTY CHAIN DRIVEN OIL-PUMP (AKA BALANCE SHAFT) ASSEMBLY THAT HAS AN EXTREMELY HIGH RATE OF FAILURE. FAILURE OF THE OIL-PUMP ASSEMBLY HAS PROVEN TO CAUSE MULTI-THOUSAND DOLLAR REPAIR BILLS FOR OWNERS THAT EXPERIENCE A FAILURE WHILE DRIVING. A BULK OF THE FAILURES HAVE BEEN OCCURRING ON 04-05 PASSAT TDI'S WELL BEFORE THE CARS REACH 100,000 MILES. THERE ARE NO WARNING SIGNS TO OIL PUMP FAILURE OTHER THAN LOUDER THAN NORMAL ENGINE NOISES. VW HAS SINCE REDESIGNED THE OIL-PUMP ASSEMBLY TO INCORPORATE A GEAR-DRIVEN MECHANISM THAT ISN'T PRONE TO FAILURE. UNFORTUNATELY VW HAS NOT TAKEN INTO CONSIDERATION THE THOUSANDS OF PASSAT TDI OWNERS THAT ARE BEING FORCED TO UPGRADE THEIR CARS ON THEIR OWN DIME. THE UPGRADE COSTS ~$2,500 (PARTS & LABOR). IT IS OF MY OPINION (AND THE THOUSANDS OF FELLOW PASSAT TDI OWNERS) THAT THIS FAULTY DESIGN SHOULD BE RECALLED IMMEDIATELY AS THE POTENTIAL FOR AN OIL-PUMP FAILURE CAUSING PROPERTY DAMAGE AND/OR DEATH IS EMINENT. *TR
NHTSA ODI #10259772
NHTSA investigations
3EA11002 · Engine Compartment Fire
Opened Jan 26, 2011 · Closed Feb 17, 2012
Status: closed (inferred from source dates) · Electrical System; Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Additional source detail variants (2)
Electrical System
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
Engine And Engine Cooling
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine cover.The fires observed were contained in the engine compartment and did not reach into the passenger compartment in contrast to those caused by an overheated catalytic converter examined in ODI?s investigation in 2007 and 2008.There were no reports of crashes or personal injury in this examination.A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will monitor this issue and reserves the right to take further action if warranted by the circumstancesSee the Closing Report for additional details.
PE08008 · Fuel Tank Leak
Opened Jan 31, 2008 · Closed May 30, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly; Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Additional source detail variants (4)
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Gasoline:storage:tank Assembly
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
Fuel System, Other:storage:tank Assembly:pressure Relief Devices
VOLKSWAGEN (VW) IS RECALLING CERTAIN VW PASSAT 4MOTION AND AUDI A6 QUATTRO AND ALLROAD QUATTRO ALL-WHEEL DRIVE PASSENGER CARS.VW VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM NOVEMBER 22, 2000 THROUGH MAY 31, 2005 AND AUDI VEHICLES SUBJECT TO RECALL WERE MANUFACTURED FROM JUNE 2, 2001 TO JUNE 1, 2005.THE NHTSA RECALL NUMBER FOR THE VW VEHICLES IS 08V-156 (VW ALSO IS CORRECTING DEFECTS RELATED TO HEAT SHIELD AND FUEL LINE HAZARDS FOR THESE VEHICLES AND FOR 1999-2000 PASSATS IN THIS RECALL ACTION.)THE NHTSA RECALL NUMBER FOR THE AUDI VEHICLES IS 08V-157.SINCE 2006, ODI HAS RECEIVED 17 COMPLAINTS OF FUEL LEAKING FROM THE SUBJECT VEHICLES' FUEL TANKS.THE 400 COMPLAINTS SHOWN ABOVE MAY INCLUDE DUPLICATE REPORTS TO ODI AND THE MANUFACTURER. WHILE THE CONSEQUENCE (FUEL LEAKS FROM THE TOP OF THE TANK) IS SIMILAR FOR BOTH THE PASSAT AND AUDI SUBJECT VEHICLES, DIFFERENCES IN DESIGN AND CONSTRUCTION REQUIRE A DIFFERENT REMEDY FOR EACH VEHICLE.ON THE PASSATS, THE VENTILATION LINE COULD HAVE BEEN INSTALLED IMPROPERLY WITH TENSION AND WITH AN INCORRECTLY POSITIONED CABLE TIE.THE TENSION COULD CAUSE CRACKED OR BROKEN NIPPLES ON THE FUEL TANK ROLLOVER VALVE.ON THE AUDI VEHICLES, A MATERIAL CHANGE (EFFECTIVE JUNE 2, 2001) WITH DIFFERENT AGING CHARACTERISTICS USED FOR THE ROLLOVER VALVE AND THE USE OF AN INFLEXIBLE ALUMINUM VENTILATION LINE COULD CAUSE CRACKING OF THE NIPPLE ON THE ROLLOVER VALVE.VW IS RECALLING ALL VEHICLES SUBJECT TO THESE DEFECTS.IT WILL INSPECT PASSATS TO ENSURE THAT THE VENT LINE IS TENSION FREE AND CORRECT THE INSTALLATION IF TENSION IS FOUND.IF A CRACK OR FUEL LEAK IS FOUND, VW WILL REPLACE THE FUEL TANK.AUDI WILL REPAIR ALL SUBJECT VEHICLES BY REINFORCING THE FUEL TANK ROLLOVER VALVE WITH AN EPOXY ADHESIVE.THIS INVESTIGATION IS CLOSED.
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
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.
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