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2004 Volkswagen Touareg

Owner reports · Recalls · Investigations

More warning signs than most Touareg years

Owner complaints for the 2004 Volkswagen Touareg are substantially higher than the model-year median of 27.5.

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When problems were reported

Mileage at the reported incident

165 reports with mileage · 66 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.

  • Power Train. Review the 50 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 49 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Tires. Review the 36 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

9 crash reports5 fire reports6 injury reports

Electrical System complaints

49 reports
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Mileage unknown · Apr 24, 2023
Electrical SystemExterior LightingFire

My SUV was sitting for a few days at the airport and I when I got in the car, it started fine but the headlights, interior lights, power folding mirrors and the voltmeter were not working. I had to leave the car there since it was night time. The next day I drove it home in daylight and started checking fuses. I noticed two fuse…

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My SUV was sitting for a few days at the airport and I when I got in the car, it started fine but the headlights, interior lights, power folding mirrors and the voltmeter were not working. I had to leave the car there since it was night time. The next day I drove it home in daylight and started checking fuses. I noticed two fuses (#2, #12) on the driver side fuse panel were failed. I replaced the #2, 5 amp, fuse and no changes were noticed. Then I replaced the #12, 25 amp, fuse and I heard a number of systems clicking and powering on; the lights flickered. Then I smelled burning and saw a puff of smoke come from under the dash. I immediately pulled the fuse . After troubleshooting, I found the body control module 7L6-937-049-K had caught fire internally and started to burn through the casing. Had I not pulled the fuse and disconnected the battery, this could have been catastrophic. Once I smelled the smoke, I realized it was like the acrid smell in the suv the night before. The fact the fuse blew the previous day saved the vehicle. It was parked on the fourth floor of parking garage at the airport so many vehicles could have been damaged and people endangered had it caught fire. Not to mention the disruption at an airport. There were no warning lamps. The only indication of a problem was the inoperable systems I mentioned. Also thinking back, the slight acrid smell was present the day I arrived at the airport, I had mistaken it for plane exhaust and car exhaust smells in the garage. The vehicle has not been inspected by any dealer, manufacturer or govermental agency. I have contacted the manufacturer for guidance and help with repairing. I am awaiting a response.

NHTSA ODI #11518742

Mileage unknown · Nov 25, 2021
Electrical SystemEngineExterior LightingFireInjury

Leaking gas caught on fire put it out but now I have no head lights no high beams replaced everything still nothing. All lights on dash go crazy kills battery all the time and had to replace something in the rear end. Overall it has cost me $2500 and I still have no headlights at all and leaking gas. It’s my only vehicle I hope…

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Leaking gas caught on fire put it out but now I have no head lights no high beams replaced everything still nothing. All lights on dash go crazy kills battery all the time and had to replace something in the rear end. Overall it has cost me $2500 and I still have no headlights at all and leaking gas. It’s my only vehicle I hope next time it doesn’t catch back on fire could have been worse and still could be. Somebody could get hurt and I have kids.

NHTSA ODI #11441658

110,000 miles · Nov 17, 2020
Electrical SystemExterior LightingFire

LIGHT WENT OUT ON DARK ROAD. NEARLY CRASHED. FOUND INSULATION ON WIRES FOR LIGHTS DETERIORATED. HARNESS WAS MELTED LOWER IN THE FENDER. ONLINE SEARCH FOUND SAME ISSUE IS COMMON AND INCLUDED FIRES.

NHTSA ODI #11375085

131,403 miles · Aug 20, 2019
Electrical SystemService Brakes

LIGHTS ON THE DASH COME ON HILL ASSIST SHUTS ON AND OFF BY ITSELF BRAKE LIGHT COMES ON AND OFF SUNROOF HAS OPEN BY ITSELF AC HAS STOPPED WORKING AND THE NEXT DAY WORKS AGAIN HEATED STEERING WHEEL WORKS WHEN IT WANTS THIS HAPPENED WHILE YOU'RE DRIVING OR SITTING STILL EVERYTHING I HAVE READ ON THE INTERNET HAS POINTED TO AN ELECT…

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LIGHTS ON THE DASH COME ON HILL ASSIST SHUTS ON AND OFF BY ITSELF BRAKE LIGHT COMES ON AND OFF SUNROOF HAS OPEN BY ITSELF AC HAS STOPPED WORKING AND THE NEXT DAY WORKS AGAIN HEATED STEERING WHEEL WORKS WHEN IT WANTS THIS HAPPENED WHILE YOU'RE DRIVING OR SITTING STILL EVERYTHING I HAVE READ ON THE INTERNET HAS POINTED TO AN ELECTRICAL ISSUE THIS IS AN EVERYDAY THING

NHTSA ODI #11245345

135,000 miles · Dec 12, 2017
Electrical System

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THAT THE VEHICLE FAILED TO START WHEN ATTEMPTING TO DRIVE. WHEN THE VEHICLE WAS STARTED, AN ELECTRICAL NOISE WAS HEARD FROM THE DASHBOARD. IN ADDITION, THE ELECTRICAL SYSTEM FAILED AFTER THREE DAYS. THE VEHICLE WAS TAKEN TO DAVID MAUS VOLKSWAGEN NORTH (1050 LEE R…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THAT THE VEHICLE FAILED TO START WHEN ATTEMPTING TO DRIVE. WHEN THE VEHICLE WAS STARTED, AN ELECTRICAL NOISE WAS HEARD FROM THE DASHBOARD. IN ADDITION, THE ELECTRICAL SYSTEM FAILED AFTER THREE DAYS. THE VEHICLE WAS TAKEN TO DAVID MAUS VOLKSWAGEN NORTH (1050 LEE RD, ORLANDO, FL 32810, PHONE: (407) 233-0529), BUT THE CAUSE OF THE FAILURE COULD NOT BE DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 135,000.

NHTSA ODI #11054179

140,232 miles · Mar 11, 2017
Electrical SystemExterior Lighting

ABOUT 2 WEEKS AGO, I STARTED BLOWING FUSES FOR THE DRIVERS SIDE TURN SIGNAL. I WOULD HAVE NO FRONT OR REAR TURN SIGNAL, AS WELL AS NO HAZARDS ON THE DRIVERS SIDE. I LOOKED INSIDE THE HEADLIGHT ASSEMBLY AND FOUND THAT ALL THE WIRING WAS EXPOSED DUE TO THE WIRING INSULATION ROTTING OFF, LEAVING EXPOSED WIRING. I AM A FIREF…

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ABOUT 2 WEEKS AGO, I STARTED BLOWING FUSES FOR THE DRIVERS SIDE TURN SIGNAL. I WOULD HAVE NO FRONT OR REAR TURN SIGNAL, AS WELL AS NO HAZARDS ON THE DRIVERS SIDE. I LOOKED INSIDE THE HEADLIGHT ASSEMBLY AND FOUND THAT ALL THE WIRING WAS EXPOSED DUE TO THE WIRING INSULATION ROTTING OFF, LEAVING EXPOSED WIRING. I AM A FIREFIGHTER, AND THIS IS A VEHICLE FIRE, WAITING TO HAPPEN. YOU CANT EVEN WRAP ELECTRICAL TAPE AROUND IT, DUE TO THE HEADLAMP UNIT NOT BEING ABLE TO BE TAKEN APART. I HAVE NO LEFT TURN SIGNALS, AND RISK BEING HIT, SIDESWIPED, OR GETTING A TICKET FROM THE POLICE FOR SOMETHING I CANNOT FIX. I HAVE REPLACED 4 DIFFERENT FUSES NOW TRYING TO FIX THIS.

NHTSA ODI #10960102

Mileage unknown · Apr 5, 2016
Electrical SystemElectronic Stability Control (esc)Steering

THE EMERGENCY BRAKE ALARM WAS GOING OFF MORE FREQUENTLY AND TO SILENCE IT I WOULD PULL THE SPING ON THE BRAKE UP. THE BRAKE ALARM RANDOMLY WAS ANOYING BUT NOT A MAJOR CONCERN. I HADN'T HAD ANY MECHANICAL ISSUES WITH MY CAR UNTIL 01/23/16 I ATTEMPTED TO START MY CAR AND RECIEVED AN ERROR MESSAGE THE READ STEERING DEFECT AND IT W…

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THE EMERGENCY BRAKE ALARM WAS GOING OFF MORE FREQUENTLY AND TO SILENCE IT I WOULD PULL THE SPING ON THE BRAKE UP. THE BRAKE ALARM RANDOMLY WAS ANOYING BUT NOT A MAJOR CONCERN. I HADN'T HAD ANY MECHANICAL ISSUES WITH MY CAR UNTIL 01/23/16 I ATTEMPTED TO START MY CAR AND RECIEVED AN ERROR MESSAGE THE READ STEERING DEFECT AND IT WOULDN'T ALLOW YOU TO START THE CAR BEYOND THE ERROR MESSAGE. I HAD MY CAR TOWED TO VOLKSWAGON MENTOR OHIO AFTER HOLDING MY CAR FOR MORE THAN A WEEK I WAS FINALLY OFFERED A DIAGNOSIS THAT THE ACCESS MODULAR WAS NOT FUNCTIONING MEANING THE BRAIN OF THE VEHICLE WASN'T FUNCTIONING AND THE VW DEALERSHIP SERVICE DEPARTMENT DIDN'T HAVE ANSWER TO HOW THIS HAPPENED THEY HAD A $2500 SOLUTION TO THE PROBLEM AND THEY WERE MORE THAN HAPPY TO ASSIST IN REPLACEMENT OF THE ACCESS MODULAR WITH THERE HEARTY COST. THE BRAIN THE VOLKSWAGON ACCESS MODULAR STOPS FUNCTIONING AND VOLKSWAGEN AT NO FAULT OF MINE AND I'M CHARGED $2500 PLUS. MECHANICAL MAINTENANCE I UNDERSTAND BUT REPLACEMENT OF THE VEHICLES ACCESS MODULAR IS A REPAIR THAT I FEEL VOLKSWGON SHOULD COVER.

NHTSA ODI #10853446

115,000 miles · Jan 26, 2015
Electrical SystemElectronic Stability Control (esc)Steering

I RECENTLY PURCHASED A 2004 VW TUAREG IN JULY 1ST OF 2014. IMMEDIATELY UPON PURCHASING THE VEHICLE I BEGAN RECEIVING A PARKING BRAKE ALARM WHEN I TURNED ON THE VEHICLE. THE ALARM WOULD PERSIST UNTIL I PUSHED DOWN ON THE PARKING BRAKE. I WOULD ALSO RECEIVE AN OCCASIONAL ALARM FOR THE TIRE PRESSURE MONITORING SYSTEM. THEN, ON DECE…

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I RECENTLY PURCHASED A 2004 VW TUAREG IN JULY 1ST OF 2014. IMMEDIATELY UPON PURCHASING THE VEHICLE I BEGAN RECEIVING A PARKING BRAKE ALARM WHEN I TURNED ON THE VEHICLE. THE ALARM WOULD PERSIST UNTIL I PUSHED DOWN ON THE PARKING BRAKE. I WOULD ALSO RECEIVE AN OCCASIONAL ALARM FOR THE TIRE PRESSURE MONITORING SYSTEM. THEN, ON DECEMBER 15, 2014 THE VEHICLE REFUSED TO TURN ON AT ALL. THE DASHBOARD DISPLAY HAD A FLASHING STEERING WHEEL. I HAD THE VEHICLE TOWED TO A VOLKSWAGEN DEALERSHIP WHERE THE TECHNICIANS LOOKED IT OVER AND TOLD ME THAT THE CAUSE OF THE PROBLEM IS THAT TWO CABLES TOUCHED AND SHORTED OUT THE SYSTEM. AFTER 3 WEEKS OF HOLDING THE VEHICLE, THE COST OF REPAIR WAS QUOTED AT AROUND $3,500 TO REPLACE SOME MODULES. I WAS ALSO INFORMED THAT THIS MIGHT BE A RECALL ISSUE AS MANY OTHER 2004 VW TUAREGS HAVE HAD SIMILAR PROBLEMS. *TR

NHTSA ODI #10679060

93,000 miles · Dec 21, 2014
Electrical SystemSteering

CAME OUT TO 2004 V8 TOUAREG,AND IT WOULD NOT START. MRI READS STEERING DEFECTIVE WORKSHOP. AFTER SOME RESEARCH I DISCOVERED THAT THIS IS A COMMON DEFECT IN TOUAREGS AND ONE WHICH VW REFUSES TO TAKE RESPONSIBILITY OF.IT RENDERS THE VEHICLE PARALYZED AND DUE TO IT BEING ALL WHEEL DRIVE, REQUIRES SPECIAL EQUIPMENT TO EVEN TOW IT. …

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CAME OUT TO 2004 V8 TOUAREG,AND IT WOULD NOT START. MRI READS STEERING DEFECTIVE WORKSHOP. AFTER SOME RESEARCH I DISCOVERED THAT THIS IS A COMMON DEFECT IN TOUAREGS AND ONE WHICH VW REFUSES TO TAKE RESPONSIBILITY OF.IT RENDERS THE VEHICLE PARALYZED AND DUE TO IT BEING ALL WHEEL DRIVE, REQUIRES SPECIAL EQUIPMENT TO EVEN TOW IT. I AM FURIOUS. THIS IS A KNOWN, DANGEROUS ISSUE AND NO RECALL FOR IT - SHAME ON YOU VW. WHAT IF I WAS WITH MY YOUNG CHILDREN? THERE IS NO WARNING FOR THIS FAILURE. ALL IS FINE AND THEN WHAM, IT WILL NOT START, TURN OVER, SHIFT INTO NEUTRAL, ETC. YOU ARE 100% PARALYZED WHERE YOU ARE - BE IT AT A GAS PUMP OR A REMOTE DIRT ROAD. *TR

NHTSA ODI #10667491

90,000 miles · Jul 9, 2012
Electrical SystemEngine And Engine CoolingPower Train

WHILE ACCELERATING ONTO THE HIGHWAY, A LOUD, REPETITIOUS BANG/CLUNK FROM THE MIDDLE UNDERSIDE OF THE VEHICLE STARTED, SOUNDING SIMILAR TO A BLOWN TIRE. NO ABNORMAL OPERATIONS NOTED PRIOR TO THIS. LIMPED THE CAR BACK TO THE SHOP AT 15 MPH AND FOUND THE CENTER DRIVESHAFT CARRIER BEARING FAILED. THE SERVICE TECH ACTED AS IF THIS…

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WHILE ACCELERATING ONTO THE HIGHWAY, A LOUD, REPETITIOUS BANG/CLUNK FROM THE MIDDLE UNDERSIDE OF THE VEHICLE STARTED, SOUNDING SIMILAR TO A BLOWN TIRE. NO ABNORMAL OPERATIONS NOTED PRIOR TO THIS. LIMPED THE CAR BACK TO THE SHOP AT 15 MPH AND FOUND THE CENTER DRIVESHAFT CARRIER BEARING FAILED. THE SERVICE TECH ACTED AS IF THIS WAS COMMON AND WAS NOT SURPRISED. I HAVE A 1981 MERCURY WITH OVER 305000 MILES AND NEVER LOST A BEARING IN MY DRIVESHAFT. MECHANICAL PARTS FAIL. THE WORST PART OF THIS EVENT IS VOA'S REACTION THAT SOMEHOW THEY ARE NOT RESPONSIBLE FOR A POOR/WEAK DESIGN. LIST OF OTHER MAJOR COMPONENT FAILURES WITH NO RECALL THAT ARE COMMON TO ALL TOUAREGS OF THIS GENERATION ACCORDING TO THE COMPANY'S OWN SERVICE TECH'S: CENTER DIFFERENTIAL LOCK MOTOR FAIL REAR DIFF. LOCK MOTOR FAIL COOLING FANS DO NOT SHUT OFF, DRAIN BATTERY THERMOSTAT HOUSING LEAK RADIO FAILURE. *TR

NHTSA ODI #10464652

Official recalls

4

17V583000 · Fuel System, Gasoline:delivery:fuel Pump

Sep 20, 2017

Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2004-2007 Touareg vehicles. These gasoline-powered vehicles have a fuel filter flange that may crack, allowing fuel to leak.

Consequence & remedy

Consequence: A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy: Volkswagen will notify owners, and dealers will inspect the fuel filter flange for cracks, replacing the flange if cracks are found. If no cracks are found, a protective cover will be installed onto the filter flange. These repairs will be performed free of charge. The recall began March 9, 2018. Owners may contact Volkswagen customer service at 1-800-893-5298. Volkswagen's number for this recall is 20Ai.

04V592000 · Seat Belts

Dec 15, 2004

CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." ALL THREE REAR SEAT POSITIONS AND THE FRONT PASSENGER POSITION ARE EQUIPPED WITH SEAT BELT RETRACTORS THAT HAVE A LOCKING FEATURE WHICH CONVERTS THE RETRACTOR FROM AN EMERGENCY LOCKING RETRACTOR (ELR) MODE TO AN AUTOMATIC LOCKING RETRACTOR (ALR) MODE FOR THE PURPOSES OF CHILD RESTRAINT INSTALLATION. THE BELT MAY DEACTIVATE THE ALR MODE WITH CERTAIN CHILD RESTRAINTS.

Consequence & remedy

Consequence: WHEN INVOLVED IN A CRASH, THE CHILD RESTRAINTS MAY NOT BE PROPERLY SECURED, INCREASING THE RISK OF INJURIES OR DEATH.

Remedy: DEALERS WILL PERMANENTLY INSTALL A 'CLIP' IN EACH OF THE TWO REAR OUTBOARD SEAT BELTS. THE CLIPS WILL PREVENT UNWANTED DEACTIVATION OF THE ALR MODE WITH CHILD SEAT INSTALLATIONS. THE RECALL BEGAN ON APRIL 11, 2005. OWNERS SHOULD CONTACT VW AT 1-800-822-8987.

04V233000 · Seat Belts:rear/other

May 19, 2004

ON CERTAIN SPORT UTILITY VEHICLES, THE REAR SEAT BELT LATCH ATTACHMENT BOLT MAY HAVE BEEN INSUFFICIENTLY RIVETED.

Consequence & remedy

Consequence: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE BELT BUCKLE. OWNER NOTIFICATION BEGAN ON JUNE 21, 2004. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

03V266000 · Electrical System:wiring

Jul 25, 2003

ON CERTAIN SPORT UTILITY VEHICLES, THE TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING HARNESS MAY HAVE BEEN IMPROPERLY ROUTED DURING ASSEMBLY. AN IMPROPERLY ROUTED TPMS WIRING HARNESS MAY CONTACT THE PARKING BRAKE CABLE SPRING.

Consequence & remedy

Consequence: IF THIS HAPPENS, THE TPMS WIRING CIRCUIT COULD BE INTERRUPTED, RESULTING IN AN INOPERATIVE TPMS, AND CAUSING A SHORT-TO-GROUND CONDITION THAT COULD POTENTIALLY RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE TPMS WIRING HARNESS ROUTING AND, IF NECESSARY, CORRECT THE WIRING HARNESS ROUTING. OWNER NOTIFICATION BEGAN AUGUST 18, 2003. OWNERS SHOULD CONTACT VWOA AT 1-800-893-5298.

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

2

PE06022 · Srs Warning Light Illumination

Opened Jun 19, 2006 · Closed Oct 30, 2006

Status: closed (inferred from source dates) · Air Bags; Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.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.

Additional source detail variants (2)

Air Bags:side/window

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.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.

Air Bags

MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN OCTOBER AND NOVEMBER 2003, MAY CONTAIN AN INCORRECTLY MANUFACTURED SIDE AIR BAG MODULE.THIS ALSO MAY PRODUCE ABL ILLUMINATION THAT WOULD BECOME EVIDENT SOON AFTER THE VEHICLE IS PUT INTO SERVICE.WARRANTY DATA INDICATES THAT THESE MODULES HAVE BEEN CORRECTED AND NO LONGER PRESENT A RISK.VW HAS NOT RECEIVED ANY ALLEGED SIDE AIR BAG NON-DEPLOYMENT REPORT.ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUE RAISED BY THIS INVESTIGATION.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.

PE05042 · Exterior Door Handle Malfunction

Opened Aug 11, 2005 · Closed Dec 21, 2005

Status: closed (inferred from source dates) · Latches/locks/linkages:doors:latch

VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB) DATED JUNE 10, 2005, DESCRIBING A CONDITION OF EXTERIOR DOOR HANDLE STICKS IN THE OPENED POSITION AFTER THE DOOR IS OPENED.VW DESCRIBED THE CAUSE OF THE PROBLEM TO BE A POTENTIAL FOR INCREASED FRICTION BETWEEN THE DOOR HANDLE AND THE LOCK CYLINDER HOUSING . . . BECAUSE SOME GUIDE NUBS THAT WERE MOLDED INTO THE PLASTIC DOOR HANDLE . . . WERE SLIGHTLY HIGHER THAN SPECIFIED.IN ADDITION TO THE TSB, VW HAS INTRODUCED PRODUCTION CHANGES (LUBRICATION, DELETION OF THE GUIDE NUBS, INTRODUCTION OF A LOW FRICTION GUIDE SURFACE ON THE LOCK CYLINDER HOUSING) TO ADDRESS THE PROBLEM.VW REPORTS THAT THE FAILURE OCCURS PREDOMINANTLY IN THE VERY EARLY LIFE STAGE OF THE VEHICLE.ODI EXAMINATION OF VW'S WARRANTY DATA SHOWS FEWER CLAIMS AS THE VEHICLE AGES.THE ONE INJURY RESULTED WHEN THE UNLATCHED DOOR HIT THE OCCUPANT'S HAND.A SAFETY 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.ODI WILL CONTINUE TO MONITOR COMPLAINTS ANDRESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.