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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

Engine complaints

7 reports
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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

103,000 miles · Jul 8, 2019
Electronic Stability Control (esc)EngineFuel/propulsion System

I WAS DRIVING ON THE HIGHWAY @ 70MPR WHEN ALL OF A SUDDEN WITHOUT WARNING THE CAR STARTS ACTING SLUGGISH FOR A MIN THEN BACK TO NORMAL, AND RANDOMLY FOR THE NEXT HOUR OR SO DOES(I HAD A WAYS TO GO) THIS A FEW MORE TIMES. I GOT TO MY DESTINATION AND LET HER REST FOR THE NIGHT. THE NEXT MORNING IT WAS DOING FINE EXCEPT NOW THE EMI…

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I WAS DRIVING ON THE HIGHWAY @ 70MPR WHEN ALL OF A SUDDEN WITHOUT WARNING THE CAR STARTS ACTING SLUGGISH FOR A MIN THEN BACK TO NORMAL, AND RANDOMLY FOR THE NEXT HOUR OR SO DOES(I HAD A WAYS TO GO) THIS A FEW MORE TIMES. I GOT TO MY DESTINATION AND LET HER REST FOR THE NIGHT. THE NEXT MORNING IT WAS DOING FINE EXCEPT NOW THE EMISSION CONTROL LIGHT CAME ON AND STAYED ON. BY THIS TIME IT WAS TIME FOR THE 100,000 MILE MAINTENANCE TO BE DONE AND IT DID GREAT UNTIL ABOUT 6 MONTHS LATER I WAS DRIVING @ 35MPR WHEN IT STARTED LOOSING POWER, THO I ONLY LOST A LITTLE BIT OF POWER STEERING WAS FORCED TO COME TO A STOP, WHICH JUST HAPPEN TO BE A ONE WAY BRIDGE, BABY IN THE CAR AND HAD TO PUSH MYSELF THE REST OF THE WAY ACROSS IT. ONCE OFF THE BRIDGE I TURNED THE CAR OFF (IT STAYED ON TIL I DID THIS) LET IT REST A MINUTE AND IT STARTED UP FINE AND LET ME GO A FEW BLOCKS STILL SLUGGISH AND THEN LOST POWER AGAIN. I REPEATED THIS PROCESS FOR ABOUT 5 MILES OR SO WHEN I WAS FORCED TO PARK IT CUZ I DIDN'T WANT TO RISK CROSSING THE HIGHWAY AGAIN. HAD IT TOWED TO DEALERSHIP WHERE THEY DID THE FLANGE RECALL, THAT DIDNT' FIX THE PROBLEM SO HAD TO REPLACE BOTH FUEL PUMPS AND THAT WAS ROUGHLY @ 103,000. 8 MONTHS LATER IT HAPPENS AGAIN THIS TIME AROUND 107,000. DEALERSHIP TOOK 4 HOURS TO DIAGNOSE ONLY TO TELL ME I NEED THE FUEL TANK REPLACED BECAUSE SOMEHOW ALL THE WIRES, CONNECTORS, AND CAPS THAT HAVE TO DO WITH THE FUEL LINES/TANK/PUMPS ARE EITHER MISSING, CRACKED, OR DAMAGED SO I NEED A WIRING HARNESS AS WELL. THEY ARE QUOTING A ME $5000 FIX!!!

NHTSA ODI #11229973

168,835 miles · Jul 28, 2018
EngineFuel/propulsion SystemUnknown Or Other

THE TOUAREG MADE SOME RATTLING NOISE WHILE I WAS DRIVING AT 35 MPH. AS SOON I STOPPED AND MADE IT MY DESTINATION AND TURNED OFF THE CAR THE CAR WOULDN'T START UP. I TOOK IT TO THE DEALERSHIP AND THE DEALERSHIP COULDN'T FIGURE OUT WHY THE CAR WOULDN'T START. FINALLY, AFTER A WELL OVER A WEEK, THEY DETERMINED THAT I NEEDED TO REPL…

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THE TOUAREG MADE SOME RATTLING NOISE WHILE I WAS DRIVING AT 35 MPH. AS SOON I STOPPED AND MADE IT MY DESTINATION AND TURNED OFF THE CAR THE CAR WOULDN'T START UP. I TOOK IT TO THE DEALERSHIP AND THE DEALERSHIP COULDN'T FIGURE OUT WHY THE CAR WOULDN'T START. FINALLY, AFTER A WELL OVER A WEEK, THEY DETERMINED THAT I NEEDED TO REPLACE ALL SIX FUEL INJECTORS. THE FUEL INJECTORS GOT REPLACED NOW THE CAR TURNS ON BUT AS SOON AS YOU STEP ON THE GAS THE CAR DIES.

NHTSA ODI #11114294

Mileage unknown · Dec 26, 2017
Air BagsEngineFuel/propulsion System

DRIVE IT SHORT DISTANCE AND IT WON'T START AGAIN FOR HOURS! HAVE TAKEN IT TO VW TO PUT ON BRAKES AND ASKED THEM TO CHECK IT OUT, FOUND NOTHING! THEY HAVE KNOWN ABOUT THIS RECALL SINCE APRIL 2017 SHOWS AIR BAG LIGHT ON ALL THE TIME !

NHTSA ODI #11056565

49,850 miles · Jun 10, 2016
Air BagsEngine

AIRBAG WARNING LIGHT COMES ON AFTER CHANGING BATTERY. LOCAL MECHANICS CAN'T TURN IT OFF. DEALER WANTS LARGE AMOUNT TO "DIAGNOSE" THE PROBLEM. SEVERAL OTHER OWNERS HAVE THE SAME ISSUE WITH THE SEATBAG WARNING SYSTEM COMING ON RANDOMLY...VERY DANGEROUS...AND VW KNOWS ABOUT THE PROBLEM. HAS BEEN HAPPENING FOR YEARS. THE OTHE…

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AIRBAG WARNING LIGHT COMES ON AFTER CHANGING BATTERY. LOCAL MECHANICS CAN'T TURN IT OFF. DEALER WANTS LARGE AMOUNT TO "DIAGNOSE" THE PROBLEM. SEVERAL OTHER OWNERS HAVE THE SAME ISSUE WITH THE SEATBAG WARNING SYSTEM COMING ON RANDOMLY...VERY DANGEROUS...AND VW KNOWS ABOUT THE PROBLEM. HAS BEEN HAPPENING FOR YEARS. THE OTHER ISSUE IS WITH THE ENGINE...THE 2004 TOUAREG ENGINE BLEW AT LESS THAN 50K...DEALER SAID WE MUST HAVE DRIVEN THE CAR WHEN IT WAS HOT. JUST NONSENSE. SEVERAL OTHERS HAVE HAD MAJOR PROBLEMS WITH THE TOUAREGS.. ENGINE PROBLEMS AND THE TRANSMISSIONS/ENGINES SURGE ON SLOWING DOWN OR EVEN SPEEDING UP. TONS OF PROBLEMS WITH THE VEHICLE LINE AND VW AMERICA AND GERMANY WILL NOT DO ANYTHING ABOUT. THE ENGINE BLEW WHEN IT WAS ABOUT 100 DEGREES OUTSIDE.. WE ALWAYS SERVICE OUR VEHICLES REGULARLY.

NHTSA ODI #10873624

31,000 miles · Oct 28, 2015
EngineService Brakes

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING AT 45 MPH, THERE WAS AN ABNORMAL NOISE COMING FROM THE FRONT PASSENGER SIDE OF THE VEHICLE AND THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT THE BRAKE PEDAL WAS DIFFICULT TO DEPRESS. THE CONTACT HAD TO APPLY FOR…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING AT 45 MPH, THERE WAS AN ABNORMAL NOISE COMING FROM THE FRONT PASSENGER SIDE OF THE VEHICLE AND THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. IN ADDITION, THE CONTACT STATED THAT THE BRAKE PEDAL WAS DIFFICULT TO DEPRESS. THE CONTACT HAD TO APPLY FORCE TO THE BRAKE PEDAL IN ORDER TO STOP THE VEHICLE. ALL WARNING LIGHTS ILLUMINATED ON THE INSTRUMENT CLUSTER. THE VEHICLE WAS TAKEN TO A DEALER MULTIPLE TIMES. THE CONTACT WAS UNSURE ABOUT WHAT REPAIRS WERE PERFORMED HOWEVER, THE FAILURE PERSISTED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 31,000. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10786723

90,000 miles · Oct 27, 2014
EnginePower Train

CAR STALLS, SKIPS GEARS, JERKS, WHEN COMING FROM A FULL STOP TO ACCELERATING JERKS AND PULL REALLY HARD GOING INTO 1ST AND 2ND GEAR,, TOOK IT TO THE DEALER AFTER PAYING 800 DOLLAR THEY COULD FIND ANYTHING WRONG,, AND THAT WAS VW DEALER.... I'VE BEEN SEEIN ALOT OF THE SAME COMPLAINTS FOR THIS SPECIFIC MODEL AND YEAR, CAN SOME P…

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CAR STALLS, SKIPS GEARS, JERKS, WHEN COMING FROM A FULL STOP TO ACCELERATING JERKS AND PULL REALLY HARD GOING INTO 1ST AND 2ND GEAR,, TOOK IT TO THE DEALER AFTER PAYING 800 DOLLAR THEY COULD FIND ANYTHING WRONG,, AND THAT WAS VW DEALER.... I'VE BEEN SEEIN ALOT OF THE SAME COMPLAINTS FOR THIS SPECIFIC MODEL AND YEAR, CAN SOME PLEASE LET ME KNOW IF VOLKSWAGEN IS NOT GOING TO TAKE RESPONSIBILITY FOR THIS ISSUE ATLEAST TELL ME WHAT COULD BE WRONG, SO I CAN FIX IT AND GET RID OF THIS STUPID CAR. IM BETTER OFF WITH AN AMERICAN CAR... *TR

NHTSA ODI #10650277

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.