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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.

About this comparison →

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 And Engine Cooling complaints

22 reports
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134,447 miles · Feb 29, 2016
Engine And Engine Cooling

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THAT THE OXYGEN SENSOR EMMISSIONS WARNING LIGHT REMAINED ILLUMINATED. THE CONTACT STATED THAT THE VEHICLE WOULD NOT ACCELERATE FAST ENOUGH DUE TO AN RPM MALFUNCTION. THE VEHICLE WAS TAKEN TO BE DIAGNOSED, BUT WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE …

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE CONTACT STATED THAT THE OXYGEN SENSOR EMMISSIONS WARNING LIGHT REMAINED ILLUMINATED. THE CONTACT STATED THAT THE VEHICLE WOULD NOT ACCELERATE FAST ENOUGH DUE TO AN RPM MALFUNCTION. THE VEHICLE WAS TAKEN TO BE DIAGNOSED, BUT WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 134,447.

NHTSA ODI #10838918

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

50,450 miles · Jul 20, 2011
Engine And Engine CoolingUnknown Or OtherFire

I WAS DRIVING A SHORT DISTANCE FROM MY HOUSE (2 MILES) WHEN I NOTICED MY CAR NOT DRIVING NORMALLY. I HAD DRIVEN IT THE 3 PREVIOUS DAYS WITH NO PROBLEM. I FINISHED MY ERRAND, THEN PROCEEDED TO HEAD HOME. IT WAS NOTICEABLY GETTING WORSE. I SMELLED SOMETHING AT A STOPLIGHT, NOT SURE IF IT WAS MY CAR, OR CAR ALONGSIDE OF ME. I S…

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I WAS DRIVING A SHORT DISTANCE FROM MY HOUSE (2 MILES) WHEN I NOTICED MY CAR NOT DRIVING NORMALLY. I HAD DRIVEN IT THE 3 PREVIOUS DAYS WITH NO PROBLEM. I FINISHED MY ERRAND, THEN PROCEEDED TO HEAD HOME. IT WAS NOTICEABLY GETTING WORSE. I SMELLED SOMETHING AT A STOPLIGHT, NOT SURE IF IT WAS MY CAR, OR CAR ALONGSIDE OF ME. I SAW A LIGHT HAD COME ON, ON MY DASHBOARD (CK. ENGINE?) AND LOOKED AT THE GAUGES, EVERYTHING WAS NORMAL. I DECIDED TO HEAD HOME FIRST TO HAVE MY NEIGHBOR FOLLOW ME UP TO REPAIR SHOP. PARKED IN DRIVEWAY, WENT INSIDE MY HOME TO CALL HER, LOOKED OUT MY OPEN FRONT DOOR ABOUT 5 MINUTES LATER WHERE I SAW SMOKE AND SMELLED IT. RAN OUT, MY AUTO WAS SERIOUSLY SMOKING HEAVY BROWN SMOKE, RAN NEXT DOOR TO CALL 911, AND AUTO BURST INTO FLAMES AND CAUGHT HOUSE ON FIRE ALSO. I AM NOW IN A HOTEL BECAUSE OF MAJOR FIRE AND SMOKE DAMAGE. *KB

NHTSA ODI #10413841

Mileage unknown · Dec 22, 2008
Electrical SystemEngine And Engine CoolingPower Train

I HAVE HAD MY 2004 VW TOUAREG SINCE JUNE 2006 AND HAVE HAD PROBLEM AFTER PROBLEM WITH THE VEHICLE. THE CATALYTIC CONVERTER WENT OUT WITHIN 6 WEEKS OF BUYING THE CAR, THE DRIVE SHAFT HAD TO BE REPLACED, THE AIR CONDITIONING COMPRESSOR HAD TO BE REPLACED, THE BRAKES HAVE HAD TO BE REPLACED AND I AM GETTING ANOTHER "CHECK BRAKE PA…

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I HAVE HAD MY 2004 VW TOUAREG SINCE JUNE 2006 AND HAVE HAD PROBLEM AFTER PROBLEM WITH THE VEHICLE. THE CATALYTIC CONVERTER WENT OUT WITHIN 6 WEEKS OF BUYING THE CAR, THE DRIVE SHAFT HAD TO BE REPLACED, THE AIR CONDITIONING COMPRESSOR HAD TO BE REPLACED, THE BRAKES HAVE HAD TO BE REPLACED AND I AM GETTING ANOTHER "CHECK BRAKE PADS" ERROR AGAIN, THE TIRE MONITORING SYSTEM CONTINUALLY TELLS ME I HAVE A FLAT, THE RADIO AMPLIFIER WAS MAKING A LOUD CRACKING SO THE DEALERSHIP REPLACED A FUSE AND BLEW THE 2 BACK SPEAKERS (WHICH THEY WOULD NOT FIX, HEWLETT VW IN GEORGETOWN, TEXAS), THE AUTO DIFFERENTIAL IS GOING OUT. THERE SEEMS TO BE NO END IN SIGHT FOR REPAIRS. *TR

NHTSA ODI #10252545

44,000 miles · Aug 15, 2008
Electrical SystemEngine And Engine CoolingPower TrainFire

MULTIPLE ENGINE LIGHT FAILURES FOR OVER 4 YEARS. ENGINE LIGHT CAME ON AND ENGINE SHUT DOWN IMMEDIATELY WHILE WIFE WAS ON THE FREEWAY. VERY DANGEROUS...ESSENTIALLY NO WARNING. HAVE REPLACED WIRING HARNESS IN THE VEHICLE AND HAVE HAD IT IN THE SHOP FOR ELECTRICAL ISSUES MANY TIMES. UNSAFE HANDLING AND ACCELERATION...CAR JUMPS …

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MULTIPLE ENGINE LIGHT FAILURES FOR OVER 4 YEARS. ENGINE LIGHT CAME ON AND ENGINE SHUT DOWN IMMEDIATELY WHILE WIFE WAS ON THE FREEWAY. VERY DANGEROUS...ESSENTIALLY NO WARNING. HAVE REPLACED WIRING HARNESS IN THE VEHICLE AND HAVE HAD IT IN THE SHOP FOR ELECTRICAL ISSUES MANY TIMES. UNSAFE HANDLING AND ACCELERATION...CAR JUMPS FORWARD AT STOPS WHILE IT IS DOWNSHIFTING. THINK THE TRANSMISSION, TIRES AND BRAKES SHOULD BE TESTED. THINK YOU WILL FIND THEY ARE DEFECTIVE. ENGINE BLEW UP AT 44,000 MILES. VERY DANGEROUS CAR..AND YOU WILL FIND OTHER TOUAREGS WITH SIMILAR ISSUES. SHOULD BE RECALLED. *TR

NHTSA ODI #10238426

Mileage unknown · May 16, 2007
Engine And Engine Cooling

I OWN A VOLKSWAGEN TOURAREG. THE CAR HESITATED BEFORE ACCELERATING INTO AN INTERSECTION. I AM ON RECORD WITH THE DEALER. THIS HAPPENED SEVERAL TIMES ,AND ONCE ALMOST CAUSED AN ACCIDENT. I AM AN ATTORNEY IN FLORIDA, AND BECAUSE OF VOLKSWAGEN'S INACTION IN THIS AREA I WAS CONSIDERING A LAWSUIT IN THE SOUTHERN DISTRICT OF FLORIDA…

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I OWN A VOLKSWAGEN TOURAREG. THE CAR HESITATED BEFORE ACCELERATING INTO AN INTERSECTION. I AM ON RECORD WITH THE DEALER. THIS HAPPENED SEVERAL TIMES ,AND ONCE ALMOST CAUSED AN ACCIDENT. I AM AN ATTORNEY IN FLORIDA, AND BECAUSE OF VOLKSWAGEN'S INACTION IN THIS AREA I WAS CONSIDERING A LAWSUIT IN THE SOUTHERN DISTRICT OF FLORIDA FEDERAL COURT SYSTEM. IN PURSUING THE INTERNET I FOUND SEVERAL OWNERS OF THE 2004 TOUAREG WITH THE SAME PROBLEM. *AK

NHTSA ODI #10190958

10,291 miles · Feb 3, 2007
Engine And Engine Cooling

THE VEHICLE IS UNDRIVABLE / UNPREDICTABLE WHEN THE AMBIENT TEMPERATURE IS BELOW ZERO (F). THIS PROBLEM WAS OBSERVED FOR 4 DAYS IN FEB. 2004. THE CAR WILL START, BUT SURGES AND BALKS SO BADLY YOU CAN'T DRIVE IT. THIS CONDITION WILL CONTINUE FOR OVER 20 MINUTES. IT WILL RE-OCCUR THE NEXT TIME YOU TRY AND USE THE VEHICLE SO LONG AS…

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THE VEHICLE IS UNDRIVABLE / UNPREDICTABLE WHEN THE AMBIENT TEMPERATURE IS BELOW ZERO (F). THIS PROBLEM WAS OBSERVED FOR 4 DAYS IN FEB. 2004. THE CAR WILL START, BUT SURGES AND BALKS SO BADLY YOU CAN'T DRIVE IT. THIS CONDITION WILL CONTINUE FOR OVER 20 MINUTES. IT WILL RE-OCCUR THE NEXT TIME YOU TRY AND USE THE VEHICLE SO LONG AS THE TEMPERATURE IS BELOW ZERO. THE SAFETY HAZARD IS THAT IT LEAVES YOU STRANDED WHEREVER THIS HAPPENS. THERE'S NOTHING THE OPERATOR CAN DO. VW HAS TRIED 3 REPAIRS: (1) CHANGE THE ENGINE OIL TO SYNTHETIC, (2) & (3) REPROGRAM THE ENGINE COMPUTER TWICE TO SUPPOSEDLY FIX THIS PROBLEM. IT'S NOW 2 YEARS LATER, AND WE ARE EXPERIENCING BELOW ZERO WEATHER AGAIN, AND THE EXACT SAME PROBLEM PERSISTS. MY DEALER IS NOT ABLE TO FIND ANY INFORMATION ON THIS PROBLEM, AND CAN'T GET ASSISTANCE FROM VW. I WILL CONTACT VWOA DIRECTLY AND INITIATE A CASE. FINALLY, IN RESEARCHING THIS PROBLEM, I HAVE FOUND MANY OTHER OWNERS OF THE V6 ENGINE WHO REPORT THIS PROBLEM AND SAY IT'S NEVER BEEN CORRECTED. *JB

NHTSA ODI #10181488

80,000 miles · Jan 20, 2007
Engine And Engine CoolingFuel System, Gasoline

I BOUGHT A 2004 VOLKSWAGEN TOUAREG NEW AND TREATED IT LIKE A BABY. DEALER SERVICE, NEVER OFF-ROAD. AT 80,000 MILES (I COMMUTE 200 MILES PER DAY ON THE FREEWAY) THE ENGINE BLEW. DEALER SAID THAT AFTER THE VEHICLE HAD BEEN PARKED AND TURNED OFF THE FUEL INJECTOR PARTIALLY FILLED A CYLINDER WITH LIQUID GASOLINE. LATER WHEN THE …

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I BOUGHT A 2004 VOLKSWAGEN TOUAREG NEW AND TREATED IT LIKE A BABY. DEALER SERVICE, NEVER OFF-ROAD. AT 80,000 MILES (I COMMUTE 200 MILES PER DAY ON THE FREEWAY) THE ENGINE BLEW. DEALER SAID THAT AFTER THE VEHICLE HAD BEEN PARKED AND TURNED OFF THE FUEL INJECTOR PARTIALLY FILLED A CYLINDER WITH LIQUID GASOLINE. LATER WHEN THE VEHICLE WAS STARTED THE PISTON SLAMMED INTO THE LIQUID AND BLEW THE ENGINE. PARTS ALONE TO REPAIR ARE $15,000. SINCE THE COST OF REPAIRS EXCEEDS THE VALUE OF THE VEHICLE I WON'T BE REPAIRING IT -- IT IS A TOTAL LOSS. *JB

NHTSA ODI #10179235

20,000 miles · Jul 17, 2006
Engine And Engine Cooling

DT*: THE CONTACT STATED THAT THE VEHICLE STALLED COMPLETELY WHILE DRIVING AT 5 MPH, AND THE STARTER MOTOR WOULD NOT ENGAGE WHEN THE KEY WAS TURNED TO RESTART THE VEHICLE. THE VEHICLE WAS TAKEN TO A SERVICE DEALER WHERE THE DEALER WAS UNABLE TO DETERMINE THE PROBLEM.

NHTSA ODI #10162579

14,685 miles · May 25, 2006
Engine And Engine Cooling

VW TOUAREG ENGINE PROBLEMS IN THE WINTER. I WILL SEND THE INFO AS VW DEALER REPAIR INFO AND ENGINE PROBLEMS WAS RECORDED ON TAPE/DVD. *JB

NHTSA ODI #10158297

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.