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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

Equipment complaints

6 reports
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Mileage unknown · Nov 26, 2007
EquipmentFuel System, GasolinePower Train

2004 VW TOUAREG WITH TIRE FAILURE AND KEY PROGRAMMING. CONSUMER STATES HE HAD TO REPLACE THE TIRES DUE TO A PUNCTURE IN ONE OF THE SIDEWALL TIRES. THE SECOND KEY RECEIVED NEEDED TO BE PROGRAMMED AND DEALER CHARGED HIM FOR PROGRAMMING. *KB THE CONSUMER STATED HE GETS LOW GAS MILEAGE. WHEN THE VEHICLE WAS RETURNED TO THE CONSUME…

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2004 VW TOUAREG WITH TIRE FAILURE AND KEY PROGRAMMING. CONSUMER STATES HE HAD TO REPLACE THE TIRES DUE TO A PUNCTURE IN ONE OF THE SIDEWALL TIRES. THE SECOND KEY RECEIVED NEEDED TO BE PROGRAMMED AND DEALER CHARGED HIM FOR PROGRAMMING. *KB THE CONSUMER STATED HE GETS LOW GAS MILEAGE. WHEN THE VEHICLE WAS RETURNED TO THE CONSUMER, THE TIRE MONITORING SYSTEM WOULD COME ON AND GO OFF REPEATEDLY. THE DRIVE SHAFT WAS REPLACED DUE TO A VIBRATION WHEN MAKING TURNS. THE FRONT BRAKES NEEDED TO BE REPLACED.*JB

NHTSA ODI #10210527

Mileage unknown · Mar 12, 2006
Electrical SystemEquipmentExterior Lighting

I TOOK DELIVERY OF MY 2004 VW TOUAREG ON 7-11-04. BY 9-9-04 IT WAS HAVING PROBLEMS. IT HAS BEEN IN 6 TIMES FOR ELECTRICAL PROBLEMS, 3 TIMES FOR THE AC, 3 TIMES FOR THE BATTERY, AND 1-2 TIMES FOR OTHER THINGS. TOMORROW, I WILL BE TAKING IT IN AGAIN FOR FURTHER A/C PROBLEMS, BRAKES THAT CATCH ON THEIR OWN WHILE IN DRIVE, INTERMITT…

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I TOOK DELIVERY OF MY 2004 VW TOUAREG ON 7-11-04. BY 9-9-04 IT WAS HAVING PROBLEMS. IT HAS BEEN IN 6 TIMES FOR ELECTRICAL PROBLEMS, 3 TIMES FOR THE AC, 3 TIMES FOR THE BATTERY, AND 1-2 TIMES FOR OTHER THINGS. TOMORROW, I WILL BE TAKING IT IN AGAIN FOR FURTHER A/C PROBLEMS, BRAKES THAT CATCH ON THEIR OWN WHILE IN DRIVE, INTERMITTENT FAULTY TRIGGERING OF TIRE PRESSURE MONITORING SYSTEM, AND A HOLE THAT I DISCOVERED ONLY DAY IN THE FIRE BLANKET UNDER THE HOOD. APPARENTLY THE ENGINE HEAT HAS BEEN BURNING A HOLE IN IT AND HAS BURNED AWAY A HOLE RIGHT THROUGH THE BLANKET TO THE HOOD ITSELF, BUT NOT THROUGH THE HOOD YET. THIS CAR HAS MEANT TIME LOST FROM WORK AND AN INORDINATE AMOUNT OF TIME SPENT IN THE SHOP AND PAYING FOR RENTAL CARS. THIS CAR IS A FIRE AND SAFETY HAZARD. FAIRFAX COUNTY CONSUMER PROTECTION (ROY SEGER) HAD CONTACTED VW AS THIS CAR FALLS UNDER THE LEMON LAW. VW RESPONDED THAT THEY WOULD NOT COMPLY, STATING THAT THEY HAD FIXED THE BATTERY. THEIR RESPONSE FAILED TO ACCOUNT FOR THE MULTITUDE OF OTHER PROBLEMS...AND NOW THIS. I HAVE NEVER FELT SO POWERLESS. IS THERE ANYTHING YOU CAN DO TO HELP?? *NM

NHTSA ODI #10152523

Mileage unknown · Sep 18, 2005
Electrical SystemEquipmentSuspension

I AM HAVING TROUBLE WITH MY VW TOUAREG V6. SINCE THEN I HAVE HAD NUMEROUS VISITS TO THE DEALER FOR FAILURES IN DESIGN. FOOTLIGHT WOULD NOT SHUT OFF WHEN THE CAR WAS OFF DUE TO TRUNK DOOR LATCH BEING BROKEN AT TIME OF PURCHASE. TIRES WERE WEARING FASTER THAN NORMAL AND THE ALIGNMENT WAS BAD. I WAS GIVEN NEW TIRES, HOWEVER, WH…

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I AM HAVING TROUBLE WITH MY VW TOUAREG V6. SINCE THEN I HAVE HAD NUMEROUS VISITS TO THE DEALER FOR FAILURES IN DESIGN. FOOTLIGHT WOULD NOT SHUT OFF WHEN THE CAR WAS OFF DUE TO TRUNK DOOR LATCH BEING BROKEN AT TIME OF PURCHASE. TIRES WERE WEARING FASTER THAN NORMAL AND THE ALIGNMENT WAS BAD. I WAS GIVEN NEW TIRES, HOWEVER, WHEN I ASKED IF THIS COULD HAPPEN AGAIN, I WAS TOLD YES AND THEY WERE UNSURE WHAT VW WOULD DO IN THE FUTURE. TIRE PRESSURE LIGHT GOES ON AND OFF AT ANY TIME. I WAS TOLD THIS WAS A MALFUNCTION THAT HAPPENS WHEN YOU HAVE NUMEROUS COMPUTER OPTIONS. IT CAME ON AFTER A TIRE ROTATION AND OIL CHANGE AND THE DEALER SAID "DON'T WORRY, IT WILL RESET ITSELF AND GO OFF".RADIO HAS MYSTERIOUSLY STOPPED WORKING FOR 24 HOURS AT A TIME. CAR HAS ACTUALLY BEEN DEAD ON TWO OCCASIONS AND HAS LEFT ME STRANDED. I WAS TOLD BY THE DEALER THAT THE BATTERY IN THE TOUAREG CAN'T SUPPORT THE CAR AND THE COMPUTER MODULES. I WAS TOLD THERE WAS NOTHING THAT COULD BE DONE ABOUT THIS AS THE BATTERY WAS FULLY CHARGED. I WAS TOLD THIS WAS A MISTAKE BY VW AND I WOULD HAVE TO LIVE WITH IT. I WAS ALSO TOLD TO NOT DRIVE IN THE CITY AS THIS MAKES THE PROBLEM MUCH WORSE. I WAS TOLD THAT THEY AREN'T SURE HOW THAT HAPPENED, BUT SIMPLY RESETTING THE CAR MADE IT RETURN. CD PLAYER WOULD NOT WORK,CAR WAS "RESET". I FIND THIS CAR TO BE THE BIGGEST JOKE EVER MADE. I UNFORTUNATELY AM OVER THE MILEAGE FOR THE LEMON LAW IN MAINE (I HAVE 27,000MILES ON THE CAR). I REALLY THINK THINGS ARE GETTING WORSE IN MY CAR THE LONGER I HAVE THE THING. MY BIGGEST CONCERN WITH THE CAR IS THAT THERE IS A POSSIBILITY IT COULD STOP WORKING AT ANY MOMENT. I FEEL I SHOULD NOT HAVE TO CARRY A SELF JUMPING SYSTEM IN A PRACTICALLY BRAND NEW $34,000 CAR. I WAS ALSO TOLD BY MY DEALERSHIP WHEN I STATED I WAS THINKING OF SELLING THE CAR, THAT THEY DIDN'T BLAME ME AS THEY HAD HEARD A LOT OF PEOPLE SAY THAT ABOUT THE TOUAREG. YEAH, I FEEL REALLY SAFE WITH THIS CAR. I THINK IT IS TIME SOMEONE DO SOMETHING ABOUT THIS CAR AND VW. *NM

NHTSA ODI #10136869

Mileage unknown · Jul 22, 2005
Air BagsEquipmentInjury

2004 VOLKSWAGEN TOUAREG HAS A BURNING ODOR COMING FROM THE VENTS. *MR THE CONSUMER ATTEMPTED TO TURN ON THE A/C WHEN THE BURNING ODOR OCCURRED. THE ODOR WAS SO STRONG THAT THE CONSUMERS DAUGHTER HAD BECOME SICK AND VOMITED IN THE VEHICLE. ALSO, THE AIR BAGS DID NOT WORK. *SC *JB

NHTSA ODI #10121545

Mileage unknown · May 18, 2005
Electrical SystemEquipmentSeat Belts

1.THE CLOCK ON THE DASHBOARD: THE TIME IS RUNNING ALMOST 1 MINUTE FASTER PER DAY. IF YOU DONT FIX IT FOR 10 DAYS, IT WOULD RUN 10 MINUTES AHEAD. 2.THE DRIVERS SEAT: WHEN I PURCHASED THIS CAR, I ASKED FOR POWER SEATS BUT THE DEALER DIDNT HAVE IT. I WAS A LITTLE UNCOMFORTABLE WITH THE MANUAL SEAT, BUT THE SALES PERSON CONVINCED M…

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1.THE CLOCK ON THE DASHBOARD: THE TIME IS RUNNING ALMOST 1 MINUTE FASTER PER DAY. IF YOU DONT FIX IT FOR 10 DAYS, IT WOULD RUN 10 MINUTES AHEAD. 2.THE DRIVERS SEAT: WHEN I PURCHASED THIS CAR, I ASKED FOR POWER SEATS BUT THE DEALER DIDNT HAVE IT. I WAS A LITTLE UNCOMFORTABLE WITH THE MANUAL SEAT, BUT THE SALES PERSON CONVINCED ME, SO I DECIDED TO TAKE THE ONE WITH MANUAL. SINCE THEN, IVE FELT THAT THE DRIVERS SEAT IS ALWAYS SINKING DOWN SO I CONSISTENTLY HAVE TO PULL UP THE STICK TO PUSH UP THE SEAT QUITE OFTEN WHILE IM DRIVING. 3.REAR SEAT: I HAD TO FOLD THE REAR SEAT ONCE TO LOAD SOMETHING IN THE BACK. AFTER, I TRIED TO UNFOLD THE SEAT BUT IT DIDNT GO BACK. I BROUGHT THIS CAR TO THE DEALERS SERVICE ON NOV. 15TH, 2004. WHILE ONE OF THE SERVICE PERSONS WAS TRYING TO UNFOLD THE REAR SEAT, HE HAD TO CUT THE SEAT BELT AND HAS SCRATCHED THE SEAT AND BROKEN SOME PIECE ON THE SEAT. HE SAID HES GOING TO ORDER SOME PARTS AND IT WOULD TAKE A FEW DAYS. EVER SINCE THEN, NOBODY KNOWS THE STATUS OF THIS ORDER. BOTH THE SERVICE DEPT AND THE CUSTOMER CARE DEPT, IN HEADQUARTERS HAVE ALWAYS BEEN TELLING ME ITS ON BACKORDER WITH NO FURTHER INFORMATION, AND THEY DONT KNOW WHEN FOR LAST SIX MONTHS. I ASKED THEM IF YOU DONT HAVE THE PART, EVEN IN GERMANY, HOW LONG WILL IT TAKE FOR THE MANUFACTURER TO MAKE THE PART? AND THEY KEEP SAYING IS DONT KNOW AND WE ARE STILL CHECKING THE STATUS OF THE PART EVERYDAY. IN A COMMON SENSE, THE PERIOD OF FOUR MONTHS SHOULD BE ENOUGH TIME TO MAKE THE PART AND SHIP IT TO THE DEALER. I ALSO SENT A COMPLAINT LETTER TO THE CEO OF THE DEALER/MCKENNA & VW NORTH AMERICA HEADQUATER A COUPLE OF MONTHS AGO. BUT STILL THEY DON'T KNOW ABOUT THE PART.

NHTSA ODI #10121331

25,000 miles · Feb 15, 2005
EquipmentTrailer HitchesVisibility

THE TOUAREG HAS TWO DEFCTS THAT WILL EVENTUALLY LEAD TO IF THEY HAVE NOT CAUSED DAMGE. FOR MONTHS I HAVE TRIED TO GET VW TO FIX THE DEFECTIVE TAIL LIGHT FAULTS AND WARNINGS DUE TO THE INSTALLATION OF THE TOW HITCH. VW CLAIMS THESE ISSUES ARE RELATED TO ALL TRAILERS. ADDITIONALLY, THIS VEHICLE HAS A DEFECTIVE DRIVERS WINDS…

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THE TOUAREG HAS TWO DEFCTS THAT WILL EVENTUALLY LEAD TO IF THEY HAVE NOT CAUSED DAMGE. FOR MONTHS I HAVE TRIED TO GET VW TO FIX THE DEFECTIVE TAIL LIGHT FAULTS AND WARNINGS DUE TO THE INSTALLATION OF THE TOW HITCH. VW CLAIMS THESE ISSUES ARE RELATED TO ALL TRAILERS. ADDITIONALLY, THIS VEHICLE HAS A DEFECTIVE DRIVERS WINDSGHIELD WIPER THAT CAUSES OBSCURED VISABILITY. BOTH ARE DANGEROUS AND VW CLAIMS NORAML OPERATION. I AM FRUSTERATED AND IN DISBELIEF THAT VW WILL NOT CORRECT THE VEHICLES ISSUES. I AM WRITTING IN AN ATTEMPT TO REPRESENT THE PEOPLE AGAINST THIS VEHICLE MANUFACTURE

NHTSA ODI #10110597

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.