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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

What owners actually said

231 reports
67,186 miles · Nov 4, 2009
Air Bags

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE OCCUPYING THE VEHICLE, THE SEAT BELT WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE VEHICLE WAS TAKEN TO THE DEALERSHIP AND THE TECHNICIAN STATED THAT THE PASSENGER AIRBAG NEEDED TO BE REPLACED. THE CURRENT AND FAILURE MILEAGES WERE 88000. UPDATED 11/23/09. *…

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TL* THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE OCCUPYING THE VEHICLE, THE SEAT BELT WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE VEHICLE WAS TAKEN TO THE DEALERSHIP AND THE TECHNICIAN STATED THAT THE PASSENGER AIRBAG NEEDED TO BE REPLACED. THE CURRENT AND FAILURE MILEAGES WERE 88000. UPDATED 11/23/09. *LJ UPDATED 11/24/09.*JB

NHTSA ODI #10290914

81,000 miles · Oct 16, 2009
Fuel System, GasolinePower TrainCrash

I WAS PARKING THE VEHICLE IN A TIGHT PARKING LOT AND MANEUVERING AROUND A TREE IN ORDER TO PULL FURTHER UP INTO THE SPACE. AS I GENTLY PUSHED DOWN ON THE ACCELERATOR TO INCH INTO THE SPOT, THE CAR LURCHED FORWARD AT A VERY HIGH RATE OF SPEED CRASHING INTO A WOODEN GARBAGE BOX. I JAMMED ON THE BRAKES BEFORE GOING THROUGH THE FE…

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I WAS PARKING THE VEHICLE IN A TIGHT PARKING LOT AND MANEUVERING AROUND A TREE IN ORDER TO PULL FURTHER UP INTO THE SPACE. AS I GENTLY PUSHED DOWN ON THE ACCELERATOR TO INCH INTO THE SPOT, THE CAR LURCHED FORWARD AT A VERY HIGH RATE OF SPEED CRASHING INTO A WOODEN GARBAGE BOX. I JAMMED ON THE BRAKES BEFORE GOING THROUGH THE FENCE. I WAS INCREDIBLY LUCKY THAT I WAS NO LONGER AIMING AT THE TREE. IT WAS AS THOUGH THE CAR SUDDENLY WANTED TO PEAL OUT IN A MANNER THAT WAS TOTALLY OUT OF SYNC WITH THE AMOUNT OF PRESSURE ON THE GAS PEDAL. IT JUST STARTED SPEEDING TOWARD THE FENCE/BOX. LOOKING BACK ON IT, I BELIEVE THAT THIS HAPPENED A COUPLE OF DAYS BEFORE AS I STARTED TO ACCELERATE AFTER STOPPING AT A STOP SIGN. THOUGH THE REACTION OF THE CAR WAS SIMILAR, IT WAS NOT NEARLY SO PRONOUNCED. IT FELT AS THOUGH THE CAR WAS TRIPPING OVER ITSELF. I HAD THE INSURANCE TOW THE CAR TO THE MECHANIC BUT SO FAR HE HAS NOT BEEN ABLE TO REPLICATE THE PROBLEM. I SPOKE WITH BOTH THE LOCAL VW SERVICEMAN AND VW NORTH AMERICA BUT THEY DENIED EVER HEARING ABOUT SUCH A PROBLEM. I HAVE HAD THIS CAR FOR OVER 6 YEARS AND HAVE NEVER HAD THIS HAPPEN BEFORE THE OTHER DAY. *TR

NHTSA ODI #10288702

40,000 miles · Aug 26, 2009
Power Train

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHEN THE CONTACT ACCELERATED MORE THAN 45 MPH, THE VEHICLE BEGAN VIBRATING, SHAKING AND WAS STUCK IN NEUTRAL. EVENTUALLY, THE VEHICLE BEGAN ACCELERATING AT THE DESIRED SPEED. OCCASIONALLY, WHEN THE FAILURE OCCURRED THE CONTACT HAD TO SHUT THE ENGINE OFF; HOWEVER, IT WOULD OPERATE NO…

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TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHEN THE CONTACT ACCELERATED MORE THAN 45 MPH, THE VEHICLE BEGAN VIBRATING, SHAKING AND WAS STUCK IN NEUTRAL. EVENTUALLY, THE VEHICLE BEGAN ACCELERATING AT THE DESIRED SPEED. OCCASIONALLY, WHEN THE FAILURE OCCURRED THE CONTACT HAD TO SHUT THE ENGINE OFF; HOWEVER, IT WOULD OPERATE NORMALLY AFTER A FEW MINUTES. THE DEALER WAS UNABLE TO DIAGNOSE THE FAILURE; HOWEVER, THE FAILURE RECURRED 4 MONTHS LATER AND THE DEALER STATED THAT THE TRANSMISSION NEEDED TO BE REPLACED. THE CONTACT IS AWARE OF THE SAFETY RISK INVOLVED. THE DEALER AND THE MANUFACTURER STATED THAT THEY WOULD NOT BE RESPONSIBLE FOR THE REPAIR COST. THE FAILURE MILEAGE WAS 40,000 AND THE CURRENT MILEAGE WAS 69,000. UPDATED 10/06/09. *LJ THE CONSUMER WAS INFORMED THE TRANSMISSION FLUID WAS BURNT. UPDATED 10/06/09

NHTSA ODI #10281787

Mileage unknown · Feb 19, 2009
Air Bags

THE AIRBAG ON THIS VEHICLE HAS NEEDED TO BE REPLACED FOUR TIMES IN FIVE YEARS. WE AWAIT THE FOURTH REPLACEMENT. THE MANUFACTURER AND DEALER WHILE RECOMMENDING THE CAR NOT BE DRIVEN UNTIL A REPLACEMENT IS AVAILABLE ARE UNWILLING TO PROVIDE A REPLACEMENT VEHICLE STATING THE RISK OF OPERATING THE VEHICLE NOW RESTS WITH THE OWNER. *…

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THE AIRBAG ON THIS VEHICLE HAS NEEDED TO BE REPLACED FOUR TIMES IN FIVE YEARS. WE AWAIT THE FOURTH REPLACEMENT. THE MANUFACTURER AND DEALER WHILE RECOMMENDING THE CAR NOT BE DRIVEN UNTIL A REPLACEMENT IS AVAILABLE ARE UNWILLING TO PROVIDE A REPLACEMENT VEHICLE STATING THE RISK OF OPERATING THE VEHICLE NOW RESTS WITH THE OWNER. *TR

NHTSA ODI #10259359

38,200 miles · Feb 6, 2009
Tires

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING APPROXIMATELY 55 MPH ON NORMAL ROAD CONDITIONS, THE FLAT TIRE CAUTION WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE CONTINUED TO TRAVEL THREE TO FOUR MILES WHEN THE EMERGENCY FLAT TIRE WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE D…

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TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. WHILE DRIVING APPROXIMATELY 55 MPH ON NORMAL ROAD CONDITIONS, THE FLAT TIRE CAUTION WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE CONTINUED TO TRAVEL THREE TO FOUR MILES WHEN THE EMERGENCY FLAT TIRE WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE DRIVER PULLED OVER TO THE SIDE OF THE ROAD, BUT DID NOT NOTICE ANY FLAT TIRES. THE WARNING INDICATORS REMAINED ILLUMINATED UNTIL THE ENGINE WAS TURNED OFF. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSTIC TESTING AND THEY STATED THAT THE FAILURE WAS RELATED TO A FAULTY MANUFACTURER DESIGN. THERE WAS NO REPAIR AVAILABLE. THE TECHNICIAN WAS UNABLE TO DISENGAGE THE TIRE PRESSURE MODULE TO AVOID THE FALSE WARNINGS DISPLAYED ON THE INSTRUMENT PANEL. THE FAILURE MILEAGE WAS 38,200 AND CURRENT MILEAGE WAS 40,083. UPDATED 3/19/09 *CN UPDATED 03/23/09. *JB

NHTSA ODI #10257731

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

34,300 miles · Dec 4, 2008
Tires

THE TIRE PRESSURE MONITORING SYSTEM WILL PERIODICALLY DISPLAY VARIOUS WARNING MESSAGES INDICATING A FLAT TIRE. TIRE PRESSURE HAS ALWAYS BEEN NORMAL (UNCHANGED FROM PRIOR TARE), AND VISUAL INSPECTION OF THE TIRE INCLUDING SOAP TEST HAS ALWAYS BEEN NORMAL. DEALER HAS BEEN UNABLE TO FIX THE PROBLEM, CITING INABILITY TO REPLICATE …

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THE TIRE PRESSURE MONITORING SYSTEM WILL PERIODICALLY DISPLAY VARIOUS WARNING MESSAGES INDICATING A FLAT TIRE. TIRE PRESSURE HAS ALWAYS BEEN NORMAL (UNCHANGED FROM PRIOR TARE), AND VISUAL INSPECTION OF THE TIRE INCLUDING SOAP TEST HAS ALWAYS BEEN NORMAL. DEALER HAS BEEN UNABLE TO FIX THE PROBLEM, CITING INABILITY TO REPLICATE IT. *TR

NHTSA ODI #10250800

Mileage unknown · Nov 17, 2008
Tires

FOR MONTHS I LISTENED TO "DEFECTIVE TIRE" WARNINGS AND "CHECK TIRE PRESSURE" WARNINGS - ALL TO NO AVAIL - EVERYTHING WAS FINE. FINALLY, A LIGHT CAME ON - "TIRE PRESSURE MONITOR SYSTEM FAULT". I TOOK IT IN THE VACAVILLE VW, AND THEY DETERMINED IT WAS THE TPMS MODULE (NOT THE SENSOR). I HAVE AN EXTENDED WARRANTY AND WAS FIRST T…

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FOR MONTHS I LISTENED TO "DEFECTIVE TIRE" WARNINGS AND "CHECK TIRE PRESSURE" WARNINGS - ALL TO NO AVAIL - EVERYTHING WAS FINE. FINALLY, A LIGHT CAME ON - "TIRE PRESSURE MONITOR SYSTEM FAULT". I TOOK IT IN THE VACAVILLE VW, AND THEY DETERMINED IT WAS THE TPMS MODULE (NOT THE SENSOR). I HAVE AN EXTENDED WARRANTY AND WAS FIRST TOLD THAT THE MODULE WAS A COVERED COMPONENT, WHILE THE SENSOR WAS NOT. I LEFT IT THERE FOR THE APPROPRIATE REPAIRS ON A THURSDAY (11-6-08). ON FRIDAY, I WAS INFORMED THAT THE REPAIRS HAD BEEN MADE, BUT WHEN TEST DRIVING THE VEHICLE, THE "CHECK ENGINE" LIGHT CAME ON. AFTER CHECKING...THEY FIND THE COIL IS BAD. VACAVILLE VW REPLACES THE COIL AND IT IS READY FOR PICKUP ON TUESDAY, 11-11-08. I PICK THE VEHICLE UP ON WEDNESDAY AND TWO DAYS LATER, THE TIRE PRESSURE MONITOR SYSTEM FAULT LIGHT COMES ON AGAIN. IT IS NOW AT VACAVILLE VW AND I AM WAITING TO FIND OUT WHAT IS WRONG NOW. *TR

NHTSA ODI #10249027

62,000 miles · Oct 17, 2008
Power Train

DRIVE SHAFT SUPPORT BEARING FAILURE @ 62,000 MILES. MANUFACTURER VW DOES NOT SELL INDIVIDUAL BROKE PART BUT SELLS ASSEMBLY WHICH COST $1,100 PLUS TAX. THIS IS COMMON AND SHOULD BE A FACTORY RECALL. *TR

NHTSA ODI #10245752

27,895 miles · Aug 27, 2008
Service Brakes, HydraulicSuspension

SCREECHING BRAKES. THE BRAKES WERE SCREECHING FOR THE PAST THREE MONTHS AND THE VW DEALERSHIP REPLACED THE PADS AND DISC. AFTER THREE ATTEMPTS, I WAS TOLD THAT THE SCREECHING IS NORMAL. ALSO, SINCE I BOUGHT THE SUV IN SETPTMBER 2004, I HAVE BEEN HAVING AN ALIGNMENT PROBLEM WHICH RESULTED IN EXCESSIVE TIRE WEAR. THE DEALER D…

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SCREECHING BRAKES. THE BRAKES WERE SCREECHING FOR THE PAST THREE MONTHS AND THE VW DEALERSHIP REPLACED THE PADS AND DISC. AFTER THREE ATTEMPTS, I WAS TOLD THAT THE SCREECHING IS NORMAL. ALSO, SINCE I BOUGHT THE SUV IN SETPTMBER 2004, I HAVE BEEN HAVING AN ALIGNMENT PROBLEM WHICH RESULTED IN EXCESSIVE TIRE WEAR. THE DEALER DID NUMEROUS ALIGNMENTS AND I CHANGED ALL FOUR TIRES( 3 TIMES), BUT THE PROBLEM STILL EXISTS. THE VEHICLE ONLY HAS ABOUT 28,000 MILES. *TR

NHTSA ODI #10239897

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.