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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
Mileage unknown · Oct 16, 2006
Air Bags

ON MY 2004 TOURAEG, AFTER TILTING THE FRONT SEATS BACK ALL THE WAY TO THE HORIZONTAL POSITION, THE AIRBAG WARNING LIGHT CAME ON. IT TURNED OUT THAT THE CONNECTORS FOR THE SIDE AIR BAGS GOT DISCONNECTED SINCE THE CABLES ARE TOO SHORT OR ARE NOT MOUNTED RIGHT. I GOT THE CONNECTORS RECONNECTED AND NOW NO LONGER MOVE THE SEATS BAC…

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ON MY 2004 TOURAEG, AFTER TILTING THE FRONT SEATS BACK ALL THE WAY TO THE HORIZONTAL POSITION, THE AIRBAG WARNING LIGHT CAME ON. IT TURNED OUT THAT THE CONNECTORS FOR THE SIDE AIR BAGS GOT DISCONNECTED SINCE THE CABLES ARE TOO SHORT OR ARE NOT MOUNTED RIGHT. I GOT THE CONNECTORS RECONNECTED AND NOW NO LONGER MOVE THE SEATS BACK IN ORDER TO AVOID THIS FROM HAPPENING AGAIN. *NM

NHTSA ODI #10171023

55,000 miles · Sep 28, 2006
Air Bags

I HAVE A 2004 VW TOUAREG....IT IS A WELL KNOW PROBLEM THOUGHT ALL VW SERVICE SHOPS AS IT WAS SENT OUT IN A TSR? I HAVE OWNED MY VW FOR 2 YRS 8 MONTHS, AND HAVE ALREADY ACQUIRED 78000 MILES, I DRIVE EVERYWHERE...LEAVING ME OUT OF WARRANTY DUE TO MILEAGE.....I HAVE EXPERIENCED THE AIRBAG ISSUE THAT YOU HAVE ALREADY REPORTED TO VW.…

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I HAVE A 2004 VW TOUAREG....IT IS A WELL KNOW PROBLEM THOUGHT ALL VW SERVICE SHOPS AS IT WAS SENT OUT IN A TSR? I HAVE OWNED MY VW FOR 2 YRS 8 MONTHS, AND HAVE ALREADY ACQUIRED 78000 MILES, I DRIVE EVERYWHERE...LEAVING ME OUT OF WARRANTY DUE TO MILEAGE.....I HAVE EXPERIENCED THE AIRBAG ISSUE THAT YOU HAVE ALREADY REPORTED TO VW...THE DRIVER SEAT BACK AND FORTH MOTION RUNS OVER THE AIRBAG WIRE HARNESS CAUSING IT TO SPLIT THE WIRES CAUSING A COMPLETE AIRBAG FAULT...IT COST ME 425.00 TO HAVE THIS FIXED....12.00 PARTS THE REST LABOR....EVEN THE VW REPAIR PERSON I DEALT WITH ADMITTED THIS IS A KNOW ISSUE BUT NO RECALL HAS BEEN ISSUED.....WHY? IS IT NOT SAFE TO ASSUME THAT YOUR VEHICLE WAS EQUIPPED WITH AIRBAGS TO SAVE YOUR LIFE? IS IT NOT ABSURD TO HAVE YOUR ENTIRE SYSTEM NOT FUNCTION DUE TO A 12.00 PART THAT WAS IMPROPERLY POSITIONED IN THE FIRST PLACE? PLEASE FOR ALL TOUAREG OWNERS ISSUE A RECALL....EVERYONE KNOWS ITS OUT THERE AFFECTING ALL 2004 TOUAREGS....PLEASE DON'T ALLOW ANYONE TO BE INJURED AND KILLED ...OR WAIT UNTIL IT COSTS THEM A WEEK OR TWO OF PAY TO HAVE IT FIXED....THIS EVENT HAS REALLY UPSET ME AND IF IT CAN SAVE JUST 1 LIFE....ISN'T IT WORTH IT?. *JB

NHTSA ODI #10169551

34,000 miles · Sep 11, 2006
Electrical SystemPower Train

DT*: THE CONTACT STATED A WEEK AFTER HAVING THE TRANSMISSION REPLACED BY THE SERVICE DEALER, THE VEHICLE WAS DRIVEN 60 MPH ON THE HIGHWAY, AND THE ENGINE WARNING MESSAGE READ "TURN THE MOTOR OFF IMMEDIATELY", AS THE ELECTRICAL SYSTEM FAILED AND STALLED THE ENGINE. THE CONTACT WAS ABLE TO STEER AND COAST TO A STOP ON THE BREAK D…

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DT*: THE CONTACT STATED A WEEK AFTER HAVING THE TRANSMISSION REPLACED BY THE SERVICE DEALER, THE VEHICLE WAS DRIVEN 60 MPH ON THE HIGHWAY, AND THE ENGINE WARNING MESSAGE READ "TURN THE MOTOR OFF IMMEDIATELY", AS THE ELECTRICAL SYSTEM FAILED AND STALLED THE ENGINE. THE CONTACT WAS ABLE TO STEER AND COAST TO A STOP ON THE BREAK DOWN LANE. THE VEHICLE RESTARTED AND STALLED 7 TIMES BEFORE MAKING ONE MILE TO THE CONTACT'S DRIVEWAY. THE SERVICE DEALER PROVIDED A NUMBER TO A TOWING SERVICE. THE SERVICE DEALER DIAGNOSED THE PROBLEM AS AN ALTERNATOR AND ELECTRICAL FAILURE, DUE TO LEAKAGE FROM THE ENGINE WHEN THE ENGINE WAS REMOVED TO REPLACE THE TRANSMISSION. NO EVIDENCE WAS FOUND IN THE GARAGE OR DRIVEWAY, BEFORE OR AFTER THE PROBLEM OR WHILE PARKED IN THE DRIVEWAY WHILE WAITING FOR THE TOW TO THE SERVICE DEALER. THE MANUFACTURER WAS NOTIFIED. UPDATED 10/25/2006 - *NM

NHTSA ODI #10167886

76,000 miles · Jul 20, 2006
Exterior LightingTires

DT*: THE CONTACT STATED WHILE DRIVING THE VEHICLE THE PASSENGER SIDE OR DRIVER'S SIDE HEADLIGHT DARKENED. THERE WERE NO WARNING INDICATORS OR DASHBOARD LIGHTS ILLUMINATED TO INDICATE THERE WAS A FAILURE WITH THE HEADLIGHT(S). EVENTUALLY, THE OTHER HEADLIGHT DARKENED. THE ONLY WAY THE LIGHTS WOULD ILLUMINATE AGAIN IS BY RESTA…

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DT*: THE CONTACT STATED WHILE DRIVING THE VEHICLE THE PASSENGER SIDE OR DRIVER'S SIDE HEADLIGHT DARKENED. THERE WERE NO WARNING INDICATORS OR DASHBOARD LIGHTS ILLUMINATED TO INDICATE THERE WAS A FAILURE WITH THE HEADLIGHT(S). EVENTUALLY, THE OTHER HEADLIGHT DARKENED. THE ONLY WAY THE LIGHTS WOULD ILLUMINATE AGAIN IS BY RESTARTED THE IGNITION. THE DEALERSHIP REPLACED A COMPUTER CHIP, CHANGED THE BULBS AND OTHER UNKNOWN REPAIRS WERE MADE, HOWEVER THE PROBLEM STILL PERSISTS. UPDATED 8/14/2006 - THE TIRE WARNING LIGHT ILLUMINATED. THE DEALER REPLACED THE CONTROL UNIT. *NM

NHTSA ODI #10162943

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

33,000 miles · Jul 12, 2006
Electrical System

I'VE BEEN HAVING VARIOUS PROBLEMS WITH THE ELECTRICAL SYSTEM ON MY 2004 VW TOUAREG FROM THE PURCHASE DATE OF 08/19/03. THE ALARM WOULD SOUND, WITHOUT CAUSE, THE DOORS WOULD NOT UNLOCK AND VARIOUS SWITCHES WOULD NOT WORK AT TIMES. ALL OF THE PROBLEMS WERE RANDOM. I BROUGHT THE CAR IN FOR REPAIR SEVERAL TIMES. BUT, THE PROBLEM…

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I'VE BEEN HAVING VARIOUS PROBLEMS WITH THE ELECTRICAL SYSTEM ON MY 2004 VW TOUAREG FROM THE PURCHASE DATE OF 08/19/03. THE ALARM WOULD SOUND, WITHOUT CAUSE, THE DOORS WOULD NOT UNLOCK AND VARIOUS SWITCHES WOULD NOT WORK AT TIMES. ALL OF THE PROBLEMS WERE RANDOM. I BROUGHT THE CAR IN FOR REPAIR SEVERAL TIMES. BUT, THE PROBLEMS WERE NOT FIXED. IN APRIL 2006, MY CAR BATTERY WAS REPLACED BECAUSE IT WAS NO LONGER HANDLING A CHARGE. THE BATTERY CHANGE WAS A WARRANTY ITEM. AFTER THE BATTERY CHANGE, THE ELECTRICAL PROBLEMS BECAME MORE FREQUENT. MY TURN SIGNALS BEGAN TO ACT UP. WHEN I SIGNAL FOR A RIGHT TURN, THE BLINKER WILL CLICK TO THE LEFT ONE TO THREE TIMES, THEN TO THE RIGHT. I TOLD MURRIETA VW ABOUT THE PROBLEM AND BROUGHT THE CAR IN FOR WARRANTY SERVICE ON 06/30/06. THEY COULDN'T FIND A "FAULT CODE" AND COULDN'T MAKE THE CAR DUPLICATE THE PROBLEM. SO, THEY DIDN'T FIX THE CAR. I VIDEO TAPED THE PROBLEM FIVE TIMES, ON TWO DIFFERENT OCCASIONS AFTER THE 06/30/06. I ALSO HAVE TWO DIFFERENT WITNESSES WHO WITNESSED THE PROBLEM. I E MAILED THE VIDEOS TO MURRIETA VW AND SCHEDULED AN APPOINTMENT. I BROUGHT THE CAR BACK ON 07/08. MURRIETA VW WASN'T ABLE TO DIAGNOSE THE PROBLEM. I FEEL THAT THE CAR IS NOW DANGEROUS. IF I WERE TO SIGNAL A RIGHT TURN AT AN INTERSECTION, WITH AN ONCOMING CAR ASSUMING THAT I AM TURNING LEFT BECAUSE OF A DEFECTIVE TURN SIGNAL, I COULD END UP IN AN ACCIDENT. I'M NOT LOOKING FOR SPECIAL TREATMENT FROM VW. I JUST WANT MY CAR FIXED. 2004 VW TOUAREG SERIAL# W V G C M 67 L 04 D 002863. *JB

NHTSA ODI #10162259

15,000 miles · Jun 28, 2006
Power Train

DT*: THE CONTACT STATED THAT THERE AUTOMATIC TRANSMISSION WAS NOT OPERATING PROPERLY. WHILE TRAVELING AT HIGHWAY SPEEDS, THE VEHICLE WOULD NOT DOWNSHIFT SMOOTHLY. AS AN ALTERNATIVE PRESSURE WAS APPLIED TO THE BRAKES WHICH IN THE EVENT OF AN EMERGENCY BRAKING SITUATION THE VEHICLE FELT AS IF IT WOULD NOT STOP IN TIME THIS WAS CA…

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DT*: THE CONTACT STATED THAT THERE AUTOMATIC TRANSMISSION WAS NOT OPERATING PROPERLY. WHILE TRAVELING AT HIGHWAY SPEEDS, THE VEHICLE WOULD NOT DOWNSHIFT SMOOTHLY. AS AN ALTERNATIVE PRESSURE WAS APPLIED TO THE BRAKES WHICH IN THE EVENT OF AN EMERGENCY BRAKING SITUATION THE VEHICLE FELT AS IF IT WOULD NOT STOP IN TIME THIS WAS CAUSED BY THE PRESSURE TO THE TRANSMISSION. THIS PROBLEM OCCURS ON A DAILY BASIS. THE VEHICLE WAS AT A DEALERSHIP FOR 3 AND A HALF WEEKS AND THE DEALER DETERMINED THE VEHICLE WAS OPERATING UNDER NORMAL OPERATING STANDARDS. THE CONTACT EXPRESSED THAT THIS IS A SERIOUS SAFETY CONCERN.*AK

NHTSA ODI #10161013

19,880 miles · Jun 5, 2006
Electrical SystemFuel System, GasolineService Brakes, Hydraulic

VOLKSWAGEN 2004 TOUAREG SPORT UTILITY 4D HAS SERIOUS ALIGNMENT PROBLEMS RESULTING IN PREMATURE TIRE WEAR ON ALL 4 TIRES! FRONT 2 TIRES ARE DOWN TO METAL SHOWING WITH ONLY 19,880 MILES. CAR HAS BEEN IN FOR ALL SCHEDULED SERVICES AND ROTATIONS. ALMOST LOST CONTROL OF CAR WHILE DRIVING! ALSO, PRE-MATURE WEAR OF FRONT & BACK BRAKE…

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VOLKSWAGEN 2004 TOUAREG SPORT UTILITY 4D HAS SERIOUS ALIGNMENT PROBLEMS RESULTING IN PREMATURE TIRE WEAR ON ALL 4 TIRES! FRONT 2 TIRES ARE DOWN TO METAL SHOWING WITH ONLY 19,880 MILES. CAR HAS BEEN IN FOR ALL SCHEDULED SERVICES AND ROTATIONS. ALMOST LOST CONTROL OF CAR WHILE DRIVING! ALSO, PRE-MATURE WEAR OF FRONT & BACK BRAKES & PADS DUE TO THE ALIGNMENT/TIRE PROBLEMS! CONDENSATION ON FRONT WINDSHIELD THAT DEFOGGER DOES NOT REMOVE. FUEL INJECTION RECALL THAT ON SERVICE BULLETIN STATED IT COULD RESULT IN A FIRE IF NOT FIXED! TIRE PRESSURE MONITORING SYSTEM FAILURE, ESP FAILURE, COMPUTER SOFTWARE FAILURE! *NM

NHTSA ODI #10158963

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

29,500 miles · May 23, 2006
Power Train

DT*: THE CONTACT STATED THE TRANSMISSION DISENGAGED WHILE DRIVING 65 MPH. THE VEHICLE ACTED AS IF IT WAS IN NEUTRAL, REGARDLESS OF THE POSITION OF THE SHIFTER. THE TRANSMISSION WOULD NOT ENGAGE IN ANY POSITION INCLUDING PARK. THE ENGINE CONTINUED TO RUN, BUT THERE WAS NO POWER TO THE WHEELS. AFTER SEVERAL ATTEMPTS TO RESTAR…

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DT*: THE CONTACT STATED THE TRANSMISSION DISENGAGED WHILE DRIVING 65 MPH. THE VEHICLE ACTED AS IF IT WAS IN NEUTRAL, REGARDLESS OF THE POSITION OF THE SHIFTER. THE TRANSMISSION WOULD NOT ENGAGE IN ANY POSITION INCLUDING PARK. THE ENGINE CONTINUED TO RUN, BUT THERE WAS NO POWER TO THE WHEELS. AFTER SEVERAL ATTEMPTS TO RESTART, THE TRANSMISSION RE-ENGAGED. THE VEHICLE HAS BEEN TO THE DEALERSHIP FIVE TIMES FOR INSPECTION AND REPAIRS. THEY HAVE REPLACED THE BATTERY, ALTERNATOR, FLASHED THE TRANSMISSION CONTROL MODULE, ENGINE CONTROL MODULE, AND DIFFERENTIAL CONTROL MODULE HOWEVER THE PROBLEM STILL EXISTS. THE VEHICLE IS CURRENTLY AT THE DEALERSHIP AWAITING FURTHER INSPECTION. THE MANUFACTURER WAS ALERTED. UPDATED 07/25/06. *JB

NHTSA ODI #10158125

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.