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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
150 miles · May 16, 2005
Service Brakes, HydraulicSteering

SINCE I PURCHASED A 2004 VW TOUAREG ON 2/28/04 I HAVE HAD VARIOUS PROBLEMS WITH IT. THE MOST SEVERE IS THE FRONT END ALLIGNMENT AND BRAKES. I HAVE HAD A TOTAL OF 6 FRONT END ALLIGNMENTS SINCE I PURCHASED THE VEHICULE. IT IS IN THE SHOP RIGHT NOW AND THEY CAN NOT CORRECT IT. THIS IS A AN EXTREME HAZARD AT HIGHER SPEEDS SINCE THE …

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SINCE I PURCHASED A 2004 VW TOUAREG ON 2/28/04 I HAVE HAD VARIOUS PROBLEMS WITH IT. THE MOST SEVERE IS THE FRONT END ALLIGNMENT AND BRAKES. I HAVE HAD A TOTAL OF 6 FRONT END ALLIGNMENTS SINCE I PURCHASED THE VEHICULE. IT IS IN THE SHOP RIGHT NOW AND THEY CAN NOT CORRECT IT. THIS IS A AN EXTREME HAZARD AT HIGHER SPEEDS SINCE THE SUV PULLS HARD TO THE RIGHT. I WAS TOLD BY THE MECHANIC THAT WORKED ON MY VEHICULE THAT HE SET THE ALLIGNMENT TO FACTOR SPECS AND IT STILL PULLS TO THE RIGHT. I TOOK IT TO TIRE KINGDOM TWICE AND THEY DID THE SAME AND DID A HIGH SPEED BALANCE ON THE TIRES AS WELL AND IT STILL PULLS TO THE RIGHT. ALSO VOLKWAGON OF AMERICA PUT OUT CIRCULAR VWA-04-12 STATING THAT THERE IS A FACTORY PROBLEM WITH FRONT END ALLIGNMENTS ON CERTIN VIN NUMBERS ON THE TOUAREG. VW WILL NOT ACKNOWLEDGE THAT THERE IS A PROBLEM. I ALSO HAVE TROUBLE WITH THE BREAKS MAKING LOUD NOISE AND WEARING OUT FAST. NOW THEY ARE TELLING ME THAT THE ROTORS ARE BAD. I HAVE COMPLAINED ABOUT THE BRAKES AND NOTHING WAS DONE. ALSO THERE IS CONDENSATION ON THE WINDSHIELD FROM THE AIR CONDITIONING AND THEY DID HAVE A RECALL ON THIS, BUT THE TROUBLE STILL EXSISTS.

NHTSA ODI #10121010

400 miles · May 6, 2005
Vehicle Speed Control

I WAS TURNING LEFT AT A FAIRLY BUSY INTERSECTION & HAD WAITED FOR 2 CARS TO GO THAT WERE IN FRONT OF ME. WHEN MY TURN CAME & A GAP APPEARED IN INCOMING TRAFFIC, I REMOVED MY LEFT FOOT FROM THE BRAKE, DEPRESSED THE ACCELERATOR WITH MY RIGHT FOOT & TURNED. HOWEVER, THE CAR DID NOT ACCELERATE. IT MOVED INTO THE LANE OF ONCOMING …

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I WAS TURNING LEFT AT A FAIRLY BUSY INTERSECTION & HAD WAITED FOR 2 CARS TO GO THAT WERE IN FRONT OF ME. WHEN MY TURN CAME & A GAP APPEARED IN INCOMING TRAFFIC, I REMOVED MY LEFT FOOT FROM THE BRAKE, DEPRESSED THE ACCELERATOR WITH MY RIGHT FOOT & TURNED. HOWEVER, THE CAR DID NOT ACCELERATE. IT MOVED INTO THE LANE OF ONCOMING TRAFFIC, BUT JUST IDLED & I COULD NOT GET THE CAR TO MOVE FOR 2 - 3 SECONDS. I PUSHED THE THROTTLE ALL THE WAY TO THE FLOOR WITH NO EFFECT. A SERIOUS ACCIDENT DID NOT OCCUR ONLY BECAUSE THE ONCOMING TRAFFIC SLAMMED ON THEIR BRAKES IN TIME. AFTER WHAT SEEMED LIKE FOREVER, THE CAR BEGAN TO MOVE & I WAS ABLE TO GET OUT OF THE WAY. THE SAME THING HAS HAPPENED 19 TIMES SINCE & THE CAR HAS BEEN RETURNED TO THE DEALER 4 TIMES TO FIX THIS PROBLEM. EACH TIME THEY 'COULD NOT DUPLICATE' THE PROBLEM. NIETHER COULD I UNTIL 3 DAYS AGO WHEN I WAS TOLD BY A VW REP THAT THIS BEHAVIOR IS DESIGNED IN AS A 'SAFETY FEATURE'. HE SAID IT OCCURS WHEN A DRIVER DEPRESSES THE THROTTLE SLIGHTLY, THEN (USING LEFT FOOT) THE BRAKE SLIGHTLY, THEN THE THROTTLE SOME MORE, THEN THE CAR WILL NOT ACCELERATE FOR 2-3 SECONDS. WHAT THAT CONTRIBUTES TO SAFETY IS BEYOND ME. IT'S A SERIOUS DEFECT THAT WILL COST SOMEONE THEIR LIFE & MUST BE CHANGED AS SOON AS POSSIBLE.

NHTSA ODI #10120137

10,000 miles · May 5, 2005
Latches/locks/linkagesInjury

DOOR HANDELS STICK IN THE OPEN POSITION SO DOORS DO NOT CLOSE. TAKEN TO DEALER, DEALER DID NOT FIX ISSUE. MY DAUGHTER'S HAND THEN WAS HURT AFTER DOOR SLAMMED INTO HER AS IT WAS DID NOT LATCH DUE TO STICKING DOOR HANDELS. CALLED VOLKSWAGEN, THEN BOOKED THE CAR FOR REPAIR. AFTER COLLECTING CAR FROM DEALER'S SECOND REPAIR, THE PROB…

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DOOR HANDELS STICK IN THE OPEN POSITION SO DOORS DO NOT CLOSE. TAKEN TO DEALER, DEALER DID NOT FIX ISSUE. MY DAUGHTER'S HAND THEN WAS HURT AFTER DOOR SLAMMED INTO HER AS IT WAS DID NOT LATCH DUE TO STICKING DOOR HANDELS. CALLED VOLKSWAGEN, THEN BOOKED THE CAR FOR REPAIR. AFTER COLLECTING CAR FROM DEALER'S SECOND REPAIR, THE PROBLEM STILL OCCURS, BUT AT NOT AS OFTEN. CAR STILL DEFECTIVE.

NHTSA ODI #10119956

Mileage unknown · Apr 27, 2005
Service Brakes, HydraulicWheelsCrash

DRIVER APPLIED THE BRAKES AND PEDAL WENT TO THE FLOOR AND THE STEERING WHEEL FAILED TO TURN. DRIVER LOST CONTROL OF THE VEHICLE AND HIT A FIRE HYDRANT. LEFT SIDE (DRIVER'S SIDE) WHEEL SHEARED OFF. DRIVER WAS NOT INJURED. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC STATED THAT A CAUSE COULD NOT BE DETERMINE…

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DRIVER APPLIED THE BRAKES AND PEDAL WENT TO THE FLOOR AND THE STEERING WHEEL FAILED TO TURN. DRIVER LOST CONTROL OF THE VEHICLE AND HIT A FIRE HYDRANT. LEFT SIDE (DRIVER'S SIDE) WHEEL SHEARED OFF. DRIVER WAS NOT INJURED. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION, AND MECHANIC STATED THAT A CAUSE COULD NOT BE DETERMINED AT THIS TIME. *AK *BF *NM

NHTSA ODI #10115589

1,500 miles · Apr 22, 2005
Electrical System

THE RADIO DISPLAY SYSTEM (DISPLAYS RADIO STATION INFO,SONG TITLE, AND ARTIST) QUIT WORKING. THE DEALER HAS RECONNECTED THE RADIO AND REPLACED THE RADIO. EACH TIME IT WORKS FINE FOR A FEW HOURS AFTER RETURNING HOME THEN IT QUITS DISPLAYING INFORMATION. THE DEALER SAID THE RADIO ISN'T DESIGNED TO DISPLAY THIS INFO, YET IT WORKE…

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THE RADIO DISPLAY SYSTEM (DISPLAYS RADIO STATION INFO,SONG TITLE, AND ARTIST) QUIT WORKING. THE DEALER HAS RECONNECTED THE RADIO AND REPLACED THE RADIO. EACH TIME IT WORKS FINE FOR A FEW HOURS AFTER RETURNING HOME THEN IT QUITS DISPLAYING INFORMATION. THE DEALER SAID THE RADIO ISN'T DESIGNED TO DISPLAY THIS INFO, YET IT WORKED FOR A MONTH AFTER GETTING THE VEHICLE! IT WORKS ON MY OTHER CAR. THE RADIO IS THE UPGRADE MONSOON SYSTEM WITH CD. *JB

NHTSA ODI #10118276

2,000 miles · Apr 11, 2005
Air BagsElectrical SystemLatches/locks/linkages

MY 2004 TOUAREG WITH LESS THAN 5000 MILES HAS BEEN IN FOR SERVICING 7 TIMES. THE BRAKES HAVE BEEN WORKED ON AND LOOKED AT THREE TIMES. THEY STILL SQUEAL BUT THE PROBLEM HAS LESSENED. OF MORE CONCERN ARE THE SAFETY ISSUES THAT HAVE AFFECTED ME. I HAVE BEEN LOCKED OUT OF MY VEHICLE TWICE, EACH TIME WITH A DIFFERENT RESOLUTION.…

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MY 2004 TOUAREG WITH LESS THAN 5000 MILES HAS BEEN IN FOR SERVICING 7 TIMES. THE BRAKES HAVE BEEN WORKED ON AND LOOKED AT THREE TIMES. THEY STILL SQUEAL BUT THE PROBLEM HAS LESSENED. OF MORE CONCERN ARE THE SAFETY ISSUES THAT HAVE AFFECTED ME. I HAVE BEEN LOCKED OUT OF MY VEHICLE TWICE, EACH TIME WITH A DIFFERENT RESOLUTION. UPDATED SOFTWARE WAS THE LATEST FIX. MY AIRBAG FAULT LIGHT IS NOW ON. ANOTHER SOFTWARE RESOLUTION IS ON THE WAY. I HAVE NO CONFIDENCE IN THE QUALITY OR SAFETY OF THIS VEHICLE OR WHEN THE NEXT ISSUE WILL ARISE. VOLKSWAGEN TOLD ME MY CAR WAS NOT PROBLEMATIC AND I HAD "BUYERS REMORSE". I AM IN AWE OF THEIR LACK OF CONCERN ESPECIALLY WHEN I KNOW I AM NOT THE ONLY TOUAREG OWNER OUT THERE WITH PROBLEMS.*AK

NHTSA ODI #10116727

19,000 miles · Mar 24, 2005
Visibility

THIS HEADLIGHT WASHER(S) THAT POP UP FROM FRONT BUMPER CAME OFF DURING DRIVE FROM CA TO MD. DURING THE DRIVE BACK TEMPERATURE WENT INTO THE FREESING RANGE. WAS NOT AWARE THAT WHEN WASH THE WINDSHIELD THESE OTHER WASHERS POP UP TO WASHER THE HEADLIGHT. ANYWAYS, THEY DO AND DUE TO COLD IT GOT STUCK IN UP POSITION AND EVENTUALLY…

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THIS HEADLIGHT WASHER(S) THAT POP UP FROM FRONT BUMPER CAME OFF DURING DRIVE FROM CA TO MD. DURING THE DRIVE BACK TEMPERATURE WENT INTO THE FREESING RANGE. WAS NOT AWARE THAT WHEN WASH THE WINDSHIELD THESE OTHER WASHERS POP UP TO WASHER THE HEADLIGHT. ANYWAYS, THEY DO AND DUE TO COLD IT GOT STUCK IN UP POSITION AND EVENTUALLY CAME OFF. DEALER INITIALLY SAID COVERED UNDER WARRANTY AND NOW SAYS THAT SINCE HAVE A SCRATCH ON SIDE BUMPER SOMEONE TEMPERED WITH THE WASHER. HOWEVER MORE IMPORTANTLY THEY SAID THAT IT HAS NEVER HAPPENED TO ANYONE BEFORE. I SAID MAYBE NOT YET OR IN DIFFERENT REGION SINCE THIS WAS WHEN DRIVING IN MUCH COLDER WEATHER. ALSO, THEY ALSO CONFIRMED THAT IT STUCKS IN THE DOWN POSITION WHEN THEY PUT IN A NEW ONE.

NHTSA ODI #10114658

Mileage unknown · Mar 4, 2005
Vehicle Speed Control

VEHICLE HESITATED TO SPEED UP WHILE AT LOW SPEEDS, AND EXPERIENCED SUDDEN ACCELERATION WHILE AT HIGHER SPEEDS. TAKEN TO DEALER FOR TESTING, AND RESULTS SHOWED THAT THE CAUSE WAS UNDETERMINED.*AK

NHTSA ODI #10113426

19,000 miles · Feb 25, 2005
Electrical System

INTERMITTENTLY, THE FACTORY ENTRY REMOTE CONTROLLER FAILS TO FUNCTION. THE DOORS HAVE TO BE OPENED MANUALLY . THE SYSTEM REGENERATES ITSELF WHEN THE KEYS IS TURNED IN THE IGNITION. THE DEALERSHIP INSPECTED THE SYSTEM AND INSTALLED A NEW BATTERY. THE FAILURE STILL OCCURS. *NM

NHTSA ODI #10113071

9,029 miles · Feb 24, 2005
Service Brakes, HydraulicSuspension

VOLKSWAGEN TOUAREG 2004 DOES NOT STOP IN INCLEMENT WEATHER. *BF ALL FOUR TIRES WERE PRACTICALLY BALD AND THE VEHICLE NEEDED AN ALIGNMENT. THE FRONT TIRES WERE SLIGHTLY MORE WORN THAN THE REAR. ALSO, THE CLOCK WAS INOPERATIVE AND THE BRAKES WOULD LOCK UP ON SNOWY CONDITIONS. *SC

NHTSA ODI #10113633

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.