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NHTSA Defect Investigation List for the 2003 Volkswagen Passat

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2003 Volkswagen Passat, both ongoing and closed, are listed below:

  1. Engine Compartment Fire NHTSA Defect Investigation #EA11002

    • Status:
      OPEN
    • Date Opened: January 26, 2011
    • Date Closed: Pending
    • Recall: possible recall

    Component: Electrical System*

    Summary: ODI has received 14 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 21 complaints of ignition coil failure that did not result in a fire. Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated. The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once. The scope of PE10-027 focused on model years (MY) 2002-2003 passat vehicles and Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles. However, based on consumer complaints, ODI also requested and received data from Volkswagen regarding MY2006-2007 passat vehicles. The failure report for this engineering analysis contains data for MY 2002-2003 and MY 2006-2007 vehicles. ODI needs to further investigate this issue. To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an engineering analysis. ODI is expanding the scope to include MY 2001-2007 passat vehicles.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA11002 »

    * This defect investigation is filed under 2 related vehicle components.

  2. Engine Compartment Fire NHTSA Defect Investigation #PE10027

    • Status:
      CLOSED
    • Date Opened: July 26, 2010
    • Date Closed: February 07, 2011
    • Recall: no recall issued

    Component: Electrical System*

    Summary: ODI has received 11 complaints alleging that a fire started in the engine compartment of the vehicle that may be related to ignition coil failure, and 9 complaints of ignition coil failure that did not result in a fire. Reports state that the vehicle hesitated or lost power, and the check engine or dashboard lights illuminated. The vehicles were repaired by replacing the faulty ignition coil(s). Some of the complaints indicated that the ignition coils were replaced more than once. The scope of PE10-027 focused on model years (my)2002-2003 passat vehicles. Volkswagen provided data regarding their analysis of the vehicle fires and faulty ignition coils for these vehicles as well as other my passat vehicles. ODI needs to further investigate this issue. To facilitate the acquisition and analysis of additional information, this investigation has been upgraded to an engineering analysis, EA11-002.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE10027 »

    * This defect investigation is filed under 2 related vehicle components.

  4. PASSENGER ENGINE COMPARTMENT FIRES NHTSA Defect Investigation #EA07014

    • Status:
    • Date Opened: September 28, 2007
    • Date Closed: July 07, 2008
    • Recall: Recall #08V156000

    Component: Electrical System:Ignition*

    Summary: The manufacturer notified NHTSA on 04-apr-08 that a safety recall action would be initiated to remedy the issue. In June 2008, the manufacturer issued a technical service bulletin (code 26E5/R5) regarding the specific procedures to be employed in this campaign. Vehicle owner notification letters were sent beginning approximately June 13, 2008. The campaign was assigned NHTSA no. 08V-156. This recall affects all MY 1999-2005, 5th generation gasoline-powered passat sedans and station wagons. Approximately 412,000 vehicles are affected. Corrective action will consist of installing additional exhaust system heat shielding to mitigate the potential thermal effects of engine ignition problems. Based on this action, the subject ea has been closed.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA07014 »

    * This defect investigation is filed under 2 related vehicle components.

  5. PASSENGER/ENGINE COMPARTMENT FIRES NHTSA Defect Investigation #PE07024

    • Status:
      CLOSED
    • Date Opened: May 10, 2007
    • Date Closed: September 28, 2007
    • Recall: no recall issued

    Component: Electrical System:Ignition

    Summary: Many of the fire reports allege that the vehicle fire was attributed to ignition coil failure. Vw provided additional data regarding its analysis of vehicle fires and a detailed description of the three different engines and ignition systems for the subject vehicles. Odifinds the need to further investigate this issue. To facilitate acquisition and analysis of additional information, this investigationhas been upgraded to an engineering analysis (EA07-014).

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE07024 »

  6. ENGINE STALLING NHTSA Defect Investigation #DP05004

    • Status:
      CLOSED
    • Date Opened: August 11, 2005
    • Date Closed: December 08, 2005
    • Recall: no recall issued

    Component: Electrical System:Ignition:Module

    Summary: By letter received on June 24, 2005, mr. Ronald M. strickland of raleigh, nc, submitted a petition requesting that the Agency investigate the performance of the ignition coil plugs on model year (MY) 2000-2003 Volkswagen jetta, golf and passat sedans. The petitioner alleges that he had experienced multiple stalling events as a result of one or more ignition coil plugs malfunctioning on his 2002 vw jetta sedan. As a result of the engine stalling, the petitioner experienced a loss of power steering and increased braking efforts when he pulled the vehicle over to the side of the road to control the vehicle. After a few minutes parked on the shoulder he was able to restart the vehicle although the engine operated at reduced power. Vw issued a customer satisfaction campaign (csc) on January 31, 2003 to instruct their dealerships to inspect the vehicles for any malfunctioning ignition coil packs and to replace them at no cost to the consumer. Consumers were notified to bring their vehicles to their dealerships via owner letters mailed out on June 6, 2003. While vw initially instructed the dealerships to only replace the malfunctioning ignition coil packs, a revised csc was issued to dealerships in December 2003 and January 2004, instructing dealerships to replace all ignition coil packs regardless of their performance. A reminder to the dealerships was sent by vw on April of 2004. Although the concerns of the petitioner could theoretically create a safety problem, the risk is very small, due to the engine still running on either 3, 5, or 7 cylinders. There are no reported crashes or injuries due to the alleged defect. Once drivers are aware of the problem (loss of power due to one of the ignition coil packs malfunctioning), drivers are able to take precautionary and compensatory measures and still maintain control of their vehicles. In addition, four fires were reported to ODI. These were ignition coil burnouts with no additional damage to the vehicle and were localized on top of the engine. During the last 24 months the number of stall and drivability complaints reported to ODI has greatly diminished from a peak of 195 in January of 2003 to only 3 in August of 2005. This coincides with the csc released by vw. A safety-related 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. The Agency reserves the right to take further action if warranted by the circumstances.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #DP05004 »

  7. FUEL TANK LEAK NHTSA Defect Investigation #PE08008

    • Status:
    • Date Opened: January 31, 2008
    • Date Closed: May 30, 2008
    • Recall: Recall #08V156000

    Component: Fuel System, Gasoline:Storage:Tank Assembly*

    Summary: Volkswagen (vw) is recalling certain vw passat 4motion and Audi A6 quattro and allroad quattro all-wheel drive passenger cars. Vw vehicles subject to recall were manufactured from November 22, 2000 through May 31, 2005 and Audi vehicles subject to recall were manufactured from June 2, 2001 to June 1, 2005. The NHTSA recall number for the vw vehicles is 08V-156 (vw also is correcting defects related to heat shield and fuel line hazards for these vehicles and for 1999-2000 passats in this recall action.)the NHTSA recall number for the Audi vehicles is 08V-157. Since 2006, ODI has received 17 complaints of fuel leaking from the subject vehicles' fuel tanks. The 400 complaints shown above may include duplicate reports to ODI and the manufacturer. While the consequence (fuel leaks from the top of the tank) is similar for both the passat and Audi subject vehicles, differences in design and construction require a different remedy for each vehicle. On the passats, the ventilation line could have been installed improperly with tension and with an incorrectly positioned cable tie. The tension could cause cracked or broken nipples on the fuel tank rollover valve. On the Audi vehicles, a material change (effective June 2, 2001) with different aging characteristics used for the rollover valve and the use of an inflexible aluminum ventilation line could cause cracking of the nipple on the rollover valve. Vw is recalling all vehicles subject to these defects. It will inspect passats to ensure that the vent line is tension free and correct the installation if tension is found. If a crack or fuel leak is found, vw will replace the fuel tank. Audi will repair all subject vehicles by reinforcing the fuel tank rollover valve with an epoxy adhesive. This investigation is closed.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE08008 »

    * This defect investigation is filed under 4 related vehicle components.

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