NHTSA Complaint #10260163 — 2005 VOLKSWAGEN PASSAT

THE BALANCE SHAFTS IN THIS ENGINE ARE DRIVEN BY A HEX SHAFT OFF THE CHAIN DRIVEN OIL PUMP. THIS UNFORTUNATE DESIGN SUBJECTS THE CHAIN TO STRESSES IT CANNOT WITHSTAND. MY OWN PASSAT HAD THE OIL PUMP AND BALANCE SHAFT REPLACED 2/16/09 WITH LESS THAN 65,000 MILES. THANKFULLY, A GOOD MECHANIC DETECTED THE PROBLEM BEFORE I HAD A CATASTROPHIC ENGINE FAILURE. A $3,500 REPAIR IS NEVER WELCOME, BUT IT WAS BETTER THAN REPLACING THE ENGINE LIKE THE VW DEALER RECOMMENDED. I DID A LOT OF RESEARCH ON THIS PROBLEM AND INQUIRED AT SEVERAL VW DEALERSHIPS AND CHOSE THE MOST EXPERIENCED MAN TO DO THE JOB. RECENTLY, VOLKSWAGEN IN EUROPE RECOGNIZED THE PROBLEM AND DESIGNED A REPAIR WHICH CHANGES THE CHAIN DRIVEN OIL PUMP TO A GEAR DRIVEN OIL PUMP. THIS APPEARS TO BE A PERMANENT FIX TO THE ORIGINAL DESIGN DEFECT. THE REPAIR IS QUITE EXPENSIVE. PARTS WILL COST IN EXCESS OF $1,400 AND LABOR WILL BE IN EXCESS OF $1,200 AT MOST SHOPS. I BELIEVE IT IS NOW OBVIOUS THAT ALL THE BHW ENGINES WILL FAIL UNLESS THE GEAR DRIVEN OIL PUMP MODIFICATION IS UNDERTAKEN. IT IS UNFAIR TO EXPECT OWNERS OF THESE VEHICLES TO PAY FOR THE REPAIRS. THE PROBLEM ORIGINATED WITH A FLAWED DESIGN. THIS IS NOT A SMALL PROBLEM, AS THIS DESIGN FLAW WILL LEAD TO TOTAL ENGINE FAILURE. MY WIFE NORMALLY DRIVES THE CAR AND SHE SHOULD NOT BE PUT THROUGH THIS. IF THE FAILURE OF THE CHAIN CAUSES ENGINE TO STOP RUNNING IN THE MIDDLE OF TRAFFIC, MERGING ONTO A HIGHWAY, OR PASSING ON THE HIGHWAY, THIS CONDITION COULD EASILY CAUSE DANGER TO ALL CITIZENS NEARBY, POSSIBLY LEADING TO DEATH. I WOULD LIKE TO KNOW WHAT STEPS VOLKSWAGEN OF AMERICA IS TAKING TO INFORM 2004 AND 2005 PASSAT TDI OWNERS OF THIS PROBLEM. GOOD CORPORATE CITIZENSHIP WOULD RECOGNIZE A PROBLEM OF THIS SEVERITY AND SHOULD BE COMMUNICATED TO THE OWNERS AS SOON AS POSSIBLE. THESE ENGINE FAILURES COULD LEAVE MOTORISTS STRANDED UNDER DIRE CIRCUMSTANCES AND THEIR SAFETY IS AT RISK. *TR