NHTSA Complaint #11448858 — 2015 AUDI A3

The Auxiliary PTC Electric Cabin Heater fails and causes an overheat/fire condition. We own a 2015 Audi A3 TDI Premium Plus sedan. This vehicle has a diesel engine. Audi fitted A3 models that have a diesel engine with an auxiliary electric cabin air heater. This heater helps to warm the cabin and provide defrost capabilities on days when the temperature is below 7 degrees C. This heater in our vehicle failed due to melting at the wiring harness connection lugs. This melting caused an overheating condition to occur. On cold days we would notice a terrible burning plastic, rubber smell coming from the air vents inside the cabin. Once the car was warmed up and the electric heater was disabled by the cars ECU (computer) the smell gradually went away. The process was repeated the next day, but the smell was worse. We took the vehicle to Zimbrick European Audi in Madison, WI. They found the electrical issue with the Auxiliary Electric Cabin Air heater. In researching this issue we found there are MANY user reports of the same failure on Volkswagon Audi Group vehicles. Audi issued a safety recall for the SAME problem on Audi A4, A5 and Q5 vehicles under Audi Safety Recall Code : 80C5 with the NHTSA document number being: RCRIT-17V622-6265.pdf This very same problem currently affects my Audi A3 TDI. I have found numerous other people reporting the same issue with VW Golf TDI models, VW Passat TDI models and Jetta TDI models. Examples are located here: https://forums.tdiclub.com/index.php?threads/burning-smell-from-heat.513304/ https://www.youtube.com/watch?v=_6tEwBzZIxs The problem is most likely the same materials defects that occurred with the Audi A4, A5 and Q5 models. The third party supplier of the Auxiliary Electric Cabin Air Heaters used TIN for some of the components. These substandard components lead to product failure and ultimately thermal overload, melting plastic/rubber and potentially a fire.