2004 VOLKSWAGEN PASSAT — Problems, Recalls & Safety Data

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N/A

Safety Rating

348

Owner Complaints

12 Crashes 31 Fires

4

Recalls

ACTIVE RECALL

15

Service Bulletins

1

Investigation

Overview of the 2004 VOLKSWAGEN PASSAT

The 2004 VOLKSWAGEN PASSAT has received a total of 348 safety complaints filed with the National Highway Traffic Safety Administration (NHTSA). There have been 4 recall campaigns affecting this vehicle, covering issues with ENGINE AND ENGINE COOLING:ENGINE, FUEL SYSTEM, GASOLINE:DELIVERY, EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH. 15 technical service bulletins have been issued by Volkswagen Group of America, Inc. for this model year. The most commonly reported problems involve the Engine And Engine Cooling (33 complaints), Fuelpropulsion System (22 complaints), and Power Trainautomatic Transmission (22 complaints).

Recalls for the 2004 VOLKSWAGEN PASSAT

NHTSA has recorded 4 recalls for the 2004 VOLKSWAGEN PASSAT, potentially affecting up to 1,433,334 vehicles.

Recall 14E007000 — ENGINE AND ENGINE COOLING:ENGINE

| 50 vehicles affected

Defect: The Gates Corporation (Gates) is recalling certain aftermarket Tru-Flow Water Pumps, part number TFW 41127, sold at certain NAPA Auto Parts and/or installed by automotive service technicians after November 1, 2013 (and manufactured August 2013 through October 2013) that have a black-colored pulley/sprocket or do not have 'US9377' stamped on the water pump housing. These service replacement parts were sold...

Consequence: A failure of the timing belt may cause the engine to shut down, potentially increasing the risk of a vehicle crash.

Remedy: Gates will notify owners, and dealers will replace the water pump, free of charge. The recall began during May 2014. Owners may contact The Gates Corporation at 1-303-744-1911.

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Recall 08V156000 — FUEL SYSTEM, GASOLINE:DELIVERY

| 412,000 vehicles affected

Defect: VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN...

Consequence: A HEAT SHIELD THAT MAY CONTACT THE EXHAUST SYSTEM CAN RESULT IN A VEHICLE FIRE. IN ADDITION, A FUEL LEAK FROM A FUEL LINE OR FUEL TANK VENTILATION VALVE, IN THE PRESENCE OF AN IGNITION SOURCE, CAN LEAD TO A VEHICLE FIRE.

Remedy: DEALERS WILL INSTALL ADDITIONAL UNDERBODY HEAT SHIELDS ON VEHICLES WITH AUTOMATIC TRANSMISSIONS TO COVER THE POSSIBLY DAMAGED AREAS AND FLASH ALL 1.8T ENGINES WITH A PRECAUTIONARY SOFTWARE UPDATE. DEALERS WILL ALSO INSPECT AND ADJUST THE FUEL LINE ROUTING ON 1.8T...

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Recall 07V063000 — EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH

| 1,002,000 vehicles affected

Defect: ON CERTAIN PASSENGER, WAGON, AND CONVERTIBLE VEHICLES EQUIPPED WITH OR WITHOUT CRUISE CONTROL, A BRAKE LIGHT SWITCH MAY MALFUNCTION IF IT WAS INSTALLED INCORRECTLY.

Consequence: THE BRAKE LIGHTS COULD BECOME INOPERATIVE, OR REMAIN ON. FAILURE TO PROVIDE THE PROPER SIGNAL WHEN BRAKING COULD LEAD TO A CRASH WITHOUT WARNING.

Remedy: DEALERS WILL INSTALL THE NEWLY DESIGNED BRAKE LIGHT SWITCH FREE OF CHARGE. THE RECALL BEGAN ON APRIL 27, 2007, AND WILL BE CONDUCTED IN SEVERAL STAGGERED MAILINGS THROUGH SEPTEMBER 21, 2007. VEHICLES WITHIN THE MAKE, MODEL, AND MODEL YEAR OF...

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Recall 04V586000 — FUEL SYSTEM, DIESEL

| 19,284 vehicles affected

Defect: ON CERTAIN PASSENGER VEHICLES, THE HIGH PRESSURE DIESEL PUMPS WERE PRODUCED WITH AN IMPROPER FASTENER, WHICH COULD ALLOW DIESEL FUEL TO ESCAPE FROM THE PUMP.

Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY LEAD TO A FIRE.

Remedy: DEALERS WILL REPLACE THE DIESEL PUMP. THE RECALL BEGAN ON FEBRUARY 8, 2005. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

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Owner Complaints for the 2004 VOLKSWAGEN PASSAT

348 complaints have been filed with NHTSA for the 2004 VOLKSWAGEN PASSAT. Below is a breakdown by vehicle component.

Engine And Engine Cooling
Complaints: 33 2 Fires
Fuelpropulsion System
Complaints: 22
Power Trainautomatic Transmission
Complaints: 22 1 Crash 2 Injuries
Fuel System Gasoline
Complaints: 21 2 Fires
Seatsfront Assemblyseat Heatercooler
Complaints: 20 8 Fires 10 Injuries
Engine
Complaints: 18 3 Fires
Engine And Engine Coolingengine
Complaints: 18 1 Fire
Electrical System
Complaints: 16 5 Fires 1 Injury
Seats
Complaints: 15 5 Fires 4 Injuries
Power Trainautomatic Transmissioncontrol Module Tcmpcmtecm
Complaints: 9
Structure
Complaints: 9
Exterior Lightingbrake Lightsswitch
Complaints: 7 1 Crash 1 Injury
Structurebody
Complaints: 7 1 Fire 1 Injury
Engine And Engine Coolingcooling System
Complaints: 6
Fuel System Gasolinedeliveryfuel Pump
Complaints: 6
Unknown Or Other
Complaints: 6
Fuel System Gasolinedelivery
Complaints: 5
Service Brakes Hydraulic
Complaints: 5 1 Crash
Exterior Lighting
Complaints: 4
Fuel System Diesel
Complaints: 4
Vehicle Speed Control
Complaints: 4
Visibilitypower Window Devices And Controls
Complaints: 4
Air Bags
Complaints: 3 2 Crashes 2 Injuries
Air Bagsfrontal
Complaints: 3 3 Crashes 2 Injuries
Electrical Systemwiring
Complaints: 3 1 Fire
Equipment
Complaints: 3
Exterior Lightingbrake Lights
Complaints: 3
Interior Lighting
Complaints: 3
Power Train
Complaints: 3
Power Trainclutch Assembly
Complaints: 3
Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slip
Complaints: 3 2 Crashes 2 Injuries
Visibilitysunmoon Roof Assembly
Complaints: 3
Air Bagssidewindow
Complaints: 2 1 Injury
Electrical Systemignition
Complaints: 2 1 Fire
Electronic Stability Control Esc
Complaints: 2
Engine And Engine Coolingenginegasoline
Complaints: 2 1 Fire
Exterior Lightingheadlights
Complaints: 2 1 Crash
Fuel System Other
Complaints: 2
Service Brakes
Complaints: 2
Service Brakes Hydraulicfoundation Componentsdiscpads
Complaints: 2
Suspension
Complaints: 2
Tires
Complaints: 2
Tiressidewall
Complaints: 2
Tirestreadbelt
Complaints: 2
Vehicle Speed Controlcruise Control
Complaints: 2
Visibility
Complaints: 2
Visibilitywindshield Wiperwasher
Complaints: 2
Child Seat
Complaints: 1
Electrical System Instrument Clusterpanel
Complaints: 1
Electrical Systemhorn
Complaints: 1
Electrical Systemwiringfuses And Circuit Breakers
Complaints: 1
Engine And Engine Coolingexhaust System
Complaints: 1
Engine And Engine Coolingexhaust Systememission Control
Complaints: 1
Engine And Engine Coolingexhaust Systememission Controlcatalytic Convertor
Complaints: 1 1 Fire
Equipmentapplianceair Conditioner
Complaints: 1
Equipmentelectricalradiotape Deckcd Etc
Complaints: 1
Equipmentrecreational Vehicletrailerlpg Systemstank Assembly
Complaints: 1
Fuel System Otherfuel Injection System
Complaints: 1
Fuel System Otherstoragetank Assemblyfillingcharging
Complaints: 1
Latcheslockslinkagesdoorslatch
Complaints: 1
Power Trainclutch Assemblypedalhand Levermotorcycle
Complaints: 1
Seat Belts
Complaints: 1 1 Crash 1 Injury
Service Brakes Airantilock
Complaints: 1
Service Brakes Electric
Complaints: 1
Service Brakes Hydraulicantilocktraction Controlelectronic Limited Slipabs Warning Light
Complaints: 1
Service Brakes Hydraulicfoundation Componentsdiscrotor
Complaints: 1
Steering
Complaints: 1
Steeringhydraulic Power Assistpower Steering Fluid
Complaints: 1
Tiresbead
Complaints: 1
Tiresvalve
Complaints: 1
Visibilitydefrosterdefoggerhvac System
Complaints: 1
Visibilitywindshield
Complaints: 1

Most Recent Complaints

#11677910 | FUEL/PROPULSION SYSTEM | | N/A miles
A fuel leak has developed from the top side of the fuel tank on the drivers side of me vehicle. A fuel leak in this manner is a serious critical and immediate safety risk. Recall 08V156000 was 'performed' on my vehicle back in 2008 but the exact same fuel system safety defect has returned. VW acknowledges the recall and claims it was completed while only an inspection to check for fuel leaks was performed at the time. VW Care and my local dealership refuse to address the ongoing issue. This poses a continued fire risk, and I am now being told to pay out of pocket for a known safety recall that clearly failed to remedy the original defect.
#11662869 | FUEL/PROPULSION SYSTEM | | N/A miles
There was a recall reported by the manufacturer, Volkswagenm in 2008. There were multiple Fuel System issues: A Heat Shield that may contact the exhaust system and result in a vehicle fire; a fuel leak from a fuel line or fuel tank ventilation valve, in the presence of an ignition source, can lead to a vehicle fire. In 2008, my car was inspected and the recall was deemed "complete." However, the car was only 4 years old at the time and no repairs were made. Only a visual inspection was done. I bought the car used 6 years ago, and it has been diagnosed as having a defective fuel tank ventilation valve. VW should pay for the parts and labor to have this fixed because it was never fixed. I've been told there's no statue of limitations on recalls. VW claims that because the recall was deemed "Complete" that they "fixed" the issue but they didn't.
#11433670 | FUEL SYSTEM, GASOLINE | | 97,361 miles
The contact owns a 2004 Volkswagen Passat. The contact stated that there was gasoline leaking in his driveway where the vehicle was parked, after he had refueled the vehicle the day before. The vehicle was taken to an independent mechanic and the mechanic informed the contact that it was a known failure related to NHTSA Campaign Number: 08V156000 (Fuel System, Gasoline). The dealer and manufacturer were made aware of the failure but informed the contact that the failure was addressed in 2012 and the recall was closed on the VIN. The failure mileage was 97,361.
#11396511 | FUEL/PROPULSION SYSTEM | | 170,000 miles
WHEN YOU FILL UP THE FUEL TANK IT LEAKS IT LEAKS A QUARTER OF A TANK OF FUEL ROUGHLY 4 TO 5 GALLONS OF FUEL DRIP OUT THERE'S A FACTORY RECALL ON THIS ISSUE I TOOK IT TO THE VOLKSWAGEN DEALER PAID MONEY TO HAVE THEM INSPECT IT AND THEY SAID YES IT'S LEAKING AT THE FACTORY RECALL I'VE HAD AN INDEPENDENT DEALER CONFIRM THAT! VOLKSWAGEN WILL NOT DO ANYTHING DUE TO WHAT THEY CLAIM A REMEDY WAS DONE BY MOVING FUEL LINES 10 YEARS AGO, OBVIOUSLY IT WAS NOT OR I WOULD NOT HAVE 4 GALLONS OF FUEL SPILL IN MY DRIVEWAY VEHICLE IS BASICALLY IN OPERABLE AND THEY WANT $3000 TO PUT A NEW FUEL TANK IN WHEN IT'S A FACTORY RECALL WHICH NEVER EXPIRES I HAVE TALK TO THE VOLKSWAGEN REP AND THE ONLY THING I HAVE FOUND IN FORUMS IS DO YOU HAVE TO GO TO VOLTS WAGON OF AMERICA AND FIGHT THEM AND THIS IS RIDICULOUS WHEN THEY KNOW THEY HAVE AN ISSUE!! TO DRIVE THIS VEHICLE WE NEVER FILL IT OVER A HALF A TANK OF FUEL SO WE DO NOT LEAK FUEL OR EXPLODE WHILE WE'RE DRIVING HOPEFULLY PLEASE HELP IN ANYWAY YOU CAN THANK YOU
#11395719 | SEATS | | 160,000 miles
A COIL FOR HEATED SEATS HAS MELTED A HOLE IN THE DRIVER'S SIDE SEAT. THIS CAUSED PAIN AND CONFUSION WHILE DRIVING ON THE HIGHWAY. THE SEAT NOW HAS AN UGLY MELTED HOLE IN IT.

View all Engine And Engine Cooling complaints →

Safety Rating for the 2004 VOLKSWAGEN PASSAT

NHTSA has not yet tested the 2004 VOLKSWAGEN PASSAT in its New Car Assessment Program.

Technical Service Bulletins for the 2004 VOLKSWAGEN PASSAT

Volkswagen Group of America, Inc. has issued 15 technical service bulletins (TSBs) for the 2004 VOLKSWAGEN PASSAT. TSBs are notices sent by manufacturers to their dealers describing a known issue and the recommended repair procedure.

171901_2012855 — EQUIPMENT:ELECTRICAL

Remote Key Battery Replacement

171901_2012855 — EQUIPMENT

Remote Key Battery Replacement

V551610-2038996 — EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

To update claiming process statement.

TB011602 — ENGINE AND ENGINE COOLING:ENGINE:GASOLINE

Gasoline quality.

TB551412 — STRUCTURE

Corrosion on the rear lid in the cut-out sections for the license plate light / handle assembly (Figures 1 and 2).

2038996 — STRUCTURE

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

TT 23-06-28 — FUEL SYSTEM, DIESEL

2.0L TDI Pumpe Duse Engine, with Hard Starting: For long crank/ difficulty starting with the engine hot: Before replacing any components for this complaint, drain the fuel from the vehicle and replace with known good diesel fuel from a reputable source. If the complaint still exists, check fuel pressure and...

TT 23-06-28 — EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

SUMMARY TO BE PROVIDED ON A FUTURE DATE.

TT451301 — SERVICE BRAKES, AIR:ANTILOCK:CONTROL UNIT/MODULE

After replacing a Bosch 5.7 ABS module, refer to the table below to determine correct module coding value based on vehicle PR codes. Listed login code must be entered under Access/authorization before coding is attempted. After completing coding, G85 steering angle sensor basic settings must be performed before cycling key....

CSC-74B8 — SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER

VOLKSWAGEN: HEATED SEATS INSTALL NEW PASSENGER SIDE SEAT HEATER SWITCH. AFFECTED VEHICLES MAY HAVE A SEAT HEATER ELEMENT THAT CAN MALFUNCTION WHEN THE IGNITION SWITCH IS ON AND THE SEAT HEATER SWITCH IS ON. *PE

Showing 10 of 15 technical service bulletins.

NHTSA Investigations for the 2004 VOLKSWAGEN PASSAT

NHTSA has opened 1 investigation into potential safety defects in the 2004 VOLKSWAGEN PASSAT.

Investigation EA07014 — ENGINE AND ENGINE COOLING:EXHAUST SYSTEM Closed

Opened:

PASSENGER ENGINE COMPARTMENT FIRES

Other Model Years of the VOLKSWAGEN PASSAT

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Other VOLKSWAGEN Models

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