RecallRepo

2004 Volkswagen Passat Recalls

Recalls on record Updated July 2026

The 2004 Volkswagen Passat has 3 NHTSA recall campaigns affecting an estimated 1,433,284 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 348 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.

Recall campaigns

FUEL SYSTEM, GASOLINE 08V156000 2008-04-07 412,000 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…

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 VEHICLES AND THE FUEL TANK VENTILATION VALVE ON…

EXTERIOR LIGHTING 07V063000 2007-02-20 1,002,000 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 THIS POPULATION MAY BE INVOLVED IN EITHER THIS RECALL OR 06V-183, BUT NOT…

FUEL SYSTEM, DIESEL 04V586000 2004-12-15 19,284 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.

Complaints by component

ENGINE AND ENGINE COOLING
33
2fires
FUEL/PROPULSION SYSTEM
22
POWER TRAIN:AUTOMATIC TRANSMISSION
22
1crashes2injuries
FUEL SYSTEM, GASOLINE
21
2fires
SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER
20
8fires10injuries
ENGINE
18
3fires
ENGINE AND ENGINE COOLING:ENGINE
18
1fires
ELECTRICAL SYSTEM
16
5fires1injuries
SEATS
15
5fires4injuries
POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)
9
Total complaints348

What owners report

Verbatim reports filed with NHTSA, lightly edited for readability and with personal information removed.

“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…”

FUEL/PROPULSION SYSTEM · reported 2025-07-30

“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…”

FUEL/PROPULSION SYSTEM · reported 2025-03-14

“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…”

FUEL SYSTEM, GASOLINE · reported 2021-09-19

“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.”

SEATS · reported 2020-12-26

“While driving on a highway, the driver seat suddenly overheated (the seat warmer was turned on). It started with a burning smell. Excessive heat burned my leg a bit (some skin redness), before I realized what is happening and turned the seat warmer off. The seat leather now appears stiff and…”

SEATS · reported 2020-11-04

“The car stalled in the road. Pulled over. Turned the car off and it would not restart full tank of gas.”

FUEL/PROPULSION SYSTEM · reported 2020-03-25

“The car stalled in the road. Pulled over. Turned the car off and it would not restart full tank of gas.”

SEATS · reported 2020-03-25

“My car 2004 vw passat almost gett on fire front passander seat have start to burn but was ok after I shutt off the car after that now I can drive but the seat its demaged”

SEATS · reported 2019-10-19

Defect investigations

Investigation EA07014 Opened 2007-09-28 · closed 2008-07-07

PASSENGER ENGINE COMPARTMENT FIRES

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…

Investigation EA07014 Opened 2007-09-28 · closed 2008-07-07

PASSENGER ENGINE COMPARTMENT FIRES

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…

Investigation EA11002 Opened 2011-01-26 · closed 2012-02-17

Engine Compartment Fire

In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and…

Investigation EA11002 Opened 2011-01-26 · closed 2012-02-17

Engine Compartment Fire

In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and…

Investigation PE08008 Opened 2008-01-31 · closed 2008-05-30

FUEL TANK LEAK

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…

Investigation PE08008 Opened 2008-01-31 · closed 2008-05-30

FUEL TANK LEAK

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…

Investigation PE08008 Opened 2008-01-31 · closed 2008-05-30

FUEL TANK LEAK

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…

Investigation PE08008 Opened 2008-01-31 · closed 2008-05-30

FUEL TANK LEAK

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…

Sources & methodology

Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL, FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Volkswagen Passat as of July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page contains ads and affiliate links. Full methodology.