Model year record

2004 Volkswagen Passat recalls & problems

The 2004 Volkswagen Passat has 4 safety recalls and 279 owner complaints on file with NHTSA. The most-reported problem area is engine and engine cooling (62 complaints).

Recalls4safety recalls

Complaints279filed by owners

Crashes · fires9 · 25reported in complaints

Injuries · deaths23 · 0reported in complaints

2004 Volkswagen Passat in an NHTSA crash test — NHTSA crash test

Safety recalls

Engine and engine coolingMar 7, 2014

Engine

Recall 14E00700050 vehicles

Problem: 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 for use in model year 1999-2005 Audi A4, 2000-2006 Audi TT, 1998-2005 Volkswagen Beetle, 1999-2006 Golf, 1999-2008 and 2011-2013 Volkswagen Jetta, and 2000-2005 Volkswagen Passat. In the affected water pumps, the pulley or sprocket that turns the timing belt may develop microfractures causing the timing belt to fail.
Risk: A failure of the timing belt may cause the engine to shut down, potentially increasing the risk of a vehicle crash.
Fix: 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.

Fuel system, gasolineApr 7, 2008

Delivery

Recall 08V156000412,000 vehiclesopened after NHTSA action (ODI)

Problem: 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 LEAK DUE TO FRACTURE.
Risk: 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.
Fix: 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 4MOTION/ALL WHEEL DRIVE VEHICLES, AND REPLACE COMPONENTS IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON JUNE 13, 2008. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.

Exterior lightingFeb 20, 2007

Brake lights › Switch

Recall 07V0630001,002,000 vehicles

Problem: ON CERTAIN PASSENGER, WAGON, AND CONVERTIBLE VEHICLES EQUIPPED WITH OR WITHOUT CRUISE CONTROL, A BRAKE LIGHT SWITCH MAY MALFUNCTION IF IT WAS INSTALLED INCORRECTLY.
Risk: THE BRAKE LIGHTS COULD BECOME INOPERATIVE, OR REMAIN ON. FAILURE TO PROVIDE THE PROPER SIGNAL WHEN BRAKING COULD LEAD TO A CRASH WITHOUT WARNING.
Fix: 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 BOTH. THE REMEDY IS THE SAME FOR EACH RECALL. VOLKSWAGEN DEALERS WILL APPLY THE REMEDY BASED ON THE VIN NUMBER OF THE VEHICLE. OWNERS MAY CONTACT VW AT 1-800-822-8987.

Fuel system, dieselDec 15, 2004

Fuel system, diesel

Recall 04V58600019,284 vehicles

Problem: 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.
Risk: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE MAY LEAD TO A FIRE.
Fix: DEALERS WILL REPLACE THE DIESEL PUMP. THE RECALL BEGAN ON FEBRUARY 8, 2005. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 Volkswagen Passat 4-DR. w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

Fuel economy

Passat Diesel

27mpg combined

City / highway	23 / 34 mpg
Fuel	Diesel

2 L · 4 cyl · Automatic (S5) · Front-Wheel Drive · about $3,550/year to fuel

Passat

23mpg combined

City / highway	19 / 28 mpg
Fuel	Premium Gasoline

1.8 L · 4 cyl · Manual 5-spd · Front-Wheel Drive · about $3,550/year to fuel

Passat 4motion

22mpg combined

City / highway	19 / 28 mpg
Fuel	Premium Gasoline

1.8 L · 4 cyl · Manual 5-spd · 4-Wheel or All-Wheel Drive · about $3,750/year to fuel

Passat

22mpg combined

City / highway	19 / 28 mpg
Fuel	Premium Gasoline

1.8 L · 4 cyl · Automatic (S5) · Front-Wheel Drive · about $3,750/year to fuel

Passat 4motion

21mpg combined

City / highway	18 / 26 mpg
Fuel	Premium Gasoline

1.8 L · 4 cyl · Automatic (S5) · 4-Wheel or All-Wheel Drive · about $3,900/year to fuel

Passat

20mpg combined

City / highway	17 / 26 mpg
Fuel	Premium Gasoline

2.8 L · 6 cyl · Manual 5-spd · Front-Wheel Drive · about $4,100/year to fuel

Passat

20mpg combined

City / highway	17 / 25 mpg
Fuel	Premium Gasoline

2.8 L · 6 cyl · Automatic (S5) · Front-Wheel Drive · about $4,100/year to fuel

Passat 4motion

19mpg combined

City / highway	17 / 24 mpg
Fuel	Premium Gasoline

2.8 L · 6 cyl · Automatic (S5) · 4-Wheel or All-Wheel Drive · about $4,350/year to fuel

Passat 4motion

18mpg combined

City / highway	15 / 22 mpg
Fuel	Premium Gasoline

4 L · 8 cyl · Manual 6-spd · 4-Wheel or All-Wheel Drive · about $4,550/year to fuel

Passat 4motion

18mpg combined

City / highway	16 / 23 mpg
Fuel	Premium Gasoline

4 L · 8 cyl · Automatic (S5) · 4-Wheel or All-Wheel Drive · about $4,550/year to fuel

EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Engine and engine coolingEngine; Cooling system	62	0	5	0	72,000 mi
Power trainAutomatic transmission; Automatic transmission › Control module (tcm/pcm/tecm)	38	1	0	2	34,240 mi
SeatsFront assembly › Seat heater/cooler	35	0	13	14	75,000 mi
Fuel system, gasolineDelivery › Fuel pump; Delivery	32	0	2	0	85,000 mi
Electrical systemWiring; Ignition	24	0	7	1	56,999 mi
Fuel/propulsion system	22	0	0	0	130,000 mi
Engine	18	0	3	0	117,000 mi
StructureBody	16	0	1	1	75,001 mi
Exterior lightingBrake lights › Switch; Brake lights	16	2	0	1	28,000 mi
VisibilityPower window devices and controls; Sun/moon roof assembly	13	0	0	0	68,000 mi
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Foundation components › Disc › Pads	12	3	0	2	20,000 mi
TiresTread/belt; Sidewall	8	0	0	0	7,793 mi

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Fuel/propulsion system
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.
Jul 30, 2025
Fuel/propulsion system
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…
Mar 14, 2025
Fuel system, gasoline
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.
Sep 19, 2021 · 97,361 miles
Fuel/propulsion system
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…
Sep 12, 2019 · 170,000 miles
Seats
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.
Dec 26, 2020 · 160,000 miles
Seats1 injury
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 WRINKLED (NOT SOFT AND SMOOTH LIKE THE REST OF THE LEATHER) IN THE AREA WHERE I FELT THE HEAT.
Nov 4, 2020 · 132,400 miles
Fuel/propulsion system
THE CAR STALLED IN THE ROAD. PULLED OVER. TURNED THE CAR OFF AND IT WOULD NOT RESTART FULL TANK OF GAS.
Mar 25, 2020 · 195,000 miles
Seats
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
Oct 19, 2019

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

Engine Compartment FireClosed
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 including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports attributable to the COP coils.After further review of the details as contained in each report, ODI determined that 43 of the 135 fire reports were actual fire/flame incidents, 83 fire reports were thermal events (smoke, spark, heat or wire melt), and another 9 fire reports were undetermined in severity due to the lack of information.These COP coil fires were characterized as initiated from within the COP coil circuit located at the top of the engine block and below the plastic engine…
EA11002 · opened Jan 26, 2011 · closed Feb 17, 2012
FUEL TANK LEAKClosedLed to recall 08V156000
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…
PE08008 · opened Jan 31, 2008 · closed May 30, 2008
PASSENGER ENGINE COMPARTMENT FIRESClosedLed to recall 08V156000
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.
EA07014 · opened Sep 28, 2007 · closed Jul 7, 2008