Model year record

2004 Volkswagen Touareg recalls & problems

The 2004 Volkswagen Touareg has 4 safety recalls and 231 owner complaints on file with NHTSA. The most-reported problem area is electrical system (52 complaints).

Recalls4safety recalls

Complaints231filed by owners

Crashes · fires9 · 5reported in complaints

Injuries · deaths6 · 0reported in complaints

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

Safety recalls

Fuel system, gasolineSep 20, 2017

Delivery › Fuel pump

Recall 17V58300073,941 vehicles

Problem: Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2004-2007 Touareg vehicles. These gasoline-powered vehicles have a fuel filter flange that may crack, allowing fuel to leak.
Risk: A fuel leak in the presence of an ignition source increases the risk of a fire.
Fix: Volkswagen will notify owners, and dealers will inspect the fuel filter flange for cracks, replacing the flange if cracks are found. If no cracks are found, a protective cover will be installed onto the filter flange. These repairs will be performed free of charge. The recall began March 9, 2018. Owners may contact Volkswagen customer service at 1-800-893-5298. Volkswagen's number for this recall is 20Ai.

Seat beltsDec 15, 2004

Seat belts

Recall 04V59200050,483 vehiclesopened after NHTSA action (OVSC)

Problem: CERTAIN PASSENGER CARS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." ALL THREE REAR SEAT POSITIONS AND THE FRONT PASSENGER POSITION ARE EQUIPPED WITH SEAT BELT RETRACTORS THAT HAVE A LOCKING FEATURE WHICH CONVERTS THE RETRACTOR FROM AN EMERGENCY LOCKING RETRACTOR (ELR) MODE TO AN AUTOMATIC LOCKING RETRACTOR (ALR) MODE FOR THE PURPOSES OF CHILD RESTRAINT INSTALLATION. THE BELT MAY DEACTIVATE THE ALR MODE WITH CERTAIN CHILD RESTRAINTS.
Risk: WHEN INVOLVED IN A CRASH, THE CHILD RESTRAINTS MAY NOT BE PROPERLY SECURED, INCREASING THE RISK OF INJURIES OR DEATH.
Fix: DEALERS WILL PERMANENTLY INSTALL A 'CLIP' IN EACH OF THE TWO REAR OUTBOARD SEAT BELTS. THE CLIPS WILL PREVENT UNWANTED DEACTIVATION OF THE ALR MODE WITH CHILD SEAT INSTALLATIONS. THE RECALL BEGAN ON APRIL 11, 2005. OWNERS SHOULD CONTACT VW AT 1-800-822-8987.

Seat beltsMay 19, 2004

Rear/other

Recall 04V23300024,269 vehicles

Problem: ON CERTAIN SPORT UTILITY VEHICLES, THE REAR SEAT BELT LATCH ATTACHMENT BOLT MAY HAVE BEEN INSUFFICIENTLY RIVETED.
Risk: IN THE EVENT OF A CRASH, THE SEAT OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Fix: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE BELT BUCKLE. OWNER NOTIFICATION BEGAN ON JUNE 21, 2004. OWNERS SHOULD CONTACT VOLKSWAGEN AT 1-800-822-8987.

Electrical systemJul 25, 2003

Wiring

Recall 03V266000670 vehicles

Problem: ON CERTAIN SPORT UTILITY VEHICLES, THE TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING HARNESS MAY HAVE BEEN IMPROPERLY ROUTED DURING ASSEMBLY. AN IMPROPERLY ROUTED TPMS WIRING HARNESS MAY CONTACT THE PARKING BRAKE CABLE SPRING.
Risk: IF THIS HAPPENS, THE TPMS WIRING CIRCUIT COULD BE INTERRUPTED, RESULTING IN AN INOPERATIVE TPMS, AND CAUSING A SHORT-TO-GROUND CONDITION THAT COULD POTENTIALLY RESULT IN A FIRE.
Fix: DEALERS WILL INSPECT THE TPMS WIRING HARNESS ROUTING AND, IF NECESSARY, CORRECT THE WIRING HARNESS ROUTING. OWNER NOTIFICATION BEGAN AUGUST 18, 2003. OWNERS SHOULD CONTACT VWOA AT 1-800-893-5298.

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 Touareg 4-Dr. w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

2004 Volkswagen Touareg NHTSA side crash test — NHTSA side barrier crash test

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

Touareg Diesel

18mpg combined

City / highway	15 / 22 mpg
Fuel	Diesel

5 L · 10 cyl · Automatic (S6) · 4-Wheel or All-Wheel Drive · about $5,300/year to fuel

Touareg

15mpg combined

City / highway	13 / 19 mpg
Fuel	Premium Gasoline

3.2 L · 6 cyl · Automatic (S6) · 4-Wheel or All-Wheel Drive · about $5,500/year to fuel

Touareg

14mpg combined

City / highway	12 / 17 mpg
Fuel	Premium Gasoline

4.2 L · 8 cyl · Automatic (S6) · 4-Wheel or All-Wheel Drive · about $5,850/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*
Electrical systemWiring; 12v/24v/48v battery	52	0	4	1	33,000 mi
Power trainAutomatic transmission; Automatic transmission › Control module (tcm/pcm/tecm)	51	2	1	1	44,500 mi
TiresPressure monitoring and regulating systems; Tread/belt	38	0	2	1	17,940 mi
Air bagsFrontal › Sensor/control module; Frontal	27	2	0	2	56,000 mi
Vehicle speed controlAccelerator pedal	23	1	0	0	8,000 mi
Fuel/propulsion system	23	0	0	0	98,085 mi
Engine and engine coolingEngine; Engine › Gasoline	22	1	2	1	16,925 mi
SuspensionFront; Rear › Springs › Air suspension system	21	1	0	0	19,880 mi
Service brakes, hydraulicAntilock/traction control/electronic limited slip; Power assist › Hydraulic	16	4	0	0	7,244 mi
Exterior lightingHeadlights	13	0	3	1	75,500 mi
Steering	12	1	0	0	56,274 mi
Fuel system, gasolineFuel injection system; Delivery › Fuel pump	10	1	0	0	80,500 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
I have contacted Volkswagen about my recall over a month ago the man claimed he ordered the parts and would be in contact but has never contacted me ever since and since then my vehicle has completely stopped working and the gas smell is at a very dangerous level
Sep 24, 2025
Fuel/propulsion system
The flange for the fuel does not leak from that i can see couse if it was leaking it would be on the ground.
Sep 3, 2025
Exterior lighting
Hello: this is the 2nd VW TOUAREG this year to repair so far, this one is a 2004 model that I have had to replace complete left & right xenon headlamp assembly Very pricy. Wiring insulation turns brittle, cracks & falls off inside the headlamp assembly, This allows the bare wires to touch & short causing fuses to blow shutting off headlamps while driving at night. This I think should be recalled, I have fixed 5 of these TOUAREGs in 4 years for this same problem. THANK YOU 10/24/24
Oct 24, 2024
Electrical systemFire
My SUV was sitting for a few days at the airport and I when I got in the car, it started fine but the headlights, interior lights, power folding mirrors and the voltmeter were not working. I had to leave the car there since it was night time. The next day I drove it home in daylight and started checking fuses. I noticed two fuses (#2, #12) on the driver side fuse panel were failed. I replaced the #2, 5 amp, fuse and no changes were noticed. Then I replaced the #12, 25 amp, fuse and I heard a number of systems clicking and powering on; the lights flickered. Then I smelled burning and saw a puff of smoke come from under the dash. I immediately pulled the fuse . After troubleshooting, I found…
Apr 20, 2023
Fuel system, gasoline › Delivery › Fuel pump
The contact owns a 2004 Volkswagen Touareg. The vehicle had previously been serviced at the dealer under NHTSA Campaign Number: 17V583000 (Fuel System, Gasoline) however, the fuel pump failed after the recall repair was performed. The vehicle was taken to the dealer and diagnosed with fuel pump failure. The vehicle was not repaired and remained at the dealer. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 130,000.
Jun 14, 2022 · 130,000 miles
EngineFire1 injury
Leaking gas caught on fire put it out but now I have no head lights no high beams replaced everything still nothing. All lights on dash go crazy kills battery all the time and had to replace something in the rear end. Overall it has cost me $2500 and I still have no headlights at all and leaking gas. Itâs my only vehicle I hope next time it doesnât catch back on fire could have been worse and still could be. Somebody could get hurt and I have kids.
Apr 1, 2021
Air bags
The contact owns a 2004 Volkswagen Touareg. The contact stated while driving approximately 75 mph, the driverâs side curtain air bag deployed inadvertently. Due to the inadvertent air bag deployment, the vehicle failed to restart. The contact had not taken the vehicle to a dealer. The vehicle had not been repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 90,000.
Jun 25, 2021 · 90,000 miles
Electrical systemFire
LIGHT WENT OUT ON DARK ROAD. NEARLY CRASHED. FOUND INSULATION ON WIRES FOR LIGHTS DETERIORATED. HARNESS WAS MELTED LOWER IN THE FENDER. ONLINE SEARCH FOUND SAME ISSUE IS COMMON AND INCLUDED FIRES.
Nov 15, 2020 · 110,000 miles

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

SRS WARNING LIGHT ILLUMINATIONClosed
MY 2004-05 (TO 11/2004) TOUAREG VEHICLES HAVE A POTENTIALLY FAULTY/LOOSE SIDE AIR BAG WIRING CONNECTOR THAT CAN CAUSE THE WIRING CIRCUIT RESISTANCE TO EXCEED THE DESIGN LIMIT AND ILLUMINATE THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG LIGHT.ON 02/2005, VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB #69-05-02) TO ADDRESS THIS CONDITION BY REPLACING THE CONNECTOR WITH A DIRECT CONNECTION.VW'S TESTING HAS SHOWN THAT PROPER DEPLOYMENT OF THE SIDE AIR BAG IS NOT AFFECTED BY THE CONNECTOR FAULT.HOWEVER, THERE ARE A LARGE NUMBER OF WARRANTY CLAIMS DUE TO AIR BAG LIGHT (ABL) ILLUMINATION.VW IS PLANNING TO INITIATE A TOUAREG SERVICE PACK/ CUSTOMER SATISFACTION CAMPAIGN (CSC) IN DECEMBER 2006.VW WILL REPLACE THE SIDE AIR BAG WIRING CONNECTOR WITH A DIRECT CONNECTION ON ALL REMAINING UNCORRECTED VEHICLES BUILT PRIOR TO 11/2004.IN ADDITION, VW REPORTS THAT A SMALL NUMBER OF VEHICLES BUILT IN…
PE06022 · opened Jun 19, 2006 · closed Oct 30, 2006
EXTERIOR DOOR HANDLE MALFUNCTIONClosed
VW ISSUED A TECHNICAL SERVICE BULLETIN (TSB) DATED JUNE 10, 2005, DESCRIBING A CONDITION OF EXTERIOR DOOR HANDLE STICKS IN THE OPENED POSITION AFTER THE DOOR IS OPENED.VW DESCRIBED THE CAUSE OF THE PROBLEM TO BE A POTENTIAL FOR INCREASED FRICTION BETWEEN THE DOOR HANDLE AND THE LOCK CYLINDER HOUSING . . . BECAUSE SOME GUIDE NUBS THAT WERE MOLDED INTO THE PLASTIC DOOR HANDLE . . . WERE SLIGHTLY HIGHER THAN SPECIFIED.IN ADDITION TO THE TSB, VW HAS INTRODUCED PRODUCTION CHANGES (LUBRICATION, DELETION OF THE GUIDE NUBS, INTRODUCTION OF A LOW FRICTION GUIDE SURFACE ON THE LOCK CYLINDER HOUSING) TO ADDRESS THE PROBLEM.VW REPORTS THAT THE FAILURE OCCURS PREDOMINANTLY IN THE VERY EARLY LIFE STAGE OF THE VEHICLE.ODI EXAMINATION OF VW'S WARRANTY DATA SHOWS FEWER CLAIMS AS THE VEHICLE AGES.THE ONE INJURY RESULTED WHEN THE UNLATCHED DOOR HIT THE OCCUPANT'S HAND.A SAFETY DEFECT TREND HAS NOT BEEN…
PE05042 · opened Aug 11, 2005 · closed Dec 21, 2005