2009 Volkswagen Jetta
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
Vehicles › Volkswagen › Jetta › 2009
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
These records cover every 2009 Volkswagen Jetta. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
7 recalls name the 2009 Volkswagen Jetta. Newest first.
Tenneco Automotive (Tenneco) is recalling certain Beck/Arnley Master Cylinders, part number 072-9831, sold as aftermarket or replacement parts for 2004-2018 Volkswagen Jetta, and 2012-2019 Volkswagen Beetle vehicles. The fluid seal crimp on the master cylinder may be insufficient, causing brake fluid to leak or the cylinder to come apart.
If there is a brake fluid leak, it can reduce braking ability, increasing the risk of a crash.
Beck/Arnley will notify the distributors that sold the master cylinders and will work with the distributors to notify the end users. Affected master cylinders will be exchanged for a new master cylinder (part number 072-9990), free of charge. The recall began October 30, 2020. Owners may contact Tenneco customer service at 1-800-625-9319.
Volkswagen Group of America, Inc. (Volkswagen) is recalling certain 2017 Volkswagen Passat, 2018 Tiguan LWB, 2007-2009 Jetta Sedan, 2011-2013, 2015 and 2019 Jetta, 2013 Jetta Hybrid, 2008-2009 Jetta Sportwagen, 2015 Golf Sportwagen, 2013 Golf, 2008-2010 and 2012-2013 Beetle and Beetle Convertible, 2008-2010 Beetle, and Beetle Convertible vehicles.…
If the vehicles do not meet all regulatory requirements, there could be an increased risk of a crash, fire, or injury.
Volkswagen will notify owners and repurchase the affected vehicles. The recall began November 6, 2019. Owners may contact Volkswagen customer service at 1-800-893-5298. Volkswagen's number for this recall is 01D7. Note: This recall is an expansion of NHTSA recall number 18V-329.
Volkswagen Group of America, Inc. (Volkswagen) is recalling certain model year 2009-2010 Volkswagen Jetta A5 Sedan, 2009 Volkswagen Jetta SportWagen, Eos, GTI, Rabbit and Audi A3 vehicles, and 2010 Volkswagen Golf A6 vehicles. The Antilock Brake System (ABS) control unit may fail during ABS or Electronic Stability Control (ESC) activation, possibly causing…
A loss of vehicle control can increase the risk of a crash.
Volkswagen will notify owners, and dealers will update the ABS control module software to improve the module's self-testing abilities. Any module that fails the new diagnostic test will be replaced. These repairs will be made free of charge. The recall began February 2017. Owners may contact Volkswagen customer service at 1-800-893-5298.
Volkswagen IS recalling certain model 2009-2012 jetta and jetta sportwagen vehicles, manufactured from may 2008 through september 2011, model year 2010-2012 volkswagen golf vehicles, manufactured from may 2009 through september 2011, and model year 2010-2012 audi A3 vehicles, manufactured from september 2009 through september 2011, that are equipped with a…
Due to the resonance condition, injector line number 2 could develop small cracks which could lead to fuel leakage. leaking fuel in the presence of an ignition source, may lead to a fire.
Volkswagen will install an improved fuel injector line for the number 2 cylinder on certain vehicles and will install vibration dampers on all of the injector lines. volkswagen and audi will notify owners to have the vehicles repaired free of charge. the safety recall IS expected to begin during november 2011. owners may contact volkswagen at 1-800-822-8987.
Volkswagen IS recalling certain model year 2006-2010 jetta, new beetle, new beetle convertible, model year 2009 jetta sportwagen and model year 2007-2009 rabbit vehicles equipped with 2.5L engines. the jetta, jetta sportwagen, and rabbit vehicles may have a small plastic tab located on the windshield washer fluid reservoir that may chafe against an…
If chafing occurs, there IS the potential for a fuel leak to develop. fuel leakage, in the presence of an ignition source, could result in a fire.
Dealers will inspect and if necessary replace the underhood fuel line. additionally, depending on the vehicle model, dealers will either remove the plastic tab from the windshield washer fluid reservoir, or inspect the position of the fastening clamp and adjust the related fastening clamp into the correct position. this service will be performed free of charge. the safety recall IS expected to begin on or before january 31, 2011. owners may contact volkswagen at 1-800-822-8987.
Volkswagen IS recalling certain model year 2009 and 2010 passenger cars manufactured between september 2008 and august 2009. the wiring harness of a temperature sensor in the direct shift gearbox (dsg) may have connector wires that were insufficiently crimped. with insufficiently crimped connector wires, a temperature sensor has the potential to falsely…
The abrupt shift to neutral could lead to a crash without warning.
Volkswagen will reprogram the transmission control module with updated software free of charge. the recall began on october 20, 2009. owners may contact volkswagen at 1-800-822-8987.
Volkswagen IS recalling 25,594 my 2006-2009 jetta 5TH generation equipped with 2.01 engine. the fastening screw contact surfaces on the driveshaft cover plate may not have been manufactured to factory specifications. some screws may not have been torqued properly during assembly and could loosen over time, causing a knocking sound when the vehicle IS in…
If the vehicle IS moving when this happens, the detached driveshaft could cause damage the gearbox housing. a damage gearbox housing could leak gearbox oil onto the street and create a risk of a vehicle crash for both the driver and other motorists.
Dealers will inspect the driveshaft screws and replace the screws free of charge. the recall began on june 24, 2009. owners may contact volkswagen at 1-800-822-8987.
I am reporting an unsafe vehicle release and failed recall remedy by Findlay Volkswagen Henderson regarding NHTSA Campaign Number 16V913000 (Volkswagen Campaign 45F2) on my 2009 Volkswagen Jetta. The dealership closed out the safety recall on October 7, 2026, via Invoice #485977, claiming the repair was finalized. However, their paperwork is explicitly non-compliant. Page 1 bills out an outdated, uncorrected factory part number (1K0-907-375-AH), completely violating the 45F2 safety protocol which mandates upgraded replacement modules 1K0-907-375-AP or 1K0-907-375-AN. Furthermore, Page 2 text contains the technician's actual notes stating he only did a temporary module reset to force a signal and explicitly writes: "CONTINUED WITH RECALL AND FOUND MODULE REQUIRES REPLACEMENT." Due to this uncompleted safety recall repair and use of non-compliant hardware, the ABS module suffered a complete network communication crash immediately upon leaving the dealership lot. This sudden network failure cut off critical speed sensor data to the vehicle’s transmission, instantly dropping the vehicle into an automatic transmission 'Limp Mode' while driving on public roads. The transmission locked into a single safety gear and refused to shift, causing a severe, sudden loss of vehicle acceleration and creating an immediate traffic hazard. When contacted immediately at 5:30 PM, the dealership refused to tow the vehicle to correct their failed recall remedy and demanded I pay an out-of-pocket diagnostic fee. The vehicle is currently un-repaired, hazardous to operate, and stranded.
The vehicle experienced a complete loss of communication with the ABS control module, resulting in multiple warning lights and loss of ABS and related safety systems. The failure is consistent with Volkswagen Recall 45F2, which describes internal ground and solder failures in the ABS module. Prior to total failure, the vehicle exhibited intermittent warning lights and an ABS fault code (01130 – Implausible Signal) in 2021 but was told the car was not under recall by dealer. After the condition progressed, the module became non-communicative and no longer generated fault codes. This is consistent with internal failure preventing communication. The failure affects braking-related safety systems, including ABS and stability control, and creates a potential safety risk, particularly during emergency braking or low-traction conditions. The condition has been confirmed by both a Volkswagen dealership and an independent Volkswagen/Audi specialist. A dealership diagnosis in 2025 once again confirmed that the ABS pump and module had no communication and required full replacement. Independent electrical testing verified that all external wiring, power, and ground inputs were functioning properly, indicating the failure is internal to the ABS module. Despite this, the manufacturer denied recall repair based on the absence of diagnostic fault codes. However, the lack of communication prevents the module from generating fault codes, creating a situation where complete failure does not qualify for recall repair. The failed ABS module is still installed in the vehicle and is available for inspection upon request.
The contact owns a 2009 Volkswagen Jetta. The contact received notification of NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control (ESC). The contact stated that while driving on several occasions at various speeds, there was a burning odor coming from outside the vehicle, and the odometer was inoperable. The ABS, Brake, DRL, and EPC warning lights were illuminated. During the failure, the vehicle drove like the parking brake was engaged. The contact stated that on two separate occasions, while driving and experiencing the failures, the vehicle was pulled over to the side of the road, and the contact exited the vehicle, and observed smoke coming from all four wheels. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that the cylinder to the ABS module had failed to communicate with the computer and needed to be replaced. The vehicle was not repaired, but the contact was made aware of an associated recall. The vehicle was taken to a dealer where it was diagnosed, and determined that the ABS module was inoperable and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, and a complaint was filed. The failure mileage was 177,000.
The contact owns a 2009 Volkswagen Jetta. The contact stated that while driving at 50 MPH, the vehicle stalled. Several unknown warning lights were illuminated. The contact was able to pull over to the side of the road. The contact stated that the failure had been recurring while driving. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that the ABS module had failed and needed to be replaced. The vehicle was not repaired. The contact stopped driving the vehicle due to safety concerns. The manufacturer was notified of the failure. The failure mileage was approximately 86,000.
ABS module
Break fluid is leaking from abs cylinder and breaks are too soft to apply
I purchased it unknown condition Accident History Damage Report - OKLAHOMA CITY, OK - [xxx] Accident or Damage Reported Vehicle Damage Reported Right Side Damage or Repair Reported Damage or Repair to Bumper Reported Damage or Repair to Hood Reported Damage or Repair to Radiator Reported Damage or Repair to Grille Reported Damage or Repair to Fender Reported INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
The contact owns a 2009 Volkswagen Jetta. The contact stated that ABS and the ESC warning lights illuminated intermittently. The contact became aware that the VIN was included in NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control (ESC). The vehicle was taken to the dealer, where it was diagnosed that the ABS module needed to be replaced; however, the dealer informed the contact that the manufacturer had denied the recall repair coverage due to lack of communication between the computer and the ABS module. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not contacted. The failure mileage was approximately 157,000. Parts distribution disconnect.
Since there has been ongoing investigation on airbags, thought to report the issue related to this. For some reason, the airbag yellow warning light came up for no reason on my dashboard. It came up months ago and never has'nt gone away. Was wondering this is part of the airbag recall debate that has been reported in the media
The contact owns a 2009 Volkswagen Jetta. The contact received notification of NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control (ESC)) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that the ABS warning chime was activated, and the warning light had illuminated on the instrument panel along with several other unknown warning lights. The dealer was contacted, and the vehicle was taken to be diagnosed. The contact was informed that the ABS module needed to be replaced. The contact stated that the dealer attempted to charge for the ABS module replacement despite the recall campaign stating that the ABS module should be replaced. The dealer stated that because the ABS had not experienced a failure, there would be a cost out-of-pocket to replace the ABS module. The manufacturer was not made aware of the issue. The failure mileage was 115,000. Parts distribution disconnect.
I received a letter stating there was a ABS Control module Software. My abs lights came on. I took it to Volkswagen to have them do the recall. They said it’s the ABs control module and pump and it isn’t part of the recall. So they didn’t do any part of the recall, they just closed out the recall and she said it’s a Volkswagen problem. This was the Volkswagen service department that said this. My daughter almost wrecked the day this happened because it was raining. She is 16.
The contact owns a 2009 Volkswagen Jetta. The contact stated that while driving at an undisclosed speed, the brake pedal was depressed, and the brake pads made grinding sounds. The brake pedal went to the floorboard, but the vehicle failed to stop immediately. The ABS, traction control, and brake warning lights were illuminated. Additionally, the speedometer was inoperable. The vehicle was taken to an independent mechanic, who related the failure to NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control) which was associated with the VIN. The vehicle was then taken to the dealer, who performed the recall repair under NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control) by updating the ABS control module software; however, the failure recurred. The dealer informed the contact that the ABS module required replacement but that the part was on backorder. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 182,000.
The contact’s daughter owns a 2009 Volkswagen Jetta. The contact stated that on several occasions while her daughter was driving at undisclosed speeds, several unknown warning lights intermittently illuminated. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the ABS had failed and needed to be replaced. The contact was informed that the VIN was included in NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control). The vehicle was then taken to the dealer where it was diagnosed that the ABS control module software needed to be updated and the ABS module needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was informed that she would be responsible for the cost of the repair. No additional assistance was provided. The failure mileage was approximately 228,255.
The contact owns a 2009 Volkswagen Jetta. The contact stated while driving at an undisclosed speed, the ABS warning light, EPC warning light, and power steering warning light illuminated. The contact mentioned that the EPC warning light and power steering warning lights illuminated intermittently; however, the ABS warning light remained illuminated. Additionally, the transmission failed to shift as needed, and the speedometer failed to function properly. The vehicle was taken to an independent mechanic, who informed the contact that the ABS module needed to be replaced. The contact related the failure to NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control). The vehicle was towed to the dealer, who informed the contact that they were unable to diagnose the vehicle due to other warning lights being illuminated, not just the ABS warning light. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 74,000.
I got the car off of some guy for 1600 dollars and I put a lot of money into and I have lights on the dash still on and the ecs is one and my steering wheel light is on as will.
The contact owns a 2009 Volkswagen Jetta. The contact stated while starting the vehicle, the ABS and ESC warning lights illuminated. The vehicle was taken to the dealer and the contact was informed that the vehicle was experiencing the failure listed in NHTSA Campaign Number: 16V913000 (Service Brakes, Hydraulic, Electronic Stability Control). The vehicle was not repaired. The manufacturer was contacted and stated that the failure that the was experiencing was not related to the recall because the computer was not able to communicate with the ABS module. The contact was referred the NHTSA Hotline for assistance. The failure mileage was 123,000.
The airbag warning light (yellow) on the driver seat side comes up for no reason
ABS Control Module Software Failure: Risks-- Reduced braking power, longer stopping distance, sudden unexpected braking, increased baking effort required, locking wheels. Yes. Confirmed by independent service center. Faulty ABS control module assembly. No. Has not been inspected by the manufacturer. Yes. Instrument panel flashing brake light. ABS malfunction in anti-lock brake system. ESP or ASR malfunctioning or switched off. Previously ABS Recall repair 45F2 May 2017, failure again 01/23/23
ABS Module Assembly all packet, It turns that this kind of vehicles are controling the power Steering, anti skid braking system, brake lights, ABS, Skid lights come ON and the Steering also come ON it is scanned and remove the codes once and seemed to work for a day or two and down again, goes back to scan and now me and the mechanic test drive it together and found that the Main ABS modulator is not connecting and goes on and of the scanner where it carries a faulty communication among its components and causing all this disconfort? problem herein is that it is hard to tell when will it do it again or why is it failing? and causing all kind of problem with lgihts blinking all the time? but the biggest problem here is: that I am not the only one complaning about it, there is many people complaning about the problem! more that I expected, and seems like they do not know about making a report it is exact same problem! and reason they are not fixing it is: becasue it is to costly, It runs an apparent $2,000.00 dollars to get parts and labor? this is indeed a recall issue that must be absorbed by manufacturer.Please help us get it done I stopped the car since it acted with all this lights september is when I started to feel the disconfort but November when I had all set of lights come ON where as I mentioned, we clear the codes, "Mechanic" and runs for few days and back again. Nope there has not been a crash and I hope I don not get in one I rather stop vehicle especialy on this winter driving conditions
This vehicle was purchased 11/2016 from a dealer/mechanic. He bought it at auction, reconstructed it and got the approvals to return it to full operation from the Massachusetts DOT. The title showed 'reconstructed' and 'prior collision'. Volkswagen notified us of Safety Recal 45F2 in 2017 - ABS control module - and we had the recall performed at Colonial VW in Westborough Mass in 2017. There is an extended warranty VWP-17-03 on vehicles repaired by Safety Recall 45F2. The car's ABS light illuminated and the dealership ran a diagnostic which ran code 16352 - control module faulty static. VW is telling the dealership that they will not honor the warranty because the car is a total loss. It is NOT a total loss, it has not been in an accident since it was reconstructed before we purchased it six years ago. I called VW and they said they won't cover it because it's a mechanical issue not a software issue but that's also not true. I see technical bulletin's online that say if Fault Code 01130 and or 16352 appear that warranty should apply, but they are not honoring their own warranty
I was driving my car down at residential area and it came to a complete stop on its own I could not get it to accelerate it all I had to get out of my car pop the hood disconnect the battery and then I was able to put in a drive and accelerate all the lights are flashing on the control panel I had no control over my car whatsoever I took it into Tracy Volkswagen and they said they couldn't diagnose it because it wasn't connecting to my computer in my car. Tracy said the control module for the ABS didn't work and they couldn't replace it for me until the headquarters approved it or something about the recall didn't include the control module I can't afford to fix this it's all ABS connected that's what the safety call is for safety.
the airbag light indicator is on and the car is 2009 which is more than 10 years old however it is under 120k miles original warranty as it is currently at 97k miles and I have contacted Volkswagen and nothing they could do or helped me. Dealerships want to charge me diagnostic fees which was ridiculous. the dealership scanned the code but did not went further without the additional fee.
The contact owns a 2009 Volkswagen Jetta. The contact stated while driving 35 MPH, the gear shift indicator started blinking on and off. The contact stated that the check engine warning light was illuminated. The contact parked on the side of the road and restarted the vehicle to reboot the gear shift indicator lights. The vehicle was not diagnosed or repaired. A dealer was not contacted. The manufacturer had not been informed of the failure. The failure mileage was approximately 125,000.
A recall was issued for the ABS software upgrade which my car was updated in 2017. That is within the 10 year timeframe. Since then, my abs light has went on and off. We kept resetting as advised by Sisk Automotive in Hopkinsville, Ky (not a VW dealer). Wyatt Johnson in Clarksville, Tn completed the recall in 2017. In Feb 2022, the abs has failed creating ECP fault and almost every light on the dash is now on. I believe the abs should have been replaced in 2017 and the dealer just put a quick fix to say the recall was complete. I need help fixing my unsafe car that VW failed to fix in the original recall.
The contact owns a 2009 Volkswagen Jetta. The contact stated that the headlights and the turn signal lights had failed. There were no warning lights illuminated. The vehicle was taken to the local dealer where it was diagnosed that the wiring was damaged. The vehicle was not repaired. The manufacturer was notified of the failure but did not provide any assistance. The approximate failure mileage was 355,000.
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
In August 2015, Volkswagen Group of America, Inc. (Volkswagen) launched Safety Recall 15V-483 to address the loss of the protection provided by the front driver air bag in several models due to the failure of the clockspring.Debris entry into the steering wheel hub can result in contamination and ultimately failure of the clockspring in 2010-2014 Model Year (MY) CC, Passat, Eos, Golf, GTI, Tiguan, Jetta and Jetta Sportwagen models.Contamination of the clockspring can cause the ribbon cable to tear resulting in loss of the electrical connection to the front driver air bag and any steering wheel mounted controls.The loss of the electrical connection to the front driver air bag will result in illumination of the air bag warning light and will prevent operation of the front driver air bag in a crash of sufficient severity requiring a commanded deployment.In November 2017, the Office of Defects Investigation (ODI) opened a Recall Query (RQ17-009) after the agency received 90 complaints alleging failure of the clockspring in the subject models.Several of the complaints allege failure of the clockspring after receiving the recall remedy.The majority of the complaints allege the same failure mode without being included in the original recall, 15V-483.In its March 2018 response to ODI's Information Request under the Recall Query, Volkswagen provided approximately 700 consumer complaints and field reports on the recalled vehicles.These reports allege clockspring failure similar to the NHTSA reports described above.To date, NHTSA has received approximately 154 allegations of clockspring failure since the recall has launched.The total of 852 reports shown in the table above eliminates 6 duplicative reports received by ODI and the manufacturer.An Engineering Analysis has been opened to further evaluate the scope and effectiveness of the remedy associated with 15V-483 and perform a thorough review of the design changes implemented by Volkswagen and its suppliers to address this issue.The ODI complaints cited above can be viewed at www.NHTSA.gov under the following ODI identification numbers: 11080741, 11079877, 11079805, 11079124, 11076709, 11076645, 11076297, 11076249, 11076133, 11075756, 11075726, 11075358, 11075259, 11075055, 11074920, 11074565, 11073090, 11072745, 11072457, 11072089, 11071933, 11071880, 11071630, 11071592, 11067396, 11067061, 11066738, 11066601, 11066511, 11065909, 11065871, 11065262, 11064701, 11064564, 11064544, 11064531, 11063961, 11063501, 11063095, 11062772, 11062464, 11062353, 11062344, 11061463, 11061310, 11061311, 11060735, 11058154, 11057519, 11057477, 11057341, 11056793, 11056243, 11056063, 11055639, 11054279, 11052812, 11052678, 11052384, 11052228, 11051336, 11051155, 11051074, 11048803, 11047037, 11044226, 11043653, 11039142, 11033893, 11033330, 11032548, 11025475, 11025356, 11024647, 11023423, 11020570, 11020312, 11019415, 11019067, 11015441, 11015431, 11014595, 11014016, 11013709, 11013415, 11012596, 11011753, 11006668, 11006521, 11006307, 11006181, 11005301, 11003865, 11001780, 11001783, 11001334, 10994184, 10993360, 10993524, 10992490, 10985926, 10983678, 10981220, 10980831, 10980941, 10980549, 10979418, 10971152, 10967344, 10967155, 10959968, 10958624, 10957279, 10956488, 10949129, 10947562, 10945122, 10936498, 10936543, 10933950, 10927311, 10925421, 10924034, 10915612, 10915569, 10911171, 10902066, 10898733, 10896537, 10896510, 10895526, 10893938, 10891686, 10864967, 10863742, 10861984, 10851242, 10822505, 10821562, 10818403, 10795068, 10794402, 10788738, 10787804, 10782544, 10780725, 10780145, 10779145, 10776477, 10775448, 10763492, 10763423, 10763289, 10762670, 10760644, 10758777, 10749901, 10748922
By letter dated October 3, 2011, Volkswagen Group of America, Inc. (VW) notified the National Highway Traffic Safety Administration (NHTSA) that it will conduct a safety recall to address a defect in approximately 168,275 model year (MY) 2009-2012 Volkswagen Jetta, Jetta Sportwagen, Golf, and Audi A3 vehicles equipped with the 2.0L TDI Common Rail Clean Diesel engine (NHTSA Recall No. 11V-490).The recalled Jetta and Jetta Sportwagen vehicles were built from May 2008 through September 2011, the Golf vehicles were built from May 2009 through September 2011, and the Audi A3 vehicles were built from September 2009 through September 2011.According to Volkswagen, in U.S. applications of the above cited TDI vehicles including engine codes CJAA and CBEA, the fuel injection pulses could coincide with the natural frequency of the injector line #2 in specific load and RPM conditions.This resonance creates additional stress on the fuel line which a small number of parts (based on the statistic spread of line strength) cannot withstand over its lifetime.As a contributing factor, VW indicated that a supplier used tube material with scratch marks from a grinding process during certain production periods.Lines manufactured in these periods were installed in vehicles produced in the following 10 months:December 2008, January-February 2009, October 2009, March-April 2010 and September-December 2010.Injector lines using this material exhibit a significantly higher failure rate.Dealers will replace injector line #2 in all vehicles built in these months.In addition, as a precautionary measure, all recalled vehicles will have vibration dampers installed on all four fuel injector lines.Analysis of NHTSA complaints, VW complaints, VW field reports and warranty claims found allegations of injector line leakage in 443 subject vehicles.The leaking line was not identified in 62 of the vehicles.For the 381 that did provide information about which injector lines were leaking and/or replaced, 358 (94%) involved an injector line #2 leak/repair.Almost three-quarters of the injector line #2 leak/repair incident vehicles were built in the 10 months identified by VW, which accounted for approximately one-quarter of the recalled vehicles.The failure rate for injector line #2 in vehicles built in the 10 months affected by the supplier line scratching issue is 6.0 incidents per thousand vehicles (IPTV).The failure rate for injector line #2 in other production months of recalled vehicles is 0.8 IPTV.The leak/repair rates for the other injector lines are all well under 1 IPTV.The action taken by Volkswagen is sufficient to resolve the issues raised by this investigation. The agency will continue to monitor this issue and reserves the right to take further action if warranted by the circumstances. Accordingly, this investigation is closed.
The Office of Defects Investgation (ODI) opened EA11-003 on February 7, 2011, based on 160 complaints to ODI and Volkswagen involving high pressure fuel pump (HPFP) failures in model year (MY) 2009 through 2010 Volkswagen Jetta and Golf and Audi A3 TDI vehicles and questions regarding fuel sample results provided by Volkswagen as part of its response to PE10-034.During EA11-003, ODI analyzed design information, field experience and test data for MY 2009 through 2012 Volkswagen Jetta, Golf and Touareg and Audi A3 and Q7 vehicles equipped with TDI engines. Volkswagen has not identified any design or manufacturing defects in the subject TDI Clean Diesel pumps and has stated that the subject pumps were designed, tested and approved for use in the United States market, with substantial design margins for fuels that are out of specification.Volkswagen believes that misfueling with gasoline is the primary cause of HPFP drivetrain failures in the field.Only the Q7 vehicles were built with misfuel protection devices.In May 2013 Volkswagen initiated a service campaign to install misfuel protection devices in all MY 2009 through 2012 Jetta, Golf and A3 vehicles.Volkswagen implemented misfuel protection devices in all of the subject models beginning in MY 2013. ODI?s analysis of HPFP drivetrain failure incidents indicates that most failures do not result in engine stall while driving and, when pump drivetrain failure does result in stall while driving, it is usually preceded by numerous warning symptoms (e.g., glow plug warning lamp, chime, limp mode, and driveability symptoms).The failure data for the subject vehicles show relatively low stalling rates (less than one percent at three years in service) for each of the pump designs used in the subject vehicles.There have been no reports of crashes, injuries or fatalities related to the alleged defect. Based on these facts, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.For additional information, see the closing report in the document file for EA11-003.
The Office of Defects Investigation (ODI) and Volkswagen (VW) have received a total of 160 complaints and field reports alleging incidents of engine stall and/or loss of power that appear to be related to high pressure fuel pump (HPFP) failures in certain model year (MY) 2009 through 2010 Volkswagen Jetta and MY 2010 Volkswagen Golf and Audi A3 vehicles equipped with TDI clean diesel engines.Approximately half of the reports indicate that the failure resulted in an engine stall incident, with many of these alleging stall incidents at highway speeds in traffic with no restart.There has been one minor crash alleged to have resulted from HPFP failure in the subject vehicles.In response to ODI's information request for PE10-034, VW indicated that it had found no defect related to motor vehicle safety with relation to the TDI Clean Diesel fuel system at issue in this investigation and attributed problems with HPFP failure to operation with gasoline contaminated diesel fuel.Volkswagen stated that even a small amount of gasoline in the diesel fuel may disrupt the necessary lubrication required and may cause the HPFP to fail.In response to concerns that fuel contamination was the major cause of HPFP and related fuel system failures, VW issued a Technical Service Bulletin in May 2010 (VW TB V011011 2023624 and Audi TB A011008 2023360-1), with instructions to inspect the diesel fuel for vehicles requiring fuel system service that have symptoms associated with HPFP failure.The bulletin states that fuel system damage incurred by use of fuel not complying to ASTM-D-975 Grade 2 S15 (B5 or less biodiesel content) standards will not be covered under warranty. Volkswagen also provided information about 121 mis-fueling incidents reportedly acknowledged by consumers or dealers and test results for about 50 diesel fuel samples taken from complaint vehicles in late-August through early-October 2010.The mis-fueling incidents include about 20 reports involving incorrect fueling by dealer sales or service personnel and generally report symptoms such as rough running, stalling and/or no start within a few miles of refueling the vehicle with gasoline.Volkswagen indicated that the testing of fuel samples from complaint vehicles found that nearly 90 percent contained high amounts of gasoline.Volkswagen implemented design changes for the HPFP in May 2008, September 2009 and November 2010 to improve the robustness of the pump when used with poor quality fuel.ODI analysis of HPFP failures identified from all sources shows failure rates of 0.53% for MY 2009 vehicles and 0.11% for MY 2010 vehicles.This investigation has been upgraded to an Engineering Analysis (EA11-003) to continue to investigate the issues with mis-fueling and HPFP design identified during the Preliminary Evaluation.
The subject vehicles are equipped with direct shift gearbox (dsg) transmissions, which feature a 6-speed automatic gearbox with two wet running clutches (dual clutch) in which the clutch mechanism and gear changes are electrohydraulically operated by a mechatronic control unit.the dsg mechatronic controller includes extensive self diagnostic functions and strategies to ensure safe operation and prevent system/component damage in the event of component failures or harsh operating conditions.the basic hierarchy of fault modes includes some that only result in the storage of a diagnostic trouble code (dtc) and cause no loss of function, some that store a dtc and reduce vehicle operation to a limp home mode, and some that store a dtc and cause an interruption of motive power (i.e., open clutch).the driver IS alerted to the latter two modes by the dash gear position indicator (prnds) flashing. One of the conditions that results in interruption of motive power IS excess gearbox temperature.the system initially responds to increased gearbox temperature by ramping down engine torque.if the temperature keeps rising the mechatronic unit responds by opening the clutch.in a defect information report submitted to nhtsa on august 20, 2009, volkswagen described a potential defect in the wiring harnesses of the dsg gearbox temperature sensors used in approximately 16,000 model year (my) 2009 and 2010 volkswagen (eos, jetta and GTI) and audi (A3 and tt/tt roadster) vehicles equipped with dsg transmissions and built from september 2008 through august 2009 (nhtsa recall no. 09V-333, volkswagen recall no. 37E3/s7 and audi recall no 37e4/j7). Volkswagen provided this description of the defect, the wiring harness of a temperature sensor in the dsg may have connector wires that were insufficiently crimped by the connector supplier during a limited production period.with insufficiently crimped connector wires, a temperature sensor has the potential to falsely detect a high gearbox oil temperature, causing the transmission to abruptly shift to neutral.if this happens, the selector lever position indicator within the instrument panel will flash.in addition, the depress brake pedal indicator light will be illuminated, alerting the driver to apply the brakes.in heavy traffic, the abrupt shift to neutral could lead to a crash without warning.volkswagen estimated that less than one percent of the recalled vehicles may contain the defect condition. Odi identified 40 complaints that appear to be related to the temperature sensor defect condition described by volkswagen.volkswagen received 139 complaints related to the condition, with 7 involving vehicles reported to odi, resulting a 172 total complaints to odi and volkswagen.all of these complaints involve the my 2009 an 2010 vehicles subject to recall 09v-333. Odi also identified complaints of harsh/jerky shifting in some volkswagen vehicles with dsg.volkswagen attributed this condition, which typically occurs at very low speeds, to excessive wear in the bushings of the two solenoid valves in the mechatronic unit that control clutch operation.volkswagen does not believe that the this condition IS a safety defect because the changes in shift quality develop gradually over time, do not cause a loss of motive power and have not resulted in any fatalities, injuries or serious crashes (there were three reported property damage incidents resulting in minor body damage in very low speed, parking maneuvers).volkswagen addressed this problem in the field with a customer service program that includes the replacement of potentially affected mechatronic units as well
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