VehicleVerdict

2004 Volkswagen Passat fuel system problems

The 2004 Volkswagen Passat has 62 fuel system complaints filed with NHTSA — 18% of the year's total, and down from the prior model year.

62

Fuel System complaints

18%

Share of year

0

Crash-involved

2

Related recalls

Fuel System complaints by year

Passat fuel system complaints by model year180 complaints1990: 1 complaints1991: 5 complaints1992: 8 complaints1993: 7 complaints1994: 2 complaints1995: 3 complaints1996: 6 complaints1997: 2 complaints1998: 21 complaints1999: 31 complaints2000: 47 complaints2001: 46 complaints2002: 78 complaints2003: 180 complaints2004: 62 complaints2005: 23 complaints2006: 65 complaints2007: 43 complaints2008: 63 complaints2009: 53 complaints2010: 33 complaints2011: 4 complaints2012: 47 complaints2013: 87 complaints2014: 50 complaints2015: 22 complaints2016: 18 complaints2017: 6 complaints2018: 6 complaints2019: 2 complaints2020: 1 complaints
Passat fuel system complaints by model year. Red bars are years to avoid.

Related recalls

08V156000Fuel SystemApril 7, 2008 · 412,000 units

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 LEAK DUE TO FRACTURE.

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 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.

04V586000Fuel SystemDecember 15, 2004 · 19,284 units

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.

What owners report

“THE PASSAT IGNITED IN OUR DRIVEWAY AT 4:00 A.M. IT HAD NOT BEEN STARTED/DRIVEN IN A WEEK. WE WOKE TO THE SOUND OF THE TIRE BURSTING. THERE IS A HOUSTON POLICE DEPARTMENT /ARSON CASE # [XXX] - PHONE # [XXX]. INSPECTOR [XXX]. HE SAID THE IGNITION AREA OF THE CAR WAS THE START OF THE FIRE. I THINK HE…”

Complaint filed with NHTSA · Fuel System · May 7, 2014 · fire

Common questions

How many fuel system complaints does the 2004 Volkswagen Passat have?

NHTSA has 62 complaints about the 2004 Volkswagen Passat fuel system — 18% of all complaints filed for that model year.

Are there recalls for the 2004 Volkswagen Passat fuel system?

Yes — 2 NHTSA recall campaigns for this model year are tied to the fuel system: 04V586000, 08V156000.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.