2004 Volkswagen Touareg Exterior lighting Problems

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

NHTSA ID

11621837

Incident

Oct 24, 2024

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 the body control module 7L6-937-049-K had caught fire internally and started to burn through the casing. Had I not pulled the fuse and disconnected the battery, this could have been catastrophic. Once I smelled the smoke, I realized it was like the acrid smell in the suv the night before. The fact the fuse blew the previous day saved the vehicle. It was parked on the fourth floor of parking garage at the airport so many vehicles could have been damaged and people endangered had it caught fire. Not to mention the disruption at an airport. There were no warning lamps. The only indication of a problem was the inoperable systems I mentioned. Also thinking back, the slight acrid smell was present the day I arrived at the airport, I had mistaken it for plane exhaust and car exhaust smells in the garage. The vehicle has not been inspected by any dealer, manufacturer or govermental agency. I have contacted the manufacturer for guidance and help with repairing. I am awaiting a response.

NHTSA ID

11518742

Incident

Apr 20, 2023

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. It’s my only vehicle I hope next time it doesn’t catch back on fire could have been worse and still could be. Somebody could get hurt and I have kids.

NHTSA ID

11441658

Incident

Apr 1, 2021

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.

NHTSA ID

11375085

Incident

Nov 15, 2020

Mileage

110,000 mi

THE HEADLIGHT ASSEMBLIES ON THIS VEHICLE FAIL DUE TO THE INTERNAL WIRING INSIDE OF THE HOUSING. THIS LEADS TO ZERO VISIBILITY DURING NIGHT TIME. THE HEADLIGHTS WHEN OPERATING CORRECTLY ALSO DO NOT PRODUCE ENOUGH LIGHT OUTPUT TO BE ABLE TO SEE DURING THE NIGHT EVEN WITH A BRAND NEW ASSEMBLY.

NHTSA ID

11149899

Incident

Feb 19, 2017

Mileage

150,000 mi

THE HEADLIGHTS CONTINUOUSLY SHORT OUT AND STOP WORKING. THE WIRES ON THE HEADLIGHTS HAVE NO INSULATION BECAUSE IT HAS FALLEN OFF. THIS PROBLEM HAS BEEN FIXED MULTIPLE TIMES AND STILL CONTINUES TO HAPPEN. I CONTACTED THE LOCAL VW DEALERSHIP AND WAS NOT HELPED. I CONTACTED VW CORPORATE OFFICE AND NO HELP. THERE WAS A CLASS ACTION SUIT AGAINST VW FOR THIS VERY ISSUE. MORE THAN ONCE IT HAS LEFT MY DAD STRANDED BECAUSE HE HAD NO HEADLIGHTS TO DRIVE HOME WITH.

NHTSA ID

11092681

Incident

May 9, 2018

ABOUT 2 WEEKS AGO, I STARTED BLOWING FUSES FOR THE DRIVERS SIDE TURN SIGNAL. I WOULD HAVE NO FRONT OR REAR TURN SIGNAL, AS WELL AS NO HAZARDS ON THE DRIVERS SIDE. I LOOKED INSIDE THE HEADLIGHT ASSEMBLY AND FOUND THAT ALL THE WIRING WAS EXPOSED DUE TO THE WIRING INSULATION ROTTING OFF, LEAVING EXPOSED WIRING. I AM A FIREFIGHTER, AND THIS IS A VEHICLE FIRE, WAITING TO HAPPEN. YOU CANT EVEN WRAP ELECTRICAL TAPE AROUND IT, DUE TO THE HEADLAMP UNIT NOT BEING ABLE TO BE TAKEN APART. I HAVE NO LEFT TURN SIGNALS, AND RISK BEING HIT, SIDESWIPED, OR GETTING A TICKET FROM THE POLICE FOR SOMETHING I CANNOT FIX. I HAVE REPLACED 4 DIFFERENT FUSES NOW TRYING TO FIX THIS.

NHTSA ID

10960102

Incident

Mar 1, 2017

Mileage

140,232 mi

DEFECTIVE HEADLIGHTS IN 2004 VW TOUAREG, LIGHTS GO OUT PERIODICALLY WHILE YOU ARE DRIVING. THIS WAS AN ISSUE COVERED BY A CLASS ACTION LAWSUIT. NOW VW WON'T EVEN TALK TO YOU ABOUT IT AND REFERS YOU TO AN 800 NUMBER THAT WAS DISCONNECTED YEARS AGO. THIS IS A MAJOR SAFETY ISSUE AND VW IS RUNNING AWAY FROM THEIR LIABILITY. TYPICAL BEHAVIOR FOR VW.

NHTSA ID

10825674

Incident

Feb 11, 2016

Mileage

50,100 mi

THIS IS A PROBLEM IMPACTING A LARGE PERCENTAGE OF 2005-2006 VW TOUAREGS WITH HID HEADLIGHTS. WIRE IN HEADLAMP ASSEMBLY IS TO SMALL FOR LOAD. THE INSULATION DECAYS DUE TO HEAT AND RESULTS IN A SHORT WHICH WILL BLOW THE FUSE FOR AFFECTED HEADLIGHT. USUALLY OCCURS WHEN SWITCHING ON HIGH BEAMS OR HITTING A LARGE BUMP. WHILE THERE IS AN INEXPENSIVE DIY FIX, OUTLINED IN BELOW LINK, VW IS TELLING OWNERS THEY NEED TO SPEND $950 PER HEADLAMP TO REPLACE THE ASSEMBLY. HTTP://WWW.CLUBTOUAREG.COM/FORUMS/F43/TOUAREG-DEAD-XENON-FIX-CODE-01344-A-103130.HTML. *TR

NHTSA ID

10585130

Incident

Jan 1, 2014

Mileage

75,000 mi

WHILE DRIVING AT NIGHT ON THE GARDEN STATE PARKWAY AT 65MPH ALL OF THE LIGHTS, BOTH EXTERIOR AND INTERIOR, WENT OUT FOR ABOUT 7 SECONDS. THIS HAD HAPPENED ONCE BEFORE DURING DAYLIGHT HOURS. THE CAR DOES NOT STALL, BUT IS COMPLETELY DARK. I ADVISED VOLKSWAGEN OF AMERICA OF THIS PROBLEM BY LETTER DATED APRIL 17, 2014. ON TUESDAY APRIL 22, 2014 A REPRESENTATIVE OF VOLKSWAGEN CALLED ME AND ADVISED THAT SINCE THE VEHICLE WAS "OUT OF WARRANTY" THEY WOULD NOT INSPECT THE VEHICLE TO ANALYZE/DETERMINE THE CAUSE OF THE PROBLEM. I WAS SURPRISED BY THIS INDIFFERENCE TO A SERIOUS SAFETY PROBLEM SINCE THE 2004 TOUAREG IS NOTORIOUS FOR PROBLEMS WITH ITS ELECTRICAL SYSTEM, INCLUDING REPORTS OF STALLING. THE LOCAL DEALER INSPECTED PARTS OF THE ELECTRICAL SYSTEM AND COULD NOT DETERMINE THE CAUSE OF THE PROBLEM. *TR

NHTSA ID

10584464

Incident

Feb 11, 2014

Mileage

55,000 mi

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN TOUAREG. THE WARNING TONE OF THE TIRE PRESSURE MONITORING SYSTEM SOUNDS INTERMITTENTLY. IN ADDITION, THE HEADLIGHTS FAILED, AND THE VEHICLE PULLED TO THE RIGHT SPORADICALLY AND WITHOUT WARNING. THE DEALER WAS UNABLE TO DIAGNOSE THE CAUSE OF FAILURE. THE CONTACT POSSESSED THE REPAIR INVOICES. THE FAILURE MILEAGE BEGAN AT 100. *AK THE CONSUMER STATED THE FAILURES CONTINUE, SHE HAS HAD MULTIPLE PROBLEMS WITH THIS VEHICLE BRAKE ROTORS REPLACE AT 15,000 MILES, BRAKE PADS HAD TO BE REPLACED AT 18,000 MILES, TWO TIRES REPLACE AT 16,000 MILES, TPS LIGHTS CONTINUE TO GO ON AND OFF BEEN FIXED, FOUR NEW TIRES AT 30,000 MILES. THE CONSUMER STATES THAT THERE HAVE BEEN 9 RECALLS AND TPS LIGHTS STILL IN FAILURE. UPDATE 05/04/07*TR

NHTSA ID

10186546

Incident

Jul 28, 2005

Mileage

100 mi

DT*: THE CONTACT STATED WHILE DRIVING THE VEHICLE THE PASSENGER SIDE OR DRIVER'S SIDE HEADLIGHT DARKENED. THERE WERE NO WARNING INDICATORS OR DASHBOARD LIGHTS ILLUMINATED TO INDICATE THERE WAS A FAILURE WITH THE HEADLIGHT(S). EVENTUALLY, THE OTHER HEADLIGHT DARKENED. THE ONLY WAY THE LIGHTS WOULD ILLUMINATE AGAIN IS BY RESTARTED THE IGNITION. THE DEALERSHIP REPLACED A COMPUTER CHIP, CHANGED THE BULBS AND OTHER UNKNOWN REPAIRS WERE MADE, HOWEVER THE PROBLEM STILL PERSISTS. UPDATED 8/14/2006 - THE TIRE WARNING LIGHT ILLUMINATED. THE DEALER REPLACED THE CONTROL UNIT. *NM

NHTSA ID

10162943

Incident

Jul 19, 2006

Mileage

76,000 mi

I TOOK DELIVERY OF MY 2004 VW TOUAREG ON 7-11-04. BY 9-9-04 IT WAS HAVING PROBLEMS. IT HAS BEEN IN 6 TIMES FOR ELECTRICAL PROBLEMS, 3 TIMES FOR THE AC, 3 TIMES FOR THE BATTERY, AND 1-2 TIMES FOR OTHER THINGS. TOMORROW, I WILL BE TAKING IT IN AGAIN FOR FURTHER A/C PROBLEMS, BRAKES THAT CATCH ON THEIR OWN WHILE IN DRIVE, INTERMITTENT FAULTY TRIGGERING OF TIRE PRESSURE MONITORING SYSTEM, AND A HOLE THAT I DISCOVERED ONLY DAY IN THE FIRE BLANKET UNDER THE HOOD. APPARENTLY THE ENGINE HEAT HAS BEEN BURNING A HOLE IN IT AND HAS BURNED AWAY A HOLE RIGHT THROUGH THE BLANKET TO THE HOOD ITSELF, BUT NOT THROUGH THE HOOD YET. THIS CAR HAS MEANT TIME LOST FROM WORK AND AN INORDINATE AMOUNT OF TIME SPENT IN THE SHOP AND PAYING FOR RENTAL CARS. THIS CAR IS A FIRE AND SAFETY HAZARD. FAIRFAX COUNTY CONSUMER PROTECTION (ROY SEGER) HAD CONTACTED VW AS THIS CAR FALLS UNDER THE LEMON LAW. VW RESPONDED THAT THEY WOULD NOT COMPLY, STATING THAT THEY HAD FIXED THE BATTERY. THEIR RESPONSE FAILED TO ACCOUNT FOR THE MULTITUDE OF OTHER PROBLEMS...AND NOW THIS. I HAVE NEVER FELT SO POWERLESS. IS THERE ANYTHING YOU CAN DO TO HELP?? *NM

NHTSA ID

10152523

Incident

Sep 9, 2004