1991 VOLKSWAGEN PASSAT

1 recalls, 30 complaints - 17 TSBs

VEHICLE SPEED CONTROL

Defect Description

THE VENTURI TUBE LOCATED IN THE THROTTLE VALVE HOUSING CAN BECOME LOOSE AND FALL AGAINST THE THROTTLE PLATE.

Consequence

THE VENTURI TUBE CAN PARTIALLY BLOCK THE THROTTLE PLATEAND PREVENT IT FROM RETURNING TO ITS FULL IDLE POSITION, RESULTING IN UNWANTEDENGINE SPEED WHEN THE VEHICLE IS PLACED IN A FORWARD OR REVERSE GEAR.

Remedy

REPLACE THE PRESS-FIT VENTURI TUBE WITH A THREAD TYPE TUBE.

12,650 vehicles affected

Manufacturer: VOLKSWAGEN OF AMERICA,INC

Complaint Statistics

30 total complaints 1 fires

Top Reported Components

Component	Complaints
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT	3
ENGINE AND ENGINE COOLING:ENGINE	3
FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM	3
VISIBILITY:POWER WINDOW DEVICES AND CONTROLS	2
SEAT BELTS	2
POWER TRAIN	2
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP	2
ELECTRICAL SYSTEM	1
SEAT BELTS:FRONT:RETRACTOR	1
ENGINE AND ENGINE COOLING:COOLING SYSTEM	1

Incident date: Aug 22, 2003

BURNING HOT ANTI-FREEZE AND STEAM CLOUDED THE CABIN OF MY VW PASSAT WHILE DRIVING DOWN THE HIGHWAY, CAUSING AN UNSAFE DRIVING SITUATION AND POTENTIAL HEALTH RISKS FROM BREATHING THE HOT FUMES.

Incident date: Jan 9, 2003

WHILE TRAVELING ON THE HIGHWAY THE VEHICLE LOST POWER, STARTED VIBRATING AND SHUT DOWN. PLEASE FILL IN ADDITIONAL INFORMATION, DEALER IS AWARE OF THE PROBLEM. PH

Incident date: Jul 25, 2000

FUEL INJECTIN SYSTEM: ACCUMULATOR ( DELIVERY SYSTEM) WAS LEAKING GAS TO POINT IT WAS POURING OUT. GAS FUMES WERE STRONG FROM IN & OUTSIDE. VEHICLE WAS TOWED TO AN AUTO MOTOR GARAGE WHICH HAD SEEN A COMMON PROBLEM POSSIBLY DUE TO ROAD SALT ON STREET ADDED TO CORROSION. *AK FUMES POSSIBLY COULD ... Read more

Incident date: Jul 5, 1999

THE TIMMING BELT FAILED AT 152081 KM'S THIS IS IN CANADA. I WAS TOLD THAT I COULD CALL YOUR SITE AND REPORT THIS PROBLEM. THE TIMING BELT IS SUPPOSE TO BE GOOD FOR 100000 KM. THE TIMING BELT ONLY LASTED FOR 52 000 KM . I REPORTED IT TO VOLKSWAGEN NORTH AMERICA BUT THEY JUST GAVE ME THE RUN AROUN... Read more

ODOMETER MILLAGE IS TURNED BACK. YH

Incident date: Apr 6, 2000

WHILE DRIVING, VEHCLE CAUGHT ON FIRE IN THE ENGINE COMPARTMENT AND BURNED. VEHICLE WAS TOTALLED. PLEASE PROVIDE ANY FURTHER INFORMATION. *AK

Fire

Incident date: Oct 1, 1999

TEMPERATURE AND GAS GAUGE WERE FIXED ON MANY OCCASIONS BY THE DEALER BUT NEVER FULLY FIXED. WORK ONLY WHEN PUSHED ON THE DASH COVER. THERE IS A SERVICE BULL ON THIS BUT PROBLEM, BUT IT DIDN'T HELP FIX IT. *AK

Incident date: Oct 1, 1999

Incident date: Mar 29, 1999

HAD SMELLED GAS FUMES INSIDE VEHICLE. DIFFERENTIAL PRESSURE REGULATOR WAS LEAKING ONTO THE AIR CONDITIONER CLUTCH, WHICH WAS A SAFETY HAZARD. DIFFERENTIAL PRESSURE REGULATOR BODY (PLASTIC) HAD DELAMINATED FROM THE BRASS CORE AND WA SLEAKING HEAVILY. *AK

Incident date: Mar 29, 1999

DIFFERENTIAL PRESSURE REGULATOR MOUNTED ON FUEL DISTRIBUTOR STRUCTURALLY FAILED. COMPOSITE BODY DELAMINATED FROM BRASS CORE, CAUSING STEADY FUEL LEAK WHENEVER IGNITION KEY IS ON AND ELECTRIC FUEL PUMP IS POWERED. LEAKING GASOLINE DROPS DIRECTLY ON THE ELECTRIC CLUTCH ON THE AIR CONDITIONING COMPRE... Read more

Incident date: May 1, 1998

THE FUEL PUMP SITS IN A PLASTIC CONTAINER AND THE CONTAINER CRACKED, SUSPECTS THAT IT WAS CAUSED FROM VIBRATION. HOWEVER THE FUEL LEAKS OUT AND LEAKS APPROXIMATELY SIX INCHES FROM THE REAR RIGHT WHEEL. THIS PROBLEM COULD RESULT IN A FIRE IF SOMEONE WALKS BY WITH A CIGARETTE OR MATCH, THIS PROBLEM HA... Read more

Incident date: Dec 2, 1997

THE AUTOMATIC SEATBELT CONTROL MODULE WILL DRAIN THE CARS BATTERY IN A MATTER OF HOURS. TO USE THE CAR THE PASSIVE RESTRAINT SYSTEM MUST BE DISABLED. IT IS UNCLEAR IF THE BELTS EVEN WORK MANUALLY UNDER THESE CIRCUMSTANCES. *AK

Incident date: Aug 8, 1998

THE POWER WINDOWS IN THE 1991 PASSAT SUDDENLY DIED. THERE IS STILL ELECTRICAL POWER TO THE MECHANISM INSIDE THE DOOR, BUT THE TRACK/GUIDE OR WHATEVER MAKES THE WINDOW SLIDE UP SMOOTHLY IS BROKEN. CURRENTLY THEY ARE STUCK IN THE UP,SEALED POSITION BECAUSE IF THEY GO DOWN, THEY DONT GO BACK UP COM... Read more

AIR CONDITIONER CONTROLS FAILED THREE TIMES, A/C FAN FAILED.

TIMING BELT BROKE CAUSING DAMAGE TO VALVES ON TWO OCCASIONS.

Incident date: May 20, 1998

CONSUMER WAS DRIVING ON HIGHWAY IN STOP AND GO TRAFFIC UNDER NORMAL ROAD CONDITIONS, SUDDENLY THE ABS LIGHT SENSOR CAME ON AND VEHICLE LOST BRAKES FOR APPROXIMATELY THREE HOURS. ABS SENOR LIGHT WENT OUT, AND ABS SYSTEM RESTORED BRAKES. DEALER NOTIFIED. *AK

Incident date: Jun 1, 1996

MASTER CYLINDER HAS AN INTERNAL HYDRAULIC LEAK WHICH MAY LEAD TO A BRAKE FAILURE.

Incident date: May 20, 1998

CONSUMER DROVE ON HIGHWAY DURING NORMAL ROAD CONDITIONS IN STOP AND GO TRAFFIC. SUDDENLY ABS SENSOR LIGHT CAME ON. COSUMER LOST BRAKES. THREE HOURS LATER, THE SENSOR LIGHT WENT OUT AGAIN AND BRAKES RETURNED. AFTER 6 MONTH SIMILAR CONDITION REOCCURRED. DEALER NOTIFIED. *AK

Incident date: Apr 14, 1998

INTERIOR HEATING CORE BROKE, CAUSING SMOKE TO FILL THE CAR WHILE DRIVING. ALSO, HEATER FAN MOTOR SWITCH FAILED.

Incident date: Apr 14, 1998

INTERIOR HEATING CORE BROKE, CAUSING SMOKE TO FILL THE CAR WHILE DRIVING. ALSO, HEATER FAN MOTOR SWITCH FAILED.

THE HEATER FAN FAILED, CAUSING THE UNIT TO MELT AND BURN.

THE VEHICLE'S TIMING CHAIN BROKE, CAUSING VEHICLE TO STALL AND EXTENSIVE DAMAGE TO VEHICLE.

Incident date: May 8, 1997

MOTORIZED SEAT BELTS FAILED, OPENED WHILE DRIVING AND STAYED OPEN. *AK

WAS DRIVING AND SMOKE CAME OUT OF THE VENTILATION SWITCH . PLEASE DESCRIBE . *AK

Incident date: May 9, 1996

VEHICLE CAN BE PUT INTO GEAR FROM PARK WITHOUT KEY IN IGNITION DUE TO LACK OF INTERLOCK SYSTEM. *DSH

THE DRIVER AND PASSENGER SIDE SEAT RETRACTORS SOMETIMES DON'T WORK . TT

FAN SWITCH IS BURNING OUT ON DEFROSTER/HEATER, MELTING THE SELECTOR FACE. TT

Incident date: Mar 1, 1995

FRONT/REAR POWER WINDOWS FAILED INTERMITTENTLY, CAUSING WINDOWS TO FALL DOWN. *SKD

Incident date: Apr 21, 1995

SHOCK OCCURS TO ANYONE TOUCHING BODY OF CAR, DUE TO POSSIBLE ELECTRIC SHORT.

EPA Fuel Economy, 1991 VOLKSWAGEN PASSAT

Trim / Engine	City MPG	Highway MPG	Combined MPG	Fuel Type	Annual Fuel Cost
2.0L 4-cyl, Automatic 4-spd (Front-Wheel Drive)	18.0	26.0	21.0	Regular	$2,950
2.0L 4-cyl, Manual 5-spd (Front-Wheel Drive)	18.0	27.0	21.0	Regular	$2,950

CO2 Emissions: -1.0 g/mile (Midsize Cars)

Source: U.S. Environmental Protection Agency (EPA). Actual fuel economy may vary based on driving conditions.

Technical Service Bulletins, 1991 VOLKSWAGEN PASSAT

17 manufacturer communications from 13 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
355200 EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL	6
350000 EQUIPMENT	5
061100 ENGINE AND ENGINE COOLING:ENGINE:GASOLINE	1
070000 FUEL SYSTEM, GASOLINE	1
063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM	1
161100 STRUCTURE:FRAME AND MEMBERS:UNDERBODY SHIELDS	1
110000 ELECTRICAL SYSTEM	1
140000 AIR BAGS	1

350000 EQUIPMENT

The part number listed in the document is to be returned if it meets the criteria provided.

350000 EQUIPMENT

This special notice is to inform dealers to return all part numbers listed in the document and order the superseded part numbers going forward.

350000 EQUIPMENT

VAS 6154 Replacement Part Setup Guide