Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Volkswagen Passat owners, lightly cleaned up (personal details are redacted by NHTSA).
I own a Volkswagen Passat 2004 model. On November the 11th 2008 after working the night shift at mbusi in vance, alabama, I got in my car to go home. I turned on the heated seat just as I have done for the past 4 years only this time I got more heat than I wanted. My heated seat caught fire and burned my leg. In attempt to extinguish the fire, I wrenched my back by stomping out the fire with my foot. I did not have anything close to me to use with my hands so they would not get burned. I could not believe how fast my car filled with worst smelling smoke I have ever smelt. The seat was on fire before I even left the parking lot. If I would have waited two minutes to turn on my seat, I would have been on interstate 20/59 driving at 70 MPH and I can only imagine what would have happened. This is one of the worst experiences of my life. …
The 2004 Volkswagen Passat 1.8 t car engine caught on fire today while driving the driver barely saved his life from the flames. The car would certainly burn completely if luckily there was no fire extinguisher available at the nearby stores. Although the incident was in istanbul, turkey I happened to learn from the internet that NHTSA was conducting an investigations on the same problem for 19 Volkswagen passats. Volkswagen dealer in turkey told me that an engineer from Volkswagen Germany will come to turkey to perform an inspection on the car. Nobody touched the car yet. Since the incident was today ant the car was still at the Volkswagen authorized dealer service. I thought this information might be usefull for your investigation, and would like to learn your suggestions that you May want to share with me. …
I had been driving my car for fewer than 15 minutes with the seat heating element on. I noticed an acute burning heat near my upper left leg, and shortly thereafter noticed a hot/burning/melting smell. I immediately turned off the driver's side seat and pulled into a parking spot. After being turned off for 10 minutes, the burning smell was still hanging in the car and my seat was still extremely hot to the touch. The gray leather near the outer left edge of the seating surface is emblazoned with a singed, brownish burn mark, and a hole was burned completely through the leather. I have not turned on the seat heating element since this incident, but am quite concerned about the failure and fire hazard.
I was driving my car to have dinner with my daughter and the car started losing power. It was only a 4 minute trip and by the time I got to my daughter's driveway, the engine was smoking. After using a hose to cool off the hood, the hood was popped and there was a fire on the passenger side of the engine. After we got the fire out, lot of hoses and the wire assembly were burned badly.
Had to replace the comfort control module along with untold amount of wires due to water damage. After being parked and turned off the windows roll. Down the alarm is disabled, the doors unlock. While driving lights go. On and off doors lock and unlock emergency flashers go off and alarm will go off. Can't unlock car without setting alarm off.
On August 22 about 2:45 I was returning home from taking my daughter to work about3-miles away and I noticed smoke coming from my car I get out to look under the hood and I notice flames coming from the front right end under the hood. I panicked grabbed my belongings and called 911 the fire dept arrived and put the fire out.
2004 Passat 1.8t caught fire after a coil pack failed and the catalytic converter overheated. I only drove 5 miles after the coil pack failed trying to limp back to the dealer when the fire started. I put the fire out myself.
I have a 2004 vw Passat 4motion 1.8 turbo. I have just recently (within the last month) replaced the #2 coil. Now today either another coil is gone or the same one. I haven't gotten it to my mechanic yet to determine which one is bad. But after talking to him he related to me that he has replaced several # 2 coils this year on this make of vehicle.. So I am just guessing that this is the problem this time around. My vehicle has 52,000 miles on it. It wasn't the #2 coil it was the #1 coil. I am getting really disgusted with this car as far as reliability is concerned. I am planning on a trip to florida in the fall and am wondering if I should take a case of coils with me. I was at the dealers the first time this happened & asked about recalls on this item. They said they didn't have any.. …
2004 vw Passat 4 sedan rear cigarette lighter and ash tray are not safely and functional installed well. Have the tendency to keep coming apart entirely exposing electrical wires leading to burn and electrical shock or popping or burning of wires. Have had the problem repaired on multiple occasions by dealer as well as by myself to further prevent the mishap since out of warranty. My children bump the cigarette lighter and it caused sparks and burning smell. I was able to repair the enclosure again for the 13th or so time and since it's not under warranty it's not covered. Children sit in the rear more than adults but there has been time where the adults have causd the same issue. It's that my 9 yr old son try to repair or put back in where the entire enclosure fell out again.
2004 vw Passat tdi. Vw has a problem with their turn signal switch. The switch continues to open and close the circuit after the turn signal is in the off position. This is a problem with many of their models( jetta, Passat both gas and diesel). The dealership service personnel are aware of the problem and are replacing the defective switch only if your have all your maintenance done at a authorized vw dealer. So if you don"t have all your oil changes and repairs done by a authorized v w dealer there is no assistance for replacement of this defective switch. This is a cost of $300.00 to the consumer. This sure is safety related and need to be recalled asap. This problem has caused fires under the instrument panel.
NHTSA investigations
Engine Compartment Fire
In July 2010, the Agency opened PE10-027 to investigate allegations of coil on plug (COP) ignition coil fires in MY2002-2003 VW Passat vehicles.The investigation was upgraded in January 2011 to include all MY2001-2007 4-cylinder VW Passat, gasoline, turbo-charged vehicles.Based on the analysis of VW's response, and including ODI's consumer complaints, ODI has since identified 135 unique engine fire reports…
Passenger engine compartment fires
The manufacturer notified NHTSA on 04-apr-08 that a safety recall action would be initiated to remedy the issue.in June 2008, the manufacturer issued a technical service bulletin (code 26e5/r5) regarding the specific procedures to be employed in this campaign.vehicle owner notification letters were sent beginning approximately June 13, 2008.the campaign was assigned NHTSA no.
Electrical complaints in other Passat years
Frequently asked questions
How common are electrical problems on the 2004 Volkswagen Passat?
NHTSA has 24 complaints about the electrical system of the 2004 Volkswagen Passat, 8% of the model year's 285 complaints. The component named most often is wiring (3 mentions).
Is there a recall for 2004 Volkswagen Passat electrical problems?
No. NHTSA lists no electrical system recall for the 2004 Volkswagen Passat, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Volkswagen Passat electrical problems start?
Half of the complaints with a recorded mileage happened before about 58,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 7 fires and 1 injury to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.