Date: 2007-04-03
Volkswagen
Group of America, Inc.
NHTSA Action Number: PE07018
Components: SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM
Subject:
WATER/ICE IN BRAKE BOOSTER
Opened From: 2007-04-03 - 2007-09-04
Summary
DURING THIS INVESTIGATION, VOLKSWAGEN OF AMERICA (VW) IDENTIFIED A PROBLEM WITH WATER ACCUMULATION IN THE FRESH AIR PLENUM THAT COULD, IN CERTAIN CIRCUMSTANCES, RESULT IN REDUCED BRAKE POWER ASSIST IN MODEL YEAR (MY) 2002 PASSAT VEHICLES.VW INDICATED THAT PROBLEM IS CAUSED BY LEAVES AND OTHER DEBRIS CLOGGING THE PLENUM DRAINS, WHICH MAY RESULT IN WATER FILLING THE PLENUM TO THE LEVEL OF THE BRAKE BOOSTER AIR INTAKE.THE BOOSTER AIR INTAKE IS LOCATED IN THE FRESH AIR PLENUM IN THE MY 2002 PASSAT VEHICLES, BUT NOT IN THE MY 2001 OR 2003 VEHICLES WHICH DRAW BOOSTER AIR FROM THE CABIN.VW TESTING SHOWED THAT BRAKE ASSIST COULD BE REDUCED IF WATER ENTERS THE BOOSTER AND FREEZES.VW IS ADDRESSING THE PROBLEM WITH A SERVICE CAMPAIGN, WHICH BEGAN IN AUGUST 2007.THE FRESH AIR PLENUM IN THE SUBJECT VEHICLES IS AN ENCLOSED SPACE AT THE BASE OF THE WINDSHIELD FROM WHICH THE VEHICLE VENTILATION SYSTEM DRAWS THE FRESH AIR SUPPLY VIA A POLLEN FILTER.RAIN WATER THAT FLOWS OFF THE WINDSHIELD INTO THE PLENUM IS DRAINED THROUGH TWO VALVES LOCATED BELOW THE BATTERY AND BRAKE BOOSTER.STRAINERS AT THE BASE OF THE WINDSHIELD AND IN THE PANEL COVERING THE TOP OF THE PLENUM BLOCK LEAVES, PINE NEEDLES AND OTHER DEBRIS.OVER TIME, DEBRIS MAY ENTER THE PLENUM THROUGH OPENINGS IN THE PLENUM PANEL OR AROUND THE HOOD HINGES.IF CLOGGED DRAINS ALLOW APPROXIMATELY 3-4 GALLONS OF WATER TO ACCUMULATE IN THE PLENUM, THE WATER MAY ENTER THE BOOSTER THROUGH THE AIR INTAKE.WATER ACCUMULATION IN THE PLENUM MAY ALSO RESULT IN COMPLAINTS OF WET CARPETS IN THE VEHICLE INTERIOR IF THE WATER REACHES THE LEVEL OF THE FRESH AIR INTAKE/POLLEN FILTER. VW STATED THAT ITS TESTING SHOWED THAT BRAKE PERFORMANCE AND ACTUATING FORCE (I.E., PEDAL EFFORT) ARE NOT AFFECTED WHEN THE BOOSTER IS FILLED WITH THE MAXIMUM AMOUNT OF WATER POSSIBLE (UP TO THE HEIGHT OF THE BOOSTER ENGINE VACUUM CONNECTION, THROUGH WHICH WATER DRAWN INTO THE BOOSTER IS EVACUATED).VW'S TESTING SHOWED THAT BRAKE PERFORMANCE AND ACTUATING FORCE COULD BE AFFECTED BY WATER FREEZING IN THE BOOSTER.HOWEVER, WHEN TESTED WITH RELATIVELY LOW VOLUMES OF FROZEN WATER IN THE BOOSTER, VW SHOWED THAT THE EFFECTS WERE SIGNIFICANTLY LESS SEVERE THAN FOR CONDITIONS THAT RESULT IN A COMPLETE LOSS OF VACUUM ASSIST.WHILE VW INDICATED THAT THE EFFECTS WOULD BE MORE SEVERE WITH GREATER VOLUMES OF FROZEN WATER, IT MAINTAINED THAT THE CHANCES OF THIS OCCURRING WERE REMOTE AND WOULD BE READILY DISCERNABLE TO THE DRIVER UPON THE INITIAL BRAKE APPLICATION AFTER VEHICLE START-UP.ODI'S ANALYSIS OF COMPLAINTS AND WARRANTY DATA SHOWED DISPROPORTIONATE CONCENTRATIONS IN WINTER MONTHS AND IN NORTHERN STATES WITH COLDER WINTER CLIMATES. ODI IDENTIFIED THREE MINOR CRASHES RELATED TO THE ALLEGED DEFECT IN MY 2002 PASSAT VEHICLES.TWO OF THE CRASHES OCCURRED INGARAGES/DRIVEWAYS AND THE THIRD OCCURRED IN A DEALER SERVICE GARAGE.THERE WERE NO INJURIES ALLEGED IN THE CRASHES BUT A FOOT INJURY WAS ALLEGED IN A FOURTH INCIDENT WHERE EXCESSIVE BRAKE EFFORT REQUIRED DURING A HARD STOP. VOLKSWAGEN IS CONDUCTING A SERVICE CAMPAIGN TO REMEDY THIS CONDITION IN MY 2002 PASSAT AND AUDI A4 AND A6 VEHICLES.THE REMEDY PROCEDURE REQUIRES VW DEALERS TO INSPECT, CLEAN AND MODIFY THE AIR PLENUM DRAIN, AS WELL AS MODIFY THE SUNROOF DRAIN (IF EQUIPPED) AND INSTALL AN IMPROVED SEAL FOR THE POLLEN FILTER.IN ADDITION, VW HAS AGREED TO PROVIDE THE FOLLOWING INFORMATION TO ODI1. QUARTERLY COMPLETION REPORTS FOR ONE YEAR; AND 2. PROMPTLY REPORTING ALL CRASHES ATTRIBUTED TO THE ALLEGED DEFECT. THIS INVESTIGATION IS CLOSED BASED UPON THE ACTIONS TAKEN BY VW.THE CLOSING OF THIS INVESTIGATION DOES NOT C
Investigation Documents
For Latest Documents related to this Investigation, visit the NHTSA Website.
Click the (+) Plus Sign
Then click Associated Document(s).
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium lead positive grid, maximizes conductivity and...
- Robust envelope separator with puncture resistant back...
- Vent cap design that resists acid leakage
- High density negative paste, improves performance and...
- Enhanced life alloy or Silver Calcium stamped alloy...
- Calcium Lead positive grid, maximizes conductivity and...
- Robust Envelope Separator with puncture-resistant back...
- Vent cap design that resists acid leakage
Last update on 2026-05-30 / Affiliate links / Images from Amazon Product Advertising API
Search NHTSA Database for Recalls
Search NHTSA Database for (TSB's) Technical Service Bulletins
Technical Service Bulletins TSB's List
Previous Investigation | Next Investigation |
- 💯【Conta.ct us for Support Directly】If you met any issues about: Received a registered device/ Language Changing/ Function not Support/ VCI150 Blueto-oth connector malfunction/ Subscription Renewal, please conta.ct us via 📞autelsupply @outlook. com🛣️, we will provide perfect solution for you. ⚠️Note: Autel MK900BT comes with 1-Year Free Software Update, most features will remain active after update subscription expires. 1. For questions regarding updates or need more useful accessories, please conta.ct us via 📞autelsupply @outlook.com🛣️. 2. If the device fails to charge or turn on, please conta.ct us via 📞autelsupply @outlook. com🛣️, we will handle it promptly.
- 🔥🔥🔥【2026 AUTEL FLAGSHIP MK900BT MK900-BT, NEW MODEL OF MK808S MK900 MX900 MK808BT MX808S】2026 newest Autel MK900BT retains all features of MK808S MX900 MX808S MK808Z MK808Z-BT MK808K-BT, while EXTRA added powerful functions (value 2000+ bucks). The Pro-level Autel MK900BT makes a big leaps: 28+➡40+, 50+➡3000+ Active Tests, 2026 NEW✅CAN FD & DOIP protocols ✅Pre&Post diagnostic report ✅WIFI Print ✅Auto VIN&Auto Scan 2.0 ✅Scan VIN/ License ✅Battery Test (Need purcha.se BT506). If found defect or us.ed, please conta-ct 📞autelsupply @outlook. com📞 get perf-ect solut.ion.
- 🚗【3000+ ACTIVE TESTS (50➡3000+), SAME AS MS906 PRO】Differ from MS906BT MS906 MP808 MK808 MX808 MK808BT only 50 tests, Autel scanner MK900BT escaner automotriz professional offers 3000+ active tests, it can send command to ECUs & monitor actuators operation, quickly locating faulty components. Bidirectional scanning takes your diagnostics to the next level with menu lists 3000+ active tests, such as windows, rear mirrors, sunroof, wipers, fuel injector, coolant fans, radiator fan, AC clutch, coolant pump and more. Note: Functions are not available for all vehicles, please send vehicle VIN to us check compatibility.
- 🚗【40+ HOT SERVICES FOR 150 MAKES (28+➡40+)】Full level-up of OBD2 code reader MaxiCOM MK808S MK808 MK808Z MX808 MK808Z-BT with 28 service, Autel scan tool MK900BT/ MK900-BT offers 40+ maintenance service on 150+ brands 10,000 vehicles from 1996-2025-2026. Hottest Services like: Oil Reset, ABS Bleed, SAS Calibration, Injector Coding, SRS, Throttle Reset, Gearbox Reset, Battery Registration etc. Added 12+ advanced resets: rain slash light sensor reset, HVA.C/ SUS calibration etc. Welcome to send Vehicle Make>Model>Year>VIN>Functions you required to 📞autelsupply @ outlook . com📞 check compatibility.
- 🚗【OE ALL SYSTEM DIAGNOSE, AUTO SCAN 2.0: SCAN LICENSE/ AUTO VIN】2026 new release Autel MaxiCOM MK900-BT scan tool embodies all system diagnostic with its 8in display for all vehicles. Like Sna.p-on tools, it can perform ✔Read/Clear Codes✔Displays 5-in-1 Live Data✔Record & Playback Data✔Retrieve Info on all available systems like ABS ECM BCM SRS TCM etc. In addition to Auto VIN technology, Autel MK900BT adds Scan License/ Auto Scan 2.0 to identify vehicle’s VIN/ license, make, year, model, no need manual input; One-click WiFi Printing of Pre&Post comparison diagnostic reports, highlight root causes of problems.
- 【TURN OFF CEL】 This AL319 car scanner diagnostic tool supports Reading and Clearing DTCs, DTC Look Up, displaying Live Data, Freeze Frame & I/M Readiness, view vehicle information, etc., to figure out the root cause of the Check Engine Light (CEL) and turn it off, helping you catch any potential issues early and avoid excessive costs from unnecessary repairs.
- 【EXTENSIVE APPLICATION】 Autel AL319 Compatible with 7 languages (English, French, Spanish, etc.) and various post-1996 OBD II protocol vehicles (Toyota
, Nissan, Honda, Ford, etc.), this OBD II scanner provides accurate and fast diagnosis for worldwide car owners. - 【FOR END USER & DIYERS】 This error code reader AL319 is “plug and play” and comes with an easy interface. Even if you’re not familiar with vehicle repair, you can quickly take control of this obd2 scanner, and get the information you want.
- 【USER-FRIENDLY DESIGN】 This OBD2 scanner and check engine code reader features a patented One-Click I/M Readiness, TFT color display, built-in speaker, LED Indicator etc. The cable is long enough without being too long and getting in the way. No batteries are needed.
- 【HIGH-QUALITY SERVICES】 12 months war.ranty from the date of purchase and lifetime free update are offered by this Automobile OBDII scan tool. Welcome to contact us via Q&A, email, or hotline, and our after-sale-service team for technical support.
- 📞【Warm Tips】Dear friend, if you have any issues or need any tech support after receiving your MK900BT (received a registered item/ language changing/ functions compatibility/ renew subscription, etc.), please don't hesitate to tell us directly via 💌Autelonline @ outlook . com💌, we will do whatever we can to help you at first time. Besides, if you need other accessories, such as Autel endoscope MV108S, please don't hesitate to con-tact us.
- 🔥【Amazon Choice MK900BT, 2.0 Newer of MK900 MX900 MS906 MK808BT PRO MP808S MK808S MX808S】Big News! 2026 Autel most cost-effective 8in All System & Bidirectional Scan Tool MK900BT is born! 619 only, yet featuring 40+ Hot Services same as MaxiSys Ultra/ MS909/ Elite II Pro/ MK908P/ MS906 PRO/ MS906MAX, among lots of advanced & newer functions: ✅3000+ Active Tests ✅CAN FD/ DoIP new protocols ✅OE All System Diagnosis, Autel Scan 2.0 ✅5-in-1 Live Data ✅detailed Pre & Post Scan ✅Scan VIN/License ✅WiFi Print ✅FAC AutoAuth & Renault SGW ✅Endoscope with MV108/MV105 ✅160+ car brands coverage, etc.
- 😊【Why Choose Autel Scanner MK900-BT, Not MK808S MK900 MX900?】➊ MK900BT escaner automotriz designs with Autel MaxiVCI V150, adopting advanced German Wireless Technology with more stable&faster data transmission, allowing you to work in and around vehicles with a 10M/33FT remote diagnostics. Instead, at almost the same budget, MK900 MK808S outdated wired code reader only with 1m cable, so you must curl up on the steering wheel! ➋ MK900BT can work with Autel BT506 to perform professional cranking charging system tests and in-vehicle & out-of-vehicle battery tests, but MK900 MK808S CANNOT. Some sellers say MK900 can work with BT506, pls don't believe it, who are not Autel a.uthorized sellers.
- 🚀【Upgraded Hardware 2.0, 10X F.aster than Ever】Based on old Android 4.4.4 ver. of MX808 MK808 MK808BT MP808 MP808BT MS906 MS906BT, Autel scan tool MK900-BT takes a big leap to 🟢f.astest OS 11 🟢4-core, 1.8GHz RK3566 speed boosted + lower power consumption🔋doubled 7700mAh Battery 🟢larger & sharper 8" 1280*800 touchscreen with intuitive user interface 🟢expanded 4+64G enough to save more files/data 🟢8M Rear camera gives clearer snapshot, etc. MK900BT scanner for car, is the best bang for your b.uck in the category.
- 📢【New Released: CAN FD/DoIP + WIFI Print + Pre & Post Scan + Scan VIN/ License】MK900BT OBD2 scanner diagnostic tool updates lots of advanced features previously available only for scanners above 2000$ (MS906 Pro MS908S Pro, etc.) ✅New protocols CAN FD works for GM 2019+ ✅DOIP works for Volv.o 2018+, Jaguar&Land Rover 2017+, BM.W F&G chassis models ✅Same WIFI Print as MaxiSys Ultra ✅Detailed Pre/ Post scan reports to up repair efficiency ✅Scan VIN/License can identify your cars in seconds, more accurately! But Autel MK808S/ MK808BT PRO cannot.
Last update on 2026-06-12 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.