Two problems related to tank assembly have been reported for the 2002 Volkswagen Jetta. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Volkswagen Jetta based on all problems reported for the 2002 Jetta.
The fuel gasket decided to crack on the top of the sending unit that sends diesel to the engine. It filled the top and spilled down over the tank onto the concrete. $250 repair for the gasket + labor not at a dealership. It's probably a fire hazard and vw should recall the gaskets.
The contact owns a 2002 Volkswagen Jetta. The contact constantly smells a slight hint of gasoline after placing fuel into the vehicle. While placing gasoline into the vehicle, the smell intensified. The contact referred to the owner's manual, which advised not to overfill the fuel tank. He then realized that he was overfilling the tank unknowingly. He continued to smell the odor and removed the back seat of the vehicle, and discovered gasoline had overflowed into the interior of the vehicle. The dealer stated that he needed the fuel pump replaced at the cost of $650. The dealer stated later that a $1,600 fuel tank replacement was needed. The contact refused and sought a second opinion. He then notified Volkswagen of America and filed a complaint. He was informed that nothing could be done because the warranty had expired (case number 80256757). The failure mileage was 60,000 and current mileage was 94,000. Updated 09/10/08. The consumer stated the gas tank was defective.