Diesel Fuel System Tank Assembly Problems of Volkswagen Jetta

Filled up my 2006 Jetta tdi and diesel fuel came out all over the car and the ground. The fuel filler design will not accommodate the larger diameter truck diesel nozzle, but that's all there was available at the service station (and at most service stations along the interstate). The previous generation fuel filler did accommodate the larger diameter diesel nozzles so I don't know what vw was thinking. Vw needs to issue a recall and fix this ASAP. It is a safety issue due to spilled diesel fuel.

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I was driving down the road and heard a noise under my car. The gas tank was punctured by something on the road during normal driving conditions which prompted me to pull over and the gas was gushing out of the tank. I then had the car towed to a dealer and was later informed that it would not be covered by warranty due to "outside conditions" I then spoke to the manufacturer and explained the situation and they denied any coverage under warranty. I have reason to believe that something was propelled from the front wheel into the gas tank and that the position of the gas tank may not be proper. I believe it is a possible design flaw or that the gas tank was defective and thus more susceptible to being punctured.

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On the 'new' 2005. 5 Jetta tdi diesel vehicle, the fuel nozle inlet is too small to use a moajority of the diesel fuel pumps more commonly found at truck stops. Since when traveling cross country you would most like stop at a truck stop to fuel up, you would most likely be out of luck -and have 'search' for a gas station in a strange town, away from your route, that 'might' have a smaller nozle that would fit your fuel tank. The older Jetta, golf and passat cars use a lager fuel inlet that is universal in terms of being able to fuel up anywhere. The current 2005 passat has the larger inlet, so what gives with the new Jetta? tdi owners travel great distances and would like to not be stranded or made to go out of their way just to fuel up. Vw should retrofit the older style nozle on these cars, or purchase a smaller fueling pump nozle for every gas staion or truck stop that sells diesel in the country. Which is easier?.

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Vehicle had sending unit replaced with a different design unit to address cold weather operating condition. Mfg,r has TSB acknowledging problem. Was charged for repairs car is 4 mos old. 2003 Jetta purchased in sept. 2003.

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I own a 2001 vw Jetta with the 1. 9l tdi diesel engine. This vehicle is maintained by my local vw dealership. During cold weather conditions below 30 degrees f my vehicle would stop running stranding me at night in locations with little road traffic or cell phone service. This occurred approximately 6 times requiring the vehicle to be towed to a dealership. Each time that the vehicle was thawed in their shop and was diagnosed with "improperly treated diesel fuel". I meticulously put in the recommended amount of vw anti-gel additive to all tank fulls of fuel. I also consistently purchase my diesel fuel from the same high volume supplier who has numerous fleet accounts. I had begun to triple dose the diesel fuel additive in attempts to avoid this situation. After numerous times of being stranded in single digit conditions and having the same situation occur I checked a tdi owners website tdiclu. Com it seems that the problem lies in the fuel tank pick up which has a restriction that only surfaces when the fuel thickens during the winter months. The fuel pickup/sending unit comes in a c, d, and an h model. My vehicle had the c model. Apparently vw of canada is aware of this situation and without question or charge would replace their customers cars with the h model. I purchased the h model pickup/sender and replaced it myself and the problem has disappeared. To date I have incurred more than one thousand dollars in towing and repair charges for this problem that is clearly a vw design flaw and one that is acknowledged by vw of canada.

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