Tank Assembly problems of the 2002 Volkswagen Passat

There is a dangerous gas leak from the previously recalled fuel tank that is not damaged by the road, or other debris. The recall needs to stay open.

The contact owns a 2002 Volkswagen Passat. While parked, the contact noticed a strong fuel odor around the exterior of the vehicle. The vehicle was taken to an independent mechanic where the mechanic stated there was a leak near the top of the fuel tank. The manufacturer was made aware of the failure. There was a recall under NHTSA campaign id number: 08v156000 (fuel system, gasoline:delivery). The vehicle was included in the recall and was repaired before the failure. The vehicle was not repaired. The approximate failure mileage was 113,000.

My fuel tank is leaking for the 2nd time in 2 years. In 2009, I smelled fuel when the tank was full. I took it to the dealer and they said the tank was cracked and had to be replaced, which I paid for. In 2011, the exact same thing occurred. The dealer is paying for the replacement. This concerns me that there may be a problem with the fuel tanks in the 2002 vw Passat. I'm not sure if this is the same issue that has been reported earlier and sort of recalled under the heat shield problem. If it is the same issue as that, I shouldn't have paid for the repair in 2009. Could you please investigate the fuel tanks. . . The escape of fuel scares me!.

The contact owns a 2002 Volkswagen Passat. After adding fuel to the vehicle the contact smelled a strong odor of gasoline inside the vehicle. The contact was able to continue driving without incident; however, after the vehicle was parked the fuel tank was leaking. The vehicle was taken to an independent repair shop where they were unable to diagnose the failure. The vehicle was not repaired. The failure and current mileages were 120,000.

Fuel tank leaks when 7/8 to 8/8 full. Leaking gas damages asphalt and poses a fire threat.

The contact owns a 2002 Volkswagen Passat. The contact stated that fumes were entering the vehicle through the ventilation system and the check engine light was illuminated. The contact also mentioned that due to the failure, the vehicle was unable to pass state inspection. The vehicle was taken to the dealer who was unable to diagnose the failure and stated that in order to find the cause of failure, they would have to drop the fuel tank. The manufacturer was made aware of the failure but did not offer any assistance since because the vehicle was previously repaired under NHTSA campaign id number: 08v156000 ( fuel system, gasoline: delivery). The vehicle was not repaired. The failure and current mileage was 120,000.

Fuel leaks when gas tank is more than about half to three quarters full. Very strong odor inside and outside vehicle. Some wetness around fuel tank, but no visible drips when inspected by owner. When driving at 60 mph soon after filling tank, fuel range indicator decreases by 5 miles for every 1 to 2 miles travelled. Assuming normal fuel consumption should be 20 mpg, in 1. 5 minutes vehicle should use 0. 075 gal, but actually uses 0. 250 gal so the leak rate is approximately 0. 12 gal/min or 45 ml/min. Such leakage would be evident as drips if the leak was below the liquid level when the car is stationary so it is suspected to be in the area of the gas tank vents. Vehicle has not yet been inspected by vw. (vehicle was recently purchased used from private seller without maintenance records).

I am a the owner of a 2002 Volkswagen Passat 4motion with an automatic transmission. I am contacting you to seek action in regards to NHTSA campaign number for a recall for faulty gas tanks. I purchased this car as a certified used vehicle in 2004. I took the car to a vw dealership 4 times with a problem with something leaking under the car, and told there was not a leak found. After smelling gas, and finding fuel on my garage floor, the dealership was able to determine that the vehicle had a cracked fuel tank, and repaired the vehicle for $3000. After complaining to vw of America, the costs were covered and shortly thereafter I received a recall letter for the same issue. Now, one year later, I again smelled fumes, and found gasoline on the floor. The dealership stated that it is the same problem. Vw of America has offered to cover the cost of the repair. My car is parked in our garage where our gas hot water is located. The fuel on the floor was no more than 15 ft from the hot water heater. Had there been a spark, I am certain that there would have been a major fire, with potential fatal outcomes. I will not bring this vehicle back to my house for fear of a repeat failure. I also have concerns selling a defective vehicle to a 3rd party knowing the potential severe safety hazards. Volkswagen has clearly designed a faulty product they refuse to stand behind, and as a consumer, I will have to incur a finanical loss to replace this vehicle. These problems stem from negligent design and are a very serious potentail hazard. The 4motion cars should be removed from service and compensations should be allowed to owners. I desperately seek your assistance on this issue to review whether a second recall may be necessary. Thank you for your assistance.

Hello, my name is robert campbell and I am a the owner of a 2002 Volkswagen Passat 4motion with an automatic transmission. I am contacting you to seek action in regards to NHTSA campaign number 08v156000, which clearly indicates a recall for faulty gas tanks on this particular make/model due to fractured ventilation valves. Upon purchasing the car as a certified used vehicle in 2006, I had to have the gas tank replaced within the first week of ownership due to this very same defect. This was covered by the two year warranty provided by the dealership. A week ago, my gas tank started to leak again. Fuel is now leaking on the exhaust system creating a severe safety hazard. Upon inspection by the dealer, they have surmised the second tank has once again failed - due to a fractured ventilation valve. Both Volkswagen of american and my local dealer are refusing to acknowledge this recall and will only replace the tank if I agree to repair costs totaling $1,800. Volkswagen has clearly designed a faulty product they refuse to stand behind, and as a consumer, I should not be financially obligated to pay for repairs that clearly stem from negligent design. I desperately seek your assistance on this issue and will gladly offer my full cooperation.

Suddenly felt strong gasoline smell inside the vehicle (not a result of accident or any other occurrence. ) the problem was diagnosed as a fuel tank leak. The gas tank had to be replaced. The vw dealer in sunnyvale, CA, refused to pay for the costly repairs.

I have a 2002 vw Passat v6 glx wagon with 37,000 miles. Whenever the fuel tank is full, or near-full, there is a strong smell of gasoline from the right rear side. I have had to leave my garage door partially open because of the danger of igniting fumes from the pilot lights of my home gas water heater and furnace in the garage. I have found wet patches smelling strongly of gasoline on the underside of the fuel tank. It is obvious that the gasoline tank is leaking somehow and presents a fire safety issue. I suspect it might be the same problem that is being investigated in NHTSA action number pe08008 even though my model is not an all-wheel-drive. Meanwhile, whenever the vehicle is parked, in my garage or out in the open, there is a constant danger of fire being ignited.

This complaint is about a 2002 Passat 4-motion v6 car. Gas odor entered my house for 2 weeks and I did not know what was causing the problem. I called the gas company to see if I had a gas leak with my furnace. The gas company came and tested but found nothing wrong with my furnace or equipment using natural gas. I decided to find the root cause and began ruling out possibilities. I observes the gas smell was in my garage. I observed whenever my gas tank was filled, more odor came into the house. I filled the gas tank on 10/1/07 and parked the car out on the street. On 10/2/07, when I entered the car in the early am hours, the gas scent made me throw up and I became dizzy. I had no idea what was wrong and I drove - while praying - the car to the dealer. They immediately told me they would not let me drive the car out of there without finding out the problem because of the very strong gas odor. I was later told if anyone had thrown a cigarette by my car, it would have caught on fire! the car was dripping gas as I drove to the dealer! the dealership found the problem was cause by a leak on my fuel tank. A new fuel tank was needed - that is the only way it could be fixed. I requested my old tank and said it has to be brought and shown to the government agency over transportation and the environment because I could have died and no one would have known it was a faulty manufacturer's part. The old tank shows 3 plastic tubes used on the gas tank that drains the gas! plastic ! one of the plastic tubes broke off causing the gas leak! I visited a website and found so many other Passat owners have had this problem and vw is doing nothing to change the design! I spoke to vw and I was told there is nothing they can do and I have to pay the cost of the repair! I am asking your office to investigate this safety issue. This is a dangerous safety issue to all Passat owners! I have my old gas tank and will be happy to bring it to your office .

The contact owns a 2002 Volkswagen Passat. The contact smelled gasoline and noticed a leak coming from the rear driver side of the vehicle. The float assembly was replaced, but it did not correct the failure. The dealer stated that a new fuel tank was needed and would cost $1,700. They also stated that the metal flange seal and tank were connected and would not be replaced. The manufacturer investigated the failure and stated that there were no recalls and the vehicle was out of warranty. The current and failure mileages were 91,000.

If fuel tank is filled more than approx. 3/4 full, the odor of gas is apparent very soon after. It permeated my garage overnight and overwhelmed me when I opened the door. My mechanic told me a vent tube on the top of the fuel tank is defective and has seen a number of these, as has the dealers mechanic. They have told me the only remedy is to replace the tank. I personally have not been in any accidents, and have owned the car for over a year. My local vw dealer will be replacing this for free based on the approval of a regional vw manager, but I called vw of America and was told that this issue was news to them, and no such recalls or extended warranties applied. I feel that this is a significant safety issue, and I was only saved the ~$3,000 in repair expense because one specific dealers adviser happened to be aware of a "soft recall," as he put it. He told me a number of these tanks are failing on my particular vehicle, and have ordered extra fuel tanks to accommodate customers. Vw should be notifying customers or at the very least have information on it through their national customer care center.

2002 Volkswagen Passat with fuel odor. Consumer states that she noticed a strong fuel smell filling her garage. Mechanic stated that there was a crack in the fuel tank. Mechanic stated that the consumer hit the bottom of the fuel tank on something. The consumer stated a few months after the fuel tank was replaced, the timing belt failed.

For the past nine months I have smelled gas when I filled my gas tank past half full. I checked for recalls on your website last month an came across the vw Passat fuel tank safety recall. Since my car was at the dealership to take care of yet another problem, I told them about my gas smell problem and informed them about the recall. I told them that it only occurs when the gas tank is past half full and told them to put gas in it and test it. When I picked up the car they hadn't done the gas tank test. The service advisor looked up the recall and found information on the gas tank safety recall r5 and printed out a faq sheet. He informed me that they didn't have the new tank for the recall and he expected them on may 30th. He told me to contact him and make an appointment to have the tank replaced once they had the parts in. I called the dealer on may 30th and made an appointment for today June 3rd. I brought my car to the dealership and I was informed by another service advisor and she couldn't find any Volkswagen recall covering my VIN. The service adviser I spoke to when I had picked up my car after the repairs I had done in may came over. He recalled obtaining the information and searched for it again and it wasn't listed. They let me call Volkswagen customer service. The vw customer service representative said that there wasn't a safety recall on the my Volkswagen w8. I told him that it smells like gas when the gas tank is filled past half full. He said he would contact the service manager at the dealership I was at and see what could be done. I read the information on your website involving this recall and it seams pretty clear that any 1999- 2005 model year Passat with a gasoline engine is covered. I have a 2002 vw Passat w8 with 4motion. One of the responses from vw lists VIN number ranges, but mine doesn't appear to be within that range. I think that vw erred in their investigation and didn't look into the w8.

The 2002 Volkswagen Passat glx 4 motion with just over 66,000 miles had just been refueled with a full tank of gas and driven into our garage when my wife smelled strong gasoline fumes and noticed puddles underneath the vehicle. I brought it to Volkswagen dealership, and was charged $70 for the diagnosis , and then a total of $302. 77 to replace the gasket for the fuel pump. They did not fill the tank to confirm that the problem no longer existed, but said that the problem was fixed. A week later the same situation, gasoline fumes and puddles under vehicle. Returned to dealership, and they kept car for 4 days to diagnose. Bottom line ,they informed me that "the vehicle may need a new fuel tank , $1,622. And /or new fuel lines, $922. 25. They will need to lower the fuel tank to completely diagnose" at a cost of $700 because of 5 hours. Labor. We had already spent over $300 for repairs that apparently wasn't necessary because it did not fix the problem. They did not refund our $300. Also , my wife called Volkswagen of America, and we were told that the car was out of warranty, so they would offer no help. I purchased this car brand new. It was top of the line I expect better performance and service as I have had a number of Volkswagens and none had given me grief until this one. A gasoline tank and fuel lines were safety issues and if they fail in such a short time they would have to be either defective or poorly designed, and the responsibility to correct them should lie with the manufacturer. Any reasonable person would think that the $300 repair bill would be acceptable but not anywhere between $2000 and $3000. Why should the customer pay for a poor design that involved $700 just to diagnose? from the look of some of the other complaints found on this site they would already know and gladly extend some good will to the owners of these vehicles.

A chemical smell permeating my entire house for 2 months. I had home gas company come out and check for a gas leak,gas company did not find a gas leak. The smell would be worse some days. A friend found my tank leaking . I took my car in the next day, Monday p. M. To have it looked at baron vw. They said it was a nipple on a hose inside the tank, and the whole tank had to be replaced. This is a very expensive repair, that they are estimating to be two thousand dollars. I do not believe that this just happened, with the hose being inside the tank, I think this is a bad part. I have found other incidents of this online , for this particular 2002 Passat, with four motion. I think it is a defect of the part and it is expensive because the whole drive train must be removed to replace it. I am hoping you will look into this because that is a very dangerous problem. I don't think some people would even notice their tanks leaking. If my car was not stored in my garage everyday I would have never noticed it. It could have blown my house up when I turned my heater on for the winter with the fumes that were in this house, not to mention driving with a leaking tank, and the chance of static or a cigarette butt getting tossed my way. The car has been out of my garage for 3 days now and the attic fan has been on until last night and my house still stinks. I am afraid now to turn my home furnace on. People who own these cars should be warned to check them for gas leaks, especially if they keep them in their garage. I also think about the times I had my grandson strapped into a child seat right there over that leaking tank. The reason the smell was in my house stronger some days was because I would leave the car outside sometimes and I had the windows open and attic fan on would draw the smell out. The day I discovered it was particularly strong was because I had put the car back in and shut the windows and turned my a/c back on in the house.

2002 vw Passat, v6 4motion just turned over 50,000 miles (warranty expired) and noticed that when I filled the gas tank, for several days until the gas level went down, there was a very strong gas odor in the car and around the car. Took it to the dealer, who first pointed out that it was time for me to pay the Passat driver privilege tax, a. K. A. , $650 for standard maintenance work. Regarding the gas smell, after the mechanics allegedly checked the car, the service advisor speculated that it was a leak in one of the fuel pump seals, which are located under the back seat (where the strongest smell was coming from). He said that he had seen other Passats at around my same mileage with the same problem. The tank was only â½ full though, and the smell was not present, so he asked me to bring the car back on another day, with a full gas tank, so that the mechanics could smell it. When I suggested that it might be more difficult (and dangerous) to examine a full gas tank, he agreed and when I brought the car back a week later for the mechanics check it out, that's when the service advisor told me that the gas tank was 'cracked' (near the top) and that it would cost $2,000+ to fix it. This is obviously not caused by 'wear and tear'- nor is it a problem that I could have caused absent some sort of impact. I called vw America to ask them to pay for the repair, and after they investigated my claim, they told me that the dealership offered to pay 1/2 the cost of the repair, ($1,000). When I next spoke with the service advisor at the dealership, he told me that vw had offered to pay 1/2 the cost of the repair, or would give me a $1,000 credit toward a new car. My investigations have led me to the conclusion that this is either a defect of the vw fuel tanks or the crack is due to corrosion, which should be 100% covered under the 12 year corrosion warranty. Either way, vw should be held accountable.

My 2002 vw Passat 4 motion developed a severe fuel leak from a defective fuel tank which ruptured along the top and was leaking in 3 places. Vehicle has not been involved with any collision. Vw refused to cover the repair due to my vehicle having 65000 miles. Dealer mechanic said he has seen several other Passats with 4 motion have the same problem. Repair cost estimate is 3000. 00.

I own a 2002 vw Passat v6 glx with 42,700 miles. Within the past 2 months an intermittent problem started with very strong gasoline fumes coming from the car after the tank is filled and the car is parked in a residential garage. The gas tank is filled until the first click off of the gas nozzle ( at several different gas stations). The gasoline fumes are very strong, requiring that the garage doors be left partially open to reduce the fumes to a tolerable level. No fuel drips from the vehicle. The fumes seem to be coming from the right rear of the car. Fumes can sometimes be smelled briefly outdoors when the vehicle's gas tank is full. The fumes stop after the tank level is down to about 3/4 tank. The problem recurs consistently now for me everytime the vehicle is refueled. I brought the vehicle to the local vw dealer on 11/5/05. They pressured tested the vehicle's fuel system with argon and reported that they can find no fuel leak or duplicate the problem with a full tank of gas. The service manager contacted vw technical assistance. I brought the vehicle in on 12/15/05 with a half tank of fuel as requested. The service technicians, as recommended by vw technical assistance, removed the gas tank and weighed the charcoal canister to determine if adequate charcoal was present. The charcoal canister was within factory specifications. The service technicians reinstalled the same parts and then filled the gas tank. They then pressure tested the vehicle's fuel system with argon overnight, leaving the vehicle in the service bay. They could not detect any fuel leaks or reproduce the problem. Vw technical assistance reportedly told the tech's that they had done all that was possible and that there was nothing else to do. The service manager acknowledged that their service bay is quite large and ventilated so that the conditions do not duplicate having the vehicle in a residential garage. A fire risk and fume exposure remain.

While driving on the highway right rear michelin mxv4 tire disintegrated. Parts of the tire ruptured the gas tank. On 6/18/2003 the consumer contacted the manufacturer, who stated that vehicle was not involved in the recall# 02v026000. On 6/20/2003 the dealer called and informed the consumer all damages to the vehicle would be fixed per the recall. A recall notice was received after the call from the dealer was made.

Consumer noticed after filling vehicle with fuel vehicle intication light would flash, stating low on fuel. Dealer had been notified could not duplicate the problem.