2004 Volkswagen Passat Fuel system Problems

A fuel leak has developed from the top side of the fuel tank on the drivers side of me vehicle. A fuel leak in this manner is a serious critical and immediate safety risk. Recall 08V156000 was 'performed' on my vehicle back in 2008 but the exact same fuel system safety defect has returned. VW acknowledges the recall and claims it was completed while only an inspection to check for fuel leaks was performed at the time. VW Care and my local dealership refuse to address the ongoing issue. This poses a continued fire risk, and I am now being told to pay out of pocket for a known safety recall that clearly failed to remedy the original defect.

NHTSA ID

11677910

Incident

Jul 30, 2025

There was a recall reported by the manufacturer, Volkswagenm in 2008. There were multiple Fuel System issues: A Heat Shield that may contact the exhaust system and result in a vehicle fire; a fuel leak from a fuel line or fuel tank ventilation valve, in the presence of an ignition source, can lead to a vehicle fire. In 2008, my car was inspected and the recall was deemed "complete." However, the car was only 4 years old at the time and no repairs were made. Only a visual inspection was done. I bought the car used 6 years ago, and it has been diagnosed as having a defective fuel tank ventilation valve. VW should pay for the parts and labor to have this fixed because it was never fixed. I've been told there's no statue of limitations on recalls. VW claims that because the recall was deemed "Complete" that they "fixed" the issue but they didn't.

NHTSA ID

11662869

Incident

Mar 14, 2025

The contact owns a 2004 Volkswagen Passat. The contact stated that there was gasoline leaking in his driveway where the vehicle was parked, after he had refueled the vehicle the day before. The vehicle was taken to an independent mechanic and the mechanic informed the contact that it was a known failure related to NHTSA Campaign Number: 08V156000 (Fuel System, Gasoline). The dealer and manufacturer were made aware of the failure but informed the contact that the failure was addressed in 2012 and the recall was closed on the VIN. The failure mileage was 97,361.

NHTSA ID

11433670

Incident

Sep 19, 2021

Mileage

97,361 mi

WHEN YOU FILL UP THE FUEL TANK IT LEAKS IT LEAKS A QUARTER OF A TANK OF FUEL ROUGHLY 4 TO 5 GALLONS OF FUEL DRIP OUT THERE'S A FACTORY RECALL ON THIS ISSUE I TOOK IT TO THE VOLKSWAGEN DEALER PAID MONEY TO HAVE THEM INSPECT IT AND THEY SAID YES IT'S LEAKING AT THE FACTORY RECALL I'VE HAD AN INDEPENDENT DEALER CONFIRM THAT! VOLKSWAGEN WILL NOT DO ANYTHING DUE TO WHAT THEY CLAIM A REMEDY WAS DONE BY MOVING FUEL LINES 10 YEARS AGO, OBVIOUSLY IT WAS NOT OR I WOULD NOT HAVE 4 GALLONS OF FUEL SPILL IN MY DRIVEWAY VEHICLE IS BASICALLY IN OPERABLE AND THEY WANT $3000 TO PUT A NEW FUEL TANK IN WHEN IT'S A FACTORY RECALL WHICH NEVER EXPIRES I HAVE TALK TO THE VOLKSWAGEN REP AND THE ONLY THING I HAVE FOUND IN FORUMS IS DO YOU HAVE TO GO TO VOLTS WAGON OF AMERICA AND FIGHT THEM AND THIS IS RIDICULOUS WHEN THEY KNOW THEY HAVE AN ISSUE!! TO DRIVE THIS VEHICLE WE NEVER FILL IT OVER A HALF A TANK OF FUEL SO WE DO NOT LEAK FUEL OR EXPLODE WHILE WE'RE DRIVING HOPEFULLY PLEASE HELP IN ANYWAY YOU CAN THANK YOU

NHTSA ID

11396511

Incident

Sep 12, 2019

Mileage

170,000 mi

THE CAR STALLED IN THE ROAD. PULLED OVER. TURNED THE CAR OFF AND IT WOULD NOT RESTART FULL TANK OF GAS.

NHTSA ID

11319272

Incident

Mar 25, 2020

Mileage

195,000 mi

STRONG ODOR OF FUEL IN THE CAR REGARDLESS OF BEING PARKED OR MOVING. NOTICED PUDDLE OF GAS ON THE GROUND UNDER THE FUEL TANK. FUEL WAS DRIPPING DOWN OFF THE FUEL TANK AND THE HEAT SHIELDS. FOLLOWED DRIP TO THE ROLLOVER VALVE NIPPLE WHICH IS ATTACHED TO THE GAS TANK.

NHTSA ID

11157192

Incident

Nov 2, 2018

Mileage

162,321 mi

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN PASSAT. AFTER REFUELING AND PARKING THE VEHICLE, THE CONTACT LATER DISCOVERED FUEL HAD LEAKED OUT FROM THE VEHICLE ONTO THE FLOOR OF THE GARAGE. FUEL WAS ALSO VISIBLE UNDERNEATH THE REAR SEAT OF THE VEHICLE. UPON INSPECTION, THE CONTACT DISCOVERED THAT FUEL WAS LEAKING FROM THE FUEL VALVE. THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE, BUT THE LOCAL DEALER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 160,000.

NHTSA ID

11130976

Incident

Sep 1, 2018

Mileage

160,000 mi

GAS TANK/ FUEL LINE FRACTURE, LEAKING GAS WHEN I FILL IT UP, STRONG GAS SMELL/ODOR. STOPS LEAKING AT AROUND 3/4 TANK. VERY DANGEROUS FOR MY 16 YEAR OLD TO DRIVE. VW DEALERSHIP REFUSED TO CORRECT, WANTS TO CHARGE ME 2600, TO FIX I BOUGHT THE CAR FOR 4200 3 MONTHS AGO.

NHTSA ID

11101278

Incident

Feb 15, 2018

Mileage

135,000 mi

GAS FUEL LINE/TANK LEAKING GAS

NHTSA ID

11100304

Incident

May 11, 2018

Mileage

130,000 mi

FUEL TANK LEAK. THERE IS NO DAMAGE NO IMPACT NO VISIBLE EVIDENCE OF ANY MISUSE OF CAR. FUEL TANK LEAKS WHEN FILLED ABOVE 3/4 OF A TANK. THIS IS UNSAFE AND VERY DANGEROUS THIS SHOULD BE REPAIRED BY VOLKSWAGEN. IN ALL MY LIFE AS A MECHANIC I HAVE NEVER SEEN ANYTHING THIS UNSAFE. IF MY LOVED ONES WERE TO GET HURT I WILL HOLD VOLKSWAGEN ACCOUNTABLE. THIS NEEDS TO FIXED NOW!..

NHTSA ID

11099370

Incident

Jun 1, 2018

Mileage

56,000 mi

LEAKING AT VENT/TOP OF GAS TANK. EXACTLY THE SAME DESCRIPTION OF THAT PAST HEAT SHEILD/VENT GAS LEAKING RECALL FROM ABOUT 10 YEARS AGO

NHTSA ID

11097318

Incident

Mar 31, 2018

Mileage

130,000 mi

THE CAR DIED AS I WAS DRIVING DOWN A CITY ROAD, I WAS ABLE TO VEER THE CAR TO THE SIDE OF THE ROAD AS IT WAS ROLLING BEFORE IT STOPPED COMPLETELY. I HAD THE CAR TOWED BACK TO MY HOUSE AND AFTER TESTING ALL COMPONENTS, IT WAS DETERMINED THAT THE CAR WASN'T GETTING ANY FUEL DUE A FAULTY FUEL PUMP.

NHTSA ID

11051632

Incident

Nov 8, 2017

Mileage

100,000 mi

MY GAS GAUGE IS NOT WORKING AND I ALWAYS SMEEL GAS WHILE RIDING IN MY CAR.

NHTSA ID

10877008

Incident

Feb 19, 2015

MY VEHICLE HAS BEEN NOTHING BUT A NIGHTMARE! FIRST THE THERMOSTAT HOUSING BROKE GOT THAT FIXED AND THEN EVERYTHING ELSE WENT DOWN HILL! OIL PRESSURE LIGHT STARTED GOING AND THEN IT STARTED OVERHEATING. THE HOSES ALL BREAK AND LEAK THE COOLANT OUT PLUS THE TRANSMISSION CODE P742 WHICH THE TRANSMISSION IS STUCK OFF IS ON . I CAN'T AFFORD THE CAR WORST CAR EVER. IT IS FINE IF IDLE BUT ONCE YOUR DRIVING EVERYTHING STARTS BEEPING AND WHEN I'M TURNING YOU HEAR A NOISE ON THE SIDE THAT YOUR TURNING!

NHTSA ID

10837269

Incident

Feb 13, 2016

PURCHASED A USED 2004 VW PASSAT GLX 4MOTION WITH 91K MILES AND NO ACCIDENT OR DAMAGE HISTORY PER CARFAX.. FIRST FILL OF THE GAS TANK REVEALED A SEVERE LEAK OF GREATER THAN 180 DROPS PER MINUTE. THE LEAK OCCURRED AT ALL TIMES WITH THE CAR RUNNING OR TURNED OFF AND THE KEY REMOVED. THE LEAK STOPPED AFTER THE GAS GAUGE MOVED BELOW F. REMOVED REAR SEAT AND NOTICED FUEL WETTING ON THE EXTERIOR OF THE TANK ADJACENT TO THE FUEL LEVEL SENSOR. USING A MIRROR FUEL WAS VISIBLE COMING FROM THE VENT BOSS ADJACENT TO THE FUEL LEVEL SENSOR. THIS EXACT ISSUE IS COVERED UNDER VWOA RECALL 26E5/R5 NHTSA CAMPAIGN # 08V156000. I CONTACTED VW CUSTOMER SERVICE AND THEY INFORMED ME MY VEHICLE VIN [XXX] IS NOT ELIGIBLE HOWEVER THEY DID NOT SAY WHY. THE CARFAX REPORT STATES THAT A HEAT SHIELD WAS REPLACED 8/11/2008. RECALL 26E5/R5 INVOLVES A HEAT SHIELD AS WELL AS THE FUEL TANK. IT'S POSSIBLE THE TANK WAS OK AT THE TIME. IF THE VEHICLE HAS ALREADY HAD THE RECALL AND THE FUEL TANK DEVELOPED THE PROBLEM AFTER IS THERE ANY RECOURSE UNDER THIS RECALL? INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10825233

Incident

Feb 3, 2016

Mileage

92,000 mi

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN PASSAT. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS SERVICED UNDER NHTSA CAMPAIGN NUMBER: 08V156000 (FUEL SYSTEM, GASOLINE) BUT THE REMEDY FAILED TO REPAIR THE VEHICLE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10822774

Incident

Oct 5, 2015

THE PASSAT IGNITED IN OUR DRIVEWAY AT 4:00 A.M. IT HAD NOT BEEN STARTED/DRIVEN IN A WEEK. WE WOKE TO THE SOUND OF THE TIRE BURSTING. THERE IS A HOUSTON POLICE DEPARTMENT /ARSON CASE # [XXX] - PHONE # [XXX]. INSPECTOR [XXX]. HE SAID THE IGNITION AREA OF THE CAR WAS THE START OF THE FIRE. I THINK HE WAS ARSON DEPARTMENT. THE CAR WAS TOTALED. WE ARE LUCKY WE DID NOT LOOSE OUR HOUSE AND NEIGHBOR'S IF WE HAD NOT HEARD THE TIRE BLOW. I AM NOT EXACTLY SURE OF THE MILEAGE BUT KNOW IT WAS LOW FOR THE YEAR AND THINK IT WAS BELOW 90,000...UPDATED 05/02/16 *BF INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10767576

Incident

May 7, 2014

Mileage

85,000 mi

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN PASSAT. WHILE PUMPING FUEL INTO THE VEHICLE, THE STRONG ODOR OF FUEL WAS PRESENT. IN ADDITION, WHILE DRIVING 35 MPH, THE ODOR WAS STILL PRESENT. THE FAILURE RECURRED CONSTANTLY. THE DEALER DIAGNOSED THAT THE FUEL TANK VENTILATION VALVE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.

NHTSA ID

10761704

Incident

Jan 5, 2015

Mileage

90,000 mi

2004 VOLKSWAGEN PASSAT 4MOTION, THE FUEL TANK ROLLOVER/VENT VALVE ON THE TOP OF THE TANK HAS CRACKED AND IS LEAKING GASOLINE ONTO THE EXHAUST SYSTEM. THE TANK WAS FILLED UP ON 2/22/2015 AND STARTED LEAKING LARGE AMOUNTS OF FUEL FROM THE TOP OF THE TANK OVER THE EXHAUST. THIS CONTINUED UNTIL THE TANK REACHED 3/4 FULL. IF THE FUEL TANK IS FILLED ABOVE 3/4 IT WILL LEAK FUEL UNTIL IT GETS TO 3/4. IF THE VEHICLE IS PARKED WITH THE FRONT DOWNHILL, IT CONTINUES TO LEAK BEYOND THE 3/4 POINT. THIS FAILURE WAS PART OF A PREVIOUS VW 2008 NHTSA MANDATED RECALL 08V156000, BUT ONLY REQUIRED DEALER INSPECTION OF THE ROLLOVER/VENT VALVE AND NOT REPLACEMENT OF THE FUEL TANK WITH A FUNCTIONAL PART, IF IT WAS NOT LEAKING WHEN INSPECTED THEN DO NOTHING. THE ROLLOVER/VENT IS INTEGRAL TO THE VW PASSAT AWD TANK, AND THE COMPLETE FUEL TANK HAS TO BE REPLACED. VW CLAIM AS THE CAR WAS INSPECTED IN 2008, THEY ARE NOT RESPONSIBLE FOR THE SUBSEQUENT FAILURE OF THE ROLLOVER/VENT VALVE. *TR

NHTSA ID

10690159

Incident

Feb 22, 2015

Mileage

104,000 mi

FUEL BEGAN LEAKING FROM THE TOP OF THE FUEL TANK AFTER FILL UP. MY DAUGHTER WAS HEADING BACK TO COLLEGE, AND AS SHE PULLED AWAY I NOTICED A LARGE PUDDLE OF GASOLINE IN THE STREET. NHTSA HAD PREVIOUSLY RECALLED THE VEHICLE IN 2008 (26E5/R5) ACTION NUMBER (PE08008). VW DEALER INSPECTED AND INSTALLED HEAT SHIELD. NO FUEL LEAK AT THIS TIME. IN SEPTEMBER 2012 FUEL TANK BEGAN LEAKING, VW DEALER REPLACED THE FUEL TANK, WASHER, GASKET AND CLAMP UNDER THE RECALL. IN SEPTEMBER 2014 I BROUGHT CAR BACK TO VW DEALER, AND THEY SAID THEY ARE ONLY RESPONSIBLE TO FIX THE CAR ONCE. FED UP WITH VW, I BROUGHT CAR TO MY LOCAL MECHANIC, AND UPON INSPECTION HE FOUND THE NIPPLES ON THE FUEL TANK ROLLOVER VALVE WERE AGAIN CRACKED. I HAD HIM REPLACE THE TANK. OBVIOUSLY VW DIDN'T PROPERLY FIX THE PROBLEM, AND OR REPLACED THE TANK WITH THE SAME DEFECTIVE DESIGN AND THE TANK CRACKED AGAIN. THIS IS A VERY SERIOUS SAFETY ISSUE, AND I FEEL THAT VW SHOULD PAY FOR THIS REPAIR. IF IT WAS DONE RIGHT AND CORRECTED, THE TANK WOULD NOT BE LEAKING AGAIN AFTER LESS THAN 2 YEARS, AND 20,000 MILES. THIS COULD HAVE CAUSED A FIRE WITH MY DAUGHTER IN THE CAR, AND THAT IS VERY UPSETTING TO ME. *TR

NHTSA ID

10640452

Incident

Sep 15, 2014

Mileage

143,000 mi

VEHICLE: 2004 VW PASSAT 4MOTION SEDAN W/1.8L TURBO, AUTOMATIC TRANSMISSION FILLED VEHICLES FUEL TANK, NOTICED STRONG GASOLINE SMELL INSIDE VEHICLE, NOTICED FUEL DRIPPING FROM FUEL TANK OF VEHICLE TO GROUND. CANNOT FILL TANK WITHOUT GAS DRIPPING TO GROUND; FUEL LEAK IS NEXT TO EXHAUST SYSTEM UNDERNEATH VEHICLE (VERY DANGEROUS). FOUND FOLLOWING INFORMATION: MANUFACTURER: VOLKSWAGEN OF AMERICA, INC SUMMARY: VOLKSWAGEN IS RECALLING 412,000 MY 1999-2005 PASSAT (5TH GENERATION) VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND PRODUCED AFTER JUNE 14, 1999. THESE VEHICLES MAY HAVE AN UNDERBODY HEAT SHIELD THAT CAN BECOME DAMAGED. IN ADDITION, AFFECTED VEHICLES WITH AUTOMATIC OR MANUAL TRANSMISSIONS MAY HAVE A FUEL LINE (1.8T ENGINES ONLY) OR FUEL TANK VENTILATION VALVE (4MOTION/ALL WHEEL DRIVE ONLY) THAT CAN LEAK DUE TO FRACTURE. *TR

NHTSA ID

10629809

Incident

Aug 2, 2014

Mileage

187,249 mi

I BEGAN NOTICING A VERY STRONG SMELL OF GASOLINE COMING THROUGH THE VENT WHILE DRIVING. WHEN I PULLED OVER TO CHECK UNDER THE HOOD, I NOTICED THAT THE RIGID FUEL LINE HAD CRACKED WHERE IT PASSED THROUGH A MOUNTING BRACKET ON THE UPPER REAR OF THE ENGINE BAY. THE CRACK WAS EMITTING A STEADY FLOW OF FUEL ONTO THE ENGINE AND EXHAUST MANIFOLD. WE DID NOT DRIVE THE CAR ANY FURTHER AND HAD THE LINE REPAIRED WITH A PATCH OF FLEXIBLE FUEL LINE MATERIAL. *TR

NHTSA ID

10626953

Incident

Jul 24, 2014

Mileage

166,000 mi

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN PASSAT. THE VEHICLE WAS REPAIRED ACCORDING TO NHTSA CAMPAIGN NUMBER: 08V156000 (FUEL SYSTEM, GASOLINE); HOWEVER, THE CONTACT COULD SMELL A STRONG ODOR OF FUEL WHEN THE VEHICLE WAS PARKED. A LOCAL MECHANIC STATED THAT THE FUEL TANK VENTILATION VALVE FRACTURED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 70,000.

NHTSA ID

10619505

Incident

Aug 5, 2014

Mileage

70,000 mi

I FILLED MY GAS TANK UP ON A FRIDAY AND DROVE IT HOME AND PARKED IT IN THE DRIVEWAY AND THE NEXT DAY NOTICED A FAIRLY LARGE PUDDLE OF GASOLINE UNDER MY CAR. I TOOK IT TO MY LOCAL CAR SHOP AND THEY TOLD ME THAT IT WAS THE FUEL LINE THAT WAS LEAKING AND THAT HE CALLED A VOLKSWAGEN DEALERSHIP AND THEY HAD TOLD HIM THAT THERE WAS A RECALL ON THAT EXACT PART OF THE CAR. I WAS TOLD TO CALL VOLKSWAGEN AND SEE IF THEY WOULD BE ABLE TO FIX THE ISSUE AND THEY TOLD ME THAT THE RECALL WAS ALREADY FIXED BY THE PREVIOUS OWNER OF MY CAR. IF IT WAS ALREADY FIXED THEN THE SAME PROBLEM SHOULDN'T BE HAPPENING AGAIN. *TR

NHTSA ID

10604780

Incident

Jun 13, 2014

Mileage

145,000 mi

I HAVE A 2004 VW PASSAT W8 4-MOTION AND I FILLED THE TANK THE OTHER DAY AND PARKED THE CAR IN THE GARAGE OVERNIGHT AND WHEN I OPENED THE INTERIOR GARAGE DOOR IN THE MORNING THE FUMES WERE SO STRONG I EVACUATED MY WIFE AND 4 MONTH OLD BABY FORM THE HOUSE. THIS HAS HAPPENED 2 TIMES, BOTH WERE WHEN I FILLED THE FUEL TANK. I CALLED THE DEALER AND THEY SAID THERE WAS A RECALL THAT ADDED A HEAT SHIELD AND INSPECTED THE 4 MOTION VW PASSAT PURGE/ROLLOVER VALVE. THEY STATED THAT THE HEAT SHIELD WAS REPLACED BUT DID NOT SHOW THE VALVE BEING REPLACED. I CALLED VW AND THEY STATED THAT THE VEHICLE WAS OUT OF WARRANTY AND IS NO LONGER COVERED. I AM VERY CONCERNED FOR MY FAMILY'S SAFETY ESPECIALLY SINCE I LIVE IN A 3 STORY TOWN-HOME AND THE GARAGE IS AT THE BOTTOM OF OUR MAIN FLOOR. I WOULD LIKE THE CAR INSPECTED ASAP. *TR

NHTSA ID

10584694

Incident

Apr 24, 2014

Mileage

154,500 mi