NHTSA Complaint #10203898 — 2003 VOLKSWAGEN PASSAT

AFTER FILLING UP MY 2003 VOLKSWAGEN PASSAT 4-MOTION, V6 WITH FUEL, I NOTICED A STRONG FUEL ODOR. AFTER INSPECTING UNDER THE CAR, I FOUND A FUEL LEAK ON THE GAS TANK. I TOOK IT TO OUR LOCAL REPAIR SHOP THAT SPECIALIZES IN VOLKSWAGENS SINCE I AM 140 MILES FROM THE NEAREST DEALER TO BE CHECKED OUT. THEY DISCOVERED THAT ONE OF THE 90 DEGREE CONNECTORS FOR THE VAPOR LINE ON TOP OF THE TANK HAD CRACKED. THE WHOLE TANK HAS TO BE REPLACED AS YOU CAN'T JUST REPLACE THE CONNECTOR. THE TANK IS PLASTIC AND THE CONNECTOR HAS A STEEL SLEEVE IN IT TO MAKE IT MORE RIGID. ON INSPECTION OF THE OLD TANK, IT WAS DISCOVERED THAT THREE (3) SLEEVES ON THE 3 VENT CONNECTORS HAD WORKED THERE WAY OUT OF THE CONNECTORS SO THEY JUST SIT THERE AND FLEX UNTIL THEY FAIL. THIS TYPE OF BAD DESIGN CVOULD HAVE RESULTED IN AN EXPLOSION AND SERIOUS INJURY TO MYSELF OR MY FAMILY. ON CONTACTING VW CONSUMER LINE THEY WERE CONCERNED BUT NOT ENOUGH TO ADMIT A PROBLEM OR HELP PAY FOR THE REPLACEMENT AS MY MILEAGE WAS TOO HIGH. MILEAGE SHOULD NOT HAVE ANYTHING TO DO WITH THOSE VENT CONNECTORS FAILING. I KNOW THIS IS NOT A UNIQUE OCCURRENCE SINCE ANOTHER VW PASSAT CAME IN TWO DAYS LATER TO THE SAME REPAIR SHOP WITH EXACTLY THE SAME PROBLEM. *TR