NHTSA Complaint #10351332 — 2002 AUDI S6

ON 10 AUG 2010 MY 2002 AUDI S6 AVANT FUEL TANK ROLLOVER VALVE HOSE NIPPLE BEGAN LEAKING FUEL VAPORS AND LIQUID. THE LEAK WHICH IS CAUSED BY THE SAME MATERIAL FAILURE NOTED IN NHTSA CAMPAIGN # 08V157000 AND IS A SERIOUS SAFETY RISK BECAUSE OF FUEL AND FUEL VAPOR EXPOSURE TO HOT EXHAUST AND OTHER POSSIBLE IGNITION SOURCES. IN THIS CASE THE PLASTIC HOSE NIPPLE CRACKED WITHOUT ANY TYPE OF IMPACT, DAMAGE OR THE PRESENCE OF HARSH CONDITIONS. THE VALVE IS LOCATED ON THE DRIVER'S SIDE OF THE TANK A FEW INCHES FROM THE FUEL SENDER ACCESS HOLE UNDER THE REAR SEAT. THE P/N FOR THE ENTIRE FUEL TANK FOR THE A6 AND ALLROADS AFFECTED BY 08V157000 IS [XXX] BL. THE P/N FOR THE ENTIRE FUEL TANK IN THE S6 AND A6S W/ 4.2 V8S *NOT YET RECALLED* IS [XXX]. THE DESIGN OF THE TANKS IS NEARLY IDENTICAL, BUT THE 075 BL IS THREE GALLONS SMALLER. WHILE THE FUEL TANK P/NS ARE DIFFERENT THE PLASTIC ROLLOVER VALVE WHICH IS BONDED TO THE FUEL TANK ASSEMBLY IS COMMON TO BOTH P/NS AND IS UNAVAILABLE AS A REPLACEABLE COMPONENT. ALTHOUGH THE FUEL LINE ATTACHED TO THE VALVE IS OF A DIFFERENT MATERIAL, SIMILAR FORCES ACT UPON THE HOSE NIPPLE LEADING TO THE CRACKING ON THE 4.2S LARGER YET OTHERWISE SIMILAR TANK. THE DEFECTIVE FUEL TANK ON MY VEHICLE IS STILL INSTALLED AND THE CAR IS NOT DRIVABLE DUE TO THE SERIOUS SAFETY HAZARD. AN INSPECTION THROUGH THE FUEL SENDER ACCESS PANEL UNDER THE REAR SEAT REVEALED THAT THE PLASTIC ROLLOVER VALVE WAS THE SOURCE OF THE FUEL LEAK STREAMING DOWN THE TANK BESIDE THE EXHAUST AND POOLING BELOW CAR. NOTE: I PERSONALLY KNOW OF AT LEAST ONE OTHER INSTANCE WHERE A 2002 A6 W/ 4.2 V8 BEGAN LEAKING FUEL FROM THE SAME ROLLOVER VALVE HOSE NIPPLE AND THESE VEHICLES EQUIPPED WITH THE 4.2 HAVE NOT YET BEEN IDENTIFIED BY A NHTSA CAMPAIGN OR MANUFACTURER RECALL. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR