2004 Volkswagen Jetta Fuel System Problems

STARTING AT AROUND 130,000 MILES, WHEN GAS TANK IS AT A QUARTER OR SLIGHTLY LESS, THE CAR LOOSES POWER AND ACTS AS IF IT IS NOT GETTING FUEL TO THE ENGINE. WHEN THIS HAPPENS WHILE DRIVING DOWN A HIGHWAY AT TYPICAL HIGHWAY SPEEDS, POWER IS LOST FOR 10-15 SECONDS, RPM DROPS TO AROUND 2000 OR LESS (WHILE IN "DRIVE"). THEN ALL OF A SUDDEN, THE ENGINE JERKS TO LIFE, AND I CAN DRIVE THE CAR NORMALLY, UP UNTIL I HAVE TO REFILL THE TANK. THE STALLING DOESN'T REPEAT ITSELF UNTIL THE NEXT QUARTER TANK. WHEN THE QUARTER OF A TANK ISSUE HAPPENS IN THE CITY AT SLOWER SPEEDS, THE CAR DIES, DASHBOARD ENGINE LIGHTS COME ON, AND I HAVE TO PULL OVER, AND CRANK THE STARTER 3 OR 4 TIMES, AND EVENTUALLY, IT STARTS BACK UP AGAIN WITH NORMAL DRIVING RESUMED. ONE TIME I WAS DRIVING UP A HILL, LOST POWER, AND HAD TO PULL OVER QUICK. WHEN THE QUARTER OF A TANK ISSUE HAPPENS WHILE PARKED, ENGINE AT AN IDLE, THE CAR DIES, AND I HAVE TO CRANK THE STARTER A FEW TIMES TO RESTART THE CAR. THIS PROBLEM ONLY HAPPENS ONCE PER TANK CYCLE, ONLY AT THE (APPROXIMATE) QUARTER OF A TANK POSITION, AND DOESN'T HAPPEN BETWEEN THE FULL TO 1/4, OR THE 1/4 TO EMPTY PHASE. I KNOW I AM NOT OUT OF GAS, AS I'M FILLING UP THE TANK TO NORMAL LEVELS. THE FUEL PUMP HAS BEEN REPLACED TWICE, AND THE FUEL FILTER ONCE. MY MECHANIC CHARGED $80 TO DIAGNOSE THE CAR, ONLY TO FIND A CODE ABOUT A SPARK PLUG THAT MISFIRED - WHICH OF COURSE WILL HAPPEN DURING FUEL STARVATION. SPART PLUGS REPLACED, BUT THE PROBLEM HAPPEND AGAIN. I'VE CALLED 3 OR 4 VW REPAIR SHOPS, AND NOBODY HAS A CLUE HOW TO FIX THIS, ESPECIALLY WHEN I BRING UP THE QUARTER OF A TANK ISSUE. THE ONLY WAY TO PREVENT THIS FROM HAPPENING IS TO FILL UP BEFORE HITTING 1/4 TANK. IRRITATING !!!! ISSUE GOING FOR ABOUT A YEAR NOW.

THE CAR RANDOMLY STALLS WHILE DRIVING WHETHER AT HIGHWAY SPEEDS OR IN TOWN. THIS CAUSES A LOSS OF POWER STEERING AND POWER BRAKES WHICH IS INHERENTLY DANGEROUS IN CERTAIN SITUATIONS. IT HAS BEEN DOING THIS REGULARLY WITH THE PREVIOUS OWNER FOR THE LAST 3 OR 4 YEARS AND HAS DONE IT 4 TIMES WHILE UNDER MY OWNERSHIP SINCE SEPTEMBER 2017 IT USUALLY HAPPENS WHILE THERE IS LESS THAN 1/4 TANK OF FUEL. WHEN IT HAPPENS THERE IS NO CHECK ENGINE LIGHT NOR DOES THE ECU STORE ANY CODES FROM THE PROBLEM. PREVIOUS OWNER MADE SEVERAL REPAIRS INCLUDING A FUEL PUMP AND FILTER, ENGINE SPEED SENSOR AND ALTERNATOR WIRING HARNESS IN AN ATTEMPT TO FIX THE ISSUES WITH NO SUCCESS. THIS ISSUES ALSO COMES UP REGULARLY ON SEVERAL VW FORUMS AND NO ONE SEEMS TO HAVE AN ANSWER. THIS IS A KNOWN AND REGULAR ISSUE WITH NO CONSISTENT REPAIR AND NEEDS TO BE REMEDIED.

RANDOMLY STALLS ON THE FREEWAY WHEN DOWN TO 1/4 TANK OF GAS. AFTER PULLING OVER AND TURNING OFF THE KEY AND TURNING THE KEY BACK ON, IT WILL START AND RUN GREAT. THIS HAPPENS ABOUT EVERY OTHER TIME THE CAR GETS DOWN TO ABOUT 1/4 TANK. NO SHOP CAN DUPLICATE THE PROBLEM OR CORRECT IT. I HAVE TRIED THE IGNITION COIL, GROUNDS, FUEL PUMP... NO FIX. THERE ARE COUNTLESS THREADS ON VARIOUS VW FORUMS ABOUT THIS SAME PROBLEM. IT IS VERY DANGEROUS TO STALL ON THE FREEWAY. SOMETHING NEEDS TO BE DONE TO CORRECT THIS.

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA. THE CONTACT STATED THAT WHILE DRIVING AT UNKNOWN SPEEDS, HE NOTICED A STRONG FUEL ODOR. UPON INSPECTION, IT WAS FOUND THAT THE FUEL PUMP HAD FAILED. THE MANUFACTURER ADVISED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER 04V586000 (FUEL SYSTEM, DIESEL). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 145,000 AND THE CURRENT MILEAGE WAS 146,177.

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA. THE CONTACT STATED THAT A FUEL ODOR WAS BEING EMITTED FROM THE VEHICLE. UPON INSPECTION, IT WAS FOUND THAT FUEL WAS LEAKING AROUND THE AREA OF THE ENGINE. THE VEHICLE WAS TAKEN TO THE DEALER AND INFORMED THE CONTACT THAT THE DIESEL FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE AND ALTHOUGH THE PART NUMBER FOR THE FAILED COMPONENT WAS THE SAME AS IN THE RECALL, THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 04V586000 (FUEL SYSTEM, DIESEL). THE FAILURE AND CURRENT MILEAGES WERE 172,000.

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA. THE CONTACT STATED THAT THE VEHICLE EMITTED A STRONG FUEL ODOR, THE CONTACT INSPECTED THE VEHICLE AND FOUND THAT THE SUPPLY LINE CRACKED AND AS A RESULT, THE FUEL NECK TO SPILL OVER TOP OF THE TANK AND GROUND. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN (NHTSA CAMPAIGN ID NUMBER: 05V154000 FUEL SYSTEM, GASOLINE: DELIVERY: FUEL PUMP) THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 110,000.

A LITTLE UNDER 3 YEARS AGO (OCT. 2010) I STARTED NOTICING A FAINT GAS SMELL COMING FROM MY CAR. OVER A 2 WEEK PERIOD THE SMELL GRADUALLY GOT STRONGER AND MY MPG SLOWLY DECREASED. AFTER TAKING MY CAR INTO A SHOP IT WAS DETERMINED THERE WAS A CRACK NEAR THE FUEL PUMP GASKET AND THE FUEL PUMP NEEDED TO BE REPLACED. NOW 2 WEEKS AGO (MAY 2013) THE EXACT SAME SYMPTOMS STARTED UP AGAIN AND AFTER TAKING MY CAR BACK TO THE SHOP THEY TOLD ME THE EXACT SAME THING. THERE WAS A SMALL CRACK NEAR THE GASKET ON MY FUEL PUMP AND IT NEEDED TO BE REPLACED. THERE IS AN OBVIOUS DESIGN FLAW TO CAUSE ME TO REPLACE 2 FUEL PUMPS IN A 3 YEAR SPAN. *TR

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA. WHILE DRIVING AT SPEEDS OF 40 MPH, THE VEHICLE CAUGHT ON FIRE. THE POLICE AND FIRE DEPARTMENT WERE CALLED TO THE SCENE WHERE THE FIRE WAS EXTINGUISHED AND A FIRE REPORT WAS FILED ACCORDINGLY. THE MANUFACTURER ADVISED THERE WERE NO RECALLS ON THE VEHICLE AND WOULD NOT PROVIDE ANY ASSISTANCE. THE CONTACT INQUIRED ABOUT NHTSA CAMPAIGN ID NUMBER 04V586000 (FUEL SYSTEM, DIESEL) HOWEVER, THE MANUFACTURER ADVISED THEY HAD NO KNOWLEDGE OF THE RECALL. THE CURRENT AND FAILURE MILEAGES WERE 70,000.

I AM THE OWNER OF A 2004 VOLKSWAGEN JETTA GLI, WHICH I GARAGE AT MY CONDOMINIUM. IN MARCH 2006, THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION ISSUED A RECALL OF VOLKSWAGEN AND AUDI 2003 CARS WITH 1.8L TURBO ENGINES DUE TO ELECTRICAL FAILURE OF THE FUEL PUMPS. I RAISE THE POSSIBILITY OF MY CAR BEING INVOLVED IN THE MANUFACTURING MALFUNCTION, BUT NOT INCLUDED IN THE RECALL. 07/17/2009: CAR TOWED TO VOLKSWAGEN AUTOBARN OF EVANSTON. COSTS: $74.15. 07/25/2009: INFORMED THAT THE CAR REQUIRED A NEW BATTERY AND FUEL PUMP. PARTS & LABOR COSTS: $905.85. AFTER PAYING FOR THE REPAIRS AND WAITING FOR DELIVERY, THE CAR WOULD NOT START. 07/27/2009: RETRIEVED THE CAR AFTER VW AUTOBARN SERVICE INSTALLS A SECOND FUEL PUMP, DUE TO A DEFECT IN THE PREVIOUS PART. I DROVE THE CAR HOME AND PARKED UNDERGROUND. 07/28/2009: I DROVE TO THE FAA REGIONAL OFFICE IN DES PLAINES, IL. AT APPROXIMATELY 18:30, I ATTEMPTED TO LEAVE HOWEVER, THE CAR DID NOT START IN THE SAME FASHION THAT LED TO THE INITIAL REPAIR. THE CAR IS TOWED BACK TO VOLKSWAGEN. 08/17/2009: INFORMED BY THE VW AUTOBARN SERVICE MANAGER THAT THEY HAVE GONE TO EXTRAORDINARY EFFORTS TO REPAIR THE CAR: DRIVEN THE CAR ON MULTIPLE OCCASIONS INCLUDING TAKING IT HOME OVERNIGHT; COMMUNICATED WITH THE GERMAN SERVICE OFFICE TO PURSUE OTHER POSSIBLE CAUSES FOR FUEL PUMP FAILURES. COSTS FOR TOWING, FUSES, RELAY SWITCHES, LEADS, CONNECTORS AND TECHNICIAN LABOR: $574.11. AFTER PAYING FOR THE ABOVE REPAIRS, AGAIN, THE CAR WOULD NOT START. 08/28/2009: INFORMED THE FUEL IN THE CAR CONTAINED 40% ALCOHOL AND IS THE CAUSE OF FAILURE OF THE THREE PREVIOUS FUEL PUMPS. MOREOVER, I WAS RESPONSIBLE FOR VOIDING THE WARRANTY OF THE PREVIOUS FUEL PUMPS AND NOW FINANCIALLY RESPONSIBLE FOR $1400 IN NEW CHARGES, INCLUDING THE COST OF A FOURTH FUEL PUMP. I LAST PURCHASED 12.63 GALLONS PREMIUM FUEL ON JUNE 26 WITHOUT ISSUE UNTIL JULY 17. *TR

ELECTRONIC FUEL PUMP CRACKS AND LEAKS FUEL ONTO LIVE ELECTRICAL CONNECTIONS TO FUEL PUMP LOCATED UNDER REAR PASSENGER SEAT. BY TIME YOU SMELL GAS INSIDE OF VEHICLE, GAS HAS PUDDLED ABOUT 1/4" DEEP ON THE ELECTRICAL CONNECTIONS POWERING THE FUEL PUMP. DEALER WARNS NOT TO DRIVE DUE TO RISK OF FIRE OR EXPLOSION. HAPPENED FIRST IN MAY OF 2007 AT 64,000 MILES. VW UNCONCERNED AND DID NOT REMEDY. HAPPENED AGAIN MAY OF 2009 AT 96,000 MILES. VW AGAIN UNCONCERNED. I ASSUME IT MUST BE SAFE TO DRIVE. DOES SOMEBODY HAVE TO DIE FIRST? *TR

NOISE STARTED, A HIGH-PITCHED WHINING. TOOK MY CAR TO MY MECHANIC AND IT IS THE SAME DARNED THING IT WAS IN FEBRUARY, 2008! THE FUEL PUMP. HE TELLS ME HE CHANGES THEM OUT ON VW'S ALL THE TIME. THE PART IS A VW DEALER PART ONLY AND IT'S DEFECTIVE, JUST LIKE THE 2003 VW PASSAT PUMPS WERE! *TR

MY CAR LITERALLY TURNED OFF WHEN I WAS TURNING A CORNER...LUCKILY I WASN'T ON THE FREEWAY. THE BATTERY WAS FINE. IT TURNED OUT TO BE THE LIFT FUEL PUMP FOR MY 2004.5 VOLKSWAGEN JETTA TDI PD BEW. I WAS CHARGED $400 BY A LOCAL VW MECHANIC. THE DEALERSHIP WOULD CHARGE $800. IF I HAD IT DONE IN TDI CLUB, IT WOULD BE AROUND $200. *TR

CAR WAS SMELLING OF GAS. LOOKED UNDER CAR AND FOUND GAS LEAKING FROM UNDERNEATH CAR. TOOK IT TO CAR DEALERSHIP AND THEY SAID THE FUEL PUMP HAD TWO SMALL PIN HOLES IN IT. REPLACED IT AT NO COST. *TR

THE LATEST INCIDENT WITH THIS 2004 VW JETTA IS ONE IN WHICH EVERYTHING ELECTRIC STOPS WORKING. NO A/C, NOT LIGHTS, NO BLINKERS, NO WINDOWS, NO HORN - AND THERE IS A SMELL OF SMOKE IN THE CAR. THIS FIRST HAPPENED IN JANUARY/08 AND THE DEALERSHIP SAID IT WAS WIRING. NOW IT HAPPENED AGAIN! OCCURS JUST WHILE DRIVING ALONG. CAR SMELLS LIKE SMOKE AND EVERYTHING STOPS WORKING. I GET THE RUNAROUND FROM THE DEALER, VISTA VW IN POMPANO BEACH, FL. THEY ALWAYS SEEM TO FIND SOMETHING WRONG WITH THE CAR NOW THAT IS NOT UNDER WARRANTY. PLEASE INVESTIGATE THIS - THERE IS SOMETHING WRONG WITH THESE JETTA'S! I HAVE FOUND 100'S OF COMPLAINTS ON CONSUMER SITES ABOUT THIS CAR. I AM TIRED OF PAYING MY HARD EARNED DOLLARS TO THE DEALER WHEN THIS IS AN ISSUE WITH THE MANUFACTURER OF THIS CAR. I ADVISED THE DEALER OF THIS WHEN I TOOK IT IN IN JANUARY; HIS RESPONSE WAS, TOO BAD, YOU DO NOT QUALIFY FOR THE CAR LEMON LAW SINCE THE CAR IS OUT OF WARRANT AND PURCHASED IT IN DEC/05. PLEASE DO SOMETHING FOR US CONSUMERS THAT ARE TIRED OF BEING MANIPULATED AND OVERCHARGED FOR ISSUES THAT SHOULD BE THE RESPONSIBILITY OF THE AUTO MANUFACTURER. PLEASE LET ME KNOW IF THERE IS ANYONE OTHER AGENCY I CAN CONTACT. I WILL NOT GIVE UP ON THIS AND HOPE YOU CAN ASSIST ME. THANK YOU. *TR

CAR STARTED NORMALLY, PULLED TO ENTRANCE TO ROAD, ENGINE STALLED SUDDENLY AND WOULD NOT RESTART. AFTER SEVERAL ATTEMPTS, ENGINE STARTED AND RAN NORMALLY. AFTER 10 MILES, STOPPED AT CONVENIENCE STORE. ENGINE STARTED NORMALLY AND ABRUPTLY STALLED WHILE ENTERING INTERSTATE HIGHWAY. AGAIN DIFFICULT TO RESTART, BUT FINALLY DID. RAN FINE FOR NEXT 45 MILES. A THIRD STALL HAPPENED THE NEXT MORNING. ALL THREE STALLS HAPPENED WITHIN 30 TO 90 SECONDS OF STARTUP. SUSPECT THAT THE IN-TANK "LIFT PUMP" WAS FAILING INTERMITTENTLY. THERE WOULD BE ENOUGH FUEL IN THE FILTER TO RUN ENGINE FOR A WHILE WITHOUT THE LIFT PUMP FUNCTIONING. THE LIFT PUMP HAS NOW BEEN REPLACED. *TR

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA. THE CONTACT STATED THAT WHILE HAVING THE VEHICLE SERVICED BY AN INDEPENDENT MECHANIC, THE CONTACT WAS INFORMED THAT THE VEHICLE WAS LEAKING FUEL INTO THE ENGINE COMPARTMENT. AN INDEPENDENT MECHANIC STATED THAT THE TANDEM PUMP BECAME INOPERABLE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 220,000. UPDATED 10/9/15 *LN THE CONSUMER BELIEVED HIS VEHICLE SHOULD HAVE BEEN INCLUDED IN THE FUEL SYSTEM RECALL. HOWEVER, HIS PRODUCTION YEAR WAS NOT INCLUDED. UPDATED 04/11/16.*JB *CN

TL* THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA. THE CONTACT STATED THAT THE FUEL PUMP WAS LEAKING AND CAUSING THE VEHICLE TO BECOME RESISTANT TO STARTING. THE CONTACT REFERENCED NHTSA CAMPAIGN ID NUMBER: 04V586000 (FUEL SYSTEM, DIESEL). THE CONTACT CALLED THE DEALER REGARDING THE RECALL AND THE DEALER INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE CONTACT WAS CONCERNED THAT THE VEHICLE COULD POTENTIALLY CAUSE A FIRE. THE FAILURE MILEAGE WAS 90,500. UPDATED 06/24/11 *BF THE CONSUMER DISPUTED THE DEALERS RESPONSE SINCE HE BELEIVED HIS VIN FELL IN THE PUBLISHED VIN RANGE OF THE RECALL DESCRIBED IN VW'S DOCUMENTATION PROVIDED TO NHTSA. UPDATED 06/30/11

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA. THE CONTACT NOTICED A LEAK AND SMELLED FUMES IN THE PASSENGER COMPARTMENT. THE DEALER STATED THAT THE FAILURE WAS CAUSED BY THE DIESEL FUEL SYSTEM. SHE FOUND A RECALL ON THE EXACT SAME FAILURE ON THE MANUFACTURER'S WEBSITE; HOWEVER, THE DEALER STATED THAT HER VIN WAS NOT INCLUDED AND REFUSED TO MAKE A REPAIR. THE FAILURE MILEAGE WAS 82,000 AND CURRENT MILEAGE WAS 84,000. UPDATE 04-02-08 *BF

ON 2/4/08 AT 7:30 A.M. I GOT IN MY 2004 VW JETTA WAGON AND ALTHOUGH IT WAS TURNING OVER, IT WOULD NOT START AT ALL. IT HAD OPERATED PERFECTLY THE NIGHT BEFORE. I HAD IT TOWED TO OUR MECHANIC THAT WE HAVE USED FOR NEARLY 10 YEARS. THE MECHANIC CALLED & SAID IT WAS THE IN-TANK FUEL PUMP AND THE ASSOCIATED COMPONENT. HE STATED HE HAS HAD A LOT OF THESE BROUGHT TO HIM IN VW'S AND THIS IS A COMMON FAILURE. HE STATED WHEN HE CALLED ABOUT THE PART THEY SAID, "OH YES, WE HAVE THAT PART IN STOCK NO PROBLEM." HE REPLACED THE FUEL PUMP ON 2/6/08 AND AGAIN STATED THIS SEEMED TO BE A COMMON FAILURE IN VW'S. HE ALSO STATED THE MILEAGE ON OUR 2004 VW JETTA WAGON WAS NOT SUFFICIENT TO WARRANT SUCH A FAILURE UNLESS THERE WAS A PROBLEM WITH THE MECHANISM AND SUGGESTED I REPORT THE FAILURE. THE REPAIR COST WAS $697.59 TOTAL. *TR

TL*THE CONTACT OWNS A 2004 VOLKSWAGEN JETTA TDI. THE CONTACT SMELLED DIESEL FUEL INSIDE THE CAB AND FOUND DIESEL FUEL LEAKING UNDER THE FUEL PUMP. THE DEALER HAD NOT DIAGNOSED THE FAILURE. HOWEVER, RECALL #04V586000 WAS RELATED TO THIS FAILURE. THE CURRENT AND FAILURE MILEAGE WERE 70,000. *AK