2005 Volkswagen Passat Fuel System Problems

Approximately back in June 2021, I noticed the smell of diesel fuel coming from the rear of the vehicle, noticed hours and days after the vehicle was parked. The smell is partially present from the interior in the trunk area, but mostly evident when standing near the vicinity of the fuel tank when outside of the vehicle. After driving the vehicle, I occasionally notice small puddles of diesel fuel (as evidenced by the oily texture and smell) coming from below the fuel tank. On occasion, I can also spot actual drops of diesel fuel on the lower car frame from underneath the vicinity of the fuel pump. These puddles usually evaporate or dissipate within an hour or two after appearing. Given that these puddles only appear after driving, and not after extended periods of the vehicle sitting in my driveway, I suspect that there is a leak in the fuel pump. A more recent VCDS scan of the ECU on 29 October 2021 results in a Gateway and Dashboard fault code in the fuel pump, which may or may not be related to the fuel pump leak. The fault code is 00476, relating to the fuel pump control module, indicating "no communication"; the code is marked as "static". This fault code may not be related to the underlying fuel leak, but since it relates to the fuel pump, I thought it would be worth mentioning. Last but not least, a recall notice was issued on the diesel fuel pump assembly that impacted the make and model of my vehicle, issued in December 2004, just a couple months before the manufacture date of my vehicle (February 2005). As a result of this cut-off date, my vehicle's VIN number was not included in the official recall notice (NHTSA # 04V586000); see: https://www.vindecoderz.com/EN/Volkswagen/PASSAT/2005/fuel%20system,%20diesel/recall/04V586000. Due to the commonality of my vehicle's components with the 2004 Volkswagen Passat TDI and close temporal proximity to the recall notice, I highly suspect that my vehicle's fuel pump is impacted by this latent recall.

2005 VW PASSAT WAGON, 4 MOTION, 128,000 MILES, W/ INTENSE ODOR OF GAS IN THE CABIN OF THE CAR; AFTER DRIVING 15 MILES TO WORK, I DEVELOPED A HEADACHE AND ILLNESS SYMPTOMS WHICH LASTED FOR 2 -3 DAYS. CAR WAS TOWED TO LOCAL VW DEALER. I CONTACTED VW OF AMERICA, WHO AGREED TO DIAGNOSTICS. LARGE FUEL TANK FRACTURE CONFIRMED. AFTER MANY DISCUSSIONS WITH CUSTOMER SERVICE AT VW OF AMERICA, THEY REFUSED TO COVER REPAIRS, THOUGH THEY DID CONFIRM THAT THIS FAILURE WAS THE SAME FAILURE WHICH HAD LED TO A PREVIOUS RECALL CAMPAIGN OF THE FUEL TANK/SYSTEM, BUT SINCE MY CAR HAD ALREADY BEEN REPAIRED (2015) W/ A SUPERSEDED PART AND IT WAS PAST THE 12 MONTH WARRANTY PERIOD, I DID NOT QUALIFY, NOR WOULD THEY OFFER GOODWILL SERVICE. THEY DID ACKNOWLEDGE, HOWEVER, THAT IT WAS A SERIOUS SAFETY ISSUE AND THE CAR SHOULD NOT BE DRIVEN. I VERBALIZED IN MANY CONVERSATIONS THE SAFETY CONCERN THIS POSED NOT ONLY FOR MYSELF AND MY FAMILY BUT FOR OTHERS WHO HAD THE POTENTIAL TO FACE THE SAME SITUATION. I ASKED WHAT PROCESS VW HAD FOR DOCUMENTING AND REPORTING THESE CONSUMER SAFETY CONCERNS OF SUCH A SERIOUS NATURE AND WAS TOLD THAT IT IS REPORTED INTERNALLY BUT THERE WAS NO ONE I COULD SPEAK WITH TO DISCUSS FURTHER ANY ASPECT OF THE CASE, NOR WOULD VW REPORT THIS TO NHTSA, AS IT HAD BEEN REPORTED UNDER THE PREVIOUS CAMPAIGN. I FEEL VERY STRONGLY THAT THIS REPEATED FAILURE SHOULD BE REPORTED AND THEREFORE AM DOCUMENTING HERE. THE CAR HAS NOW BEEN TOWED TO MY HOME WHERE IT SITS IN MY DRIVEWAY D/T THE FUMES BEING AT A TOXIC LEVEL WHEN THE CAR IS IN THE CLOSED GARAGE. THE CABIN OF THE CAR ALSO REMAINS WITH A HIGH LEVEL OF GAS FUMES. I HAVE ASKED FOR WRITTEN DOCUMENTATION FROM VW OF AMERICA RELATED TO MY CASE, BUT AS OF YET HAVE NOT BEEN PROVIDED WITH SUCH.

MY 2005 PASSAT HAS DEVELOPED A FUEL LEAK UNDER THE TANK. MY VEHICLE LOOKS LIKE NEW AND ONLY HAS 72000 MILES ON IT. THIS LEAK/SMELL OCCURS AFTER WHEN THE CAR IS MOVING AS WELL AS WHEN THE CAR IS SITTING IN THE DRIVEWAY. SEEMS VERY DANGEROUS TO ME AND I'VE READ MANY COMPLAINTS DESCRIBING THIS EXACT SCENARIO. WHY IS VW NOT FORCED TO RECALL AND INSPECT FOR THIS SITUATION.

I COMPLETELY FILLED THE FUEL TANK OF MY CAR IN THE MORNING ON 4/22/2019. I THEN DROVE HOME AND PARKED THE CAR IN MY DRIVEWAY (SO IT WAS STATIONARY AT THIS TIME). THAT AFTERNOON I SMELLED A STRONG ODOR OF GASOLINE AND SAW A PUDDLE ON THE GROUND UNDERNEATH THE CAR BY THE DRIVER'S SIDE REAR WHEEL. I THOUGHT THAT MAYBE I OVERFILLED THE FUEL TANK SO I WAITED TO SEE IF THE ISSUE WOULD GO AWAY AFTER I DROVE A BIT. ON 4/23/2019 I STILL SMELLED GASOLINE AND SAW A PUDDLE UNDER THE CAR AFTER PARKING. I DETERMINED THE FUEL WAS ONLY LEAKING WHILE THE CAR WAS IN MOTION AND IT BECAME APPARENT THERE WAS A LARGER ISSUE. ON 4/24/2019 I TOOK THE CAR TO A MECHANIC TO DIAGNOSIS WHERE THE LEAK WAS COMING FROM. THE MECHANIC COULD SMELL GAS AND FOUND FUEL RESIDUE, BUT NOTHING FRESH. IT WAS RECOMMENDED THAT I FILL THE FUEL TANK AND RETURN TO SEE IF A LEAK COULD BE FOUND. SO ON 4/26/2019 I COMPLETELY FILLED THE FUEL TANK AND RETURNED TO THE MECHANIC. AND THEY FOUND THAT FUEL IS LEAKING FROM THE SEAM OF THE FUEL TANK.

TL* THE CONTACT OWNS A 2005 VOLKSWAGEN PASSAT. UPON STARTING THE VEHICLE OR DRIVING VARIOUS SPEEDS, THE CONTACT NOTICED A FUEL ODOR INSIDE THE VEHICLE. IN ADDITION, THE CHECK ENGINE AND ANTI-SLIP REGULATOR WARNING INDICATORS ILLUMINATED. THE CONTACT CALLED MOMENTUM VOLKSWAGEN OF CLEAR LAKE AT (844) 894-5461 (15100 GULF FWY, HOUSTON, TX 77034) AND WAS INFORMED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 08V156000 (FUEL SYSTEM, GASOLINE). THE FAILURE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 91,628.

DRIVING HOME FROM WORK AND SMELL GAS COMEING FROM VENT INSIDE CAB NEXT DAY DROVE IT AGAIN AND STILL SMELL GAS EVEN ON OUTSIDE OF DRIVERSIDE. *TR

THAT THE CONNECTION AT THE FUEL TANK IS DAMAGED CAUSES THE FUEL LEAK. THIS IS RELATED TO THE OLD RECALL: NHTSA CAMPAIGN ID NUMBER :08V156000 *TR

I WAS DRIVING ACROSS CONNECTICUT ON FRIDAY JUNE 27 2014 ON I-84 (DANBURY TO MASS PIKE), TRAVELING FROM PHILADELPHIA TO BOSTON. AFTER PASSING THROUGH HARTFORD THE ROAD EXPANDS FROM 2 -3 LANES TO 8, I WAS IN LANE 4. THE ROAD WAS GOING TO SPLIT GOING 84 EAST AND 383 SE. 84 WAS STILL 8 LANES WHEN MY CAR COMPLETELY DIED - NO GAS WAS GETTING TO THE ENGINE. I HAD SEMI TRACTOR TRAILER VERY CLOSE BEHIND ME, THE TIME WAS 5:30 - RUSH HOUR, EVERYONE WAS SPEEDING, AND I WAS SHUT DOWN IN LANE 4. AT THIS POINT, THANKFULLY AND MIRACULOUSLY, THE 2 HIGHWAYS SPLIT AND IT WAS ALL I COULD DO BUT FALL INTO THE NEWLY CREATED BREAKDOWN LANE; OTHERWISE I DON'T SEE HOW I COULD HAVE WALKED AWAY FROM THE ROAD. THERE WAS NO, NONE, NO WARNING THAT THE CAR WAS GOING TO DIE, NO LIGHTS, NO SHAKING, NO ALARM. I CALLED THE STATE POLICE TO GET ME OFF THE HIGHWAY. AS IT WAS FRIDAY EVENING, AAA COULD ONLY TOW ME TO A PEP BOYS AND AS IT WAS 7 PM BY THIS TIME, I HAD TO SPEND THE NIGHT IN A RESIDENCE 6 IN MANCHESTER CN. PEP BOYS LOOKED AT THE CAR THE NEXT DAY AND DETERMINED THAT NO FUEL WAS GETTING TO THE ENGINE; I WOULD NEED A NEW FUEL PUMP. ALSO, FOR NO OTHER REASON THAT IT WAS INTERESTING, APPARENTLY A 2004 ALL-WHEEL DRIVE PUMP HAD BEEN PUT ON MY (NEW) 2005 FRONT-WHEEL DRIVE CAR. I AM TOLD THIS IS NOT UNUSUAL. THEY EVENTUALLY FOUND A PUMP AND INSTALLED IT, I LEFT FOR MAINE AROUND 1 PM THAT DAY. I HAD MY CAR IN MY LOCAL SHOP BEFORE LEAVING ON THIS TRIP, AS IS ALWAYS DONE, AND WAS DEEMED SAFE TO DRIVE. I HAVE SINCE CALL VW AND THEY SAY THAT THEY HAVE NO REAL EXPLANATION FOR THE PUMP DYING OTHER THAN THIS HAPPENS. I APPRECIATE THAT EQUIPMENT NEEDS TO BE REPLACED AND CAR PARTS MAINTAINED. IT IS OUTRAGEOUS THAT NOT TO HAVE PROVISION TO GIVE WARNING TO YOUR CAR ABOUT TO GO INTO COMPLETE FAILURE IS ACCEPTABLE BY ANYONE. HOW MANY PEOPLE HAVE TO BE PUT IN DANGER BEFORE THIS CHANGES? *TR

MY 2005 PASSAT IS LEAKING GAS, LOCATION IS CLOSE TO THE REAR PASSENGER SIDE. I CALLED LOCAL VW DEALER (WHERE I PURCHASED CAR FROM ) ALONG WITH VW 800 NUMBER- BOTH TOLD ME THERE WAS NO RECALL. I TOOK THE VEHICLE TO MY LOCAL REPAIR PLACE WOODYS IN ANKENY, IOWA. THE MECHANIC CALLED ME BACK TO TELL ME THAT HE DID BELIEVE THERE WAS A RECALL 26E5-R5. I CALLED BACK VW AND HE TOLD ME THAT INDEED THERE WAS A PRIOR RECALL HOWEVER THE MECHANICS FIXED THE CAR PRIOR AND WOULD NOT FIX IT AGAIN. HE TOLD ME THAT I NEED TO HAVE THE CAR TOWED TO THE LOCAL VW MECHANIC, PAY FOR THE TOW, PAY FOR THE DIAGNOSTIC SCREENING TO DETERMINE IF THERE IS A TRUE GAS LEAK SIMILAR TO THE ONE THAT WAS RECALLED/FIXED, THEN VW WOULD POSSIBLY CONSIDER COVERING THE CHARGES. I'M LEFT PAYING FOR 2 TOWS NOW (ONE TO THE PLACE ITS AT SINCE THEY TOLD ME IN THE FIRST PLACE IT WASN'T COVERED) AND THEN A TOW TO VW, PLUS THE DIAGNOSTIC APPOINTMENT, AND POSSIBLY THE ENTIRE COST TO FIX IT, IF VW DECIDES THEY DON'T WANT TO COVER THE COST AGAIN. THERE WAS A RECALL, THE RECALL OBVIOUSLY WAS SUPPOSED TO BE FIXED AND THEY DID A POOR JOB, MY CAR IS LEAKING FUEL OUT OF IT (RAW FUEL) AND SMELLS HORRIBLE, AND THEY WANT ME TO 'CHECK' TO SEE IF THERE IS AN ISSUE AND POSSIBLY PAY TO FIX IT. THIS DOESN'T SEEM RIGHT. *TR

TL* THE CONTACT OWNS A 2005 VOLKSWAGEN PASSAT. THE VEHICLE WAS INCLUDED IN THE RECALL UNDER NHTSA CAMPAIGN ID NUMBER: 08V156000 (FUEL SYSTEM, GASOLINE:DELIVERY). AFTER THE RECALL REPAIR WAS PERFORMED THE CONTACT NOTICED A SMELL OF PLASTIC BURNING AND A FUEL LEAK. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THE VEHICLE WAS REPAIRED UNDER THE RECALL PREVIOUSLY AND ANY FURTHER REPAIRS WOULD NOT BE FREE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 58,000.

WOKE UP AT 4 AM WITH STRONG SMELL OF GASOLINE FUMES IN MY HOME. WENT TO THE GARAGE AND MY PASSAT HAD A PUDDLE OF GASOLINE BELOW IT ON THE FLOOR. MOVED THE CAR OUT OF GARAGE AND AIRED OUT THE GARAGE/HOUSE. GAS WATER HEATER WAS ALSO IN THE GARAGE. TOOK THE CAR TO DEALER. SERVICE MANAGER STATED THE FUEL TANK WAS SPLITING AT THE SEAMS. HE SAID THAT HE HAS SEEN SIX OF THESE IN BOISE, ID THIS YEAR. HE SAID THAT VOLKSWAGEN HAS NOT ISSUED A RECALL ON THIS FUEL TANK. HE SAID IT WILL COST ME $2,500.00 TO HAVE THIS FUEL TANK REPLACED. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT

2005 VOLKSWAGEN PASSAT. CONSUMER STATES GAS SPRAYING OUT OF THE FUEL LINE AND DRIPPING ON THE HOT EXHAUST *TGW THE CONSUMER HAD THE VEHICLE TOWED TO THE DEALER. THE CONSUMER DISCOVERED A RECALL HAD BEEN ISSUED FOR THE PROBLEM. HOWEVER, THE DEALER INFORMED THE CONSUMER HIS VEHICLE IDENTIFICATION NUMBER WAS NOT A PART OF THE RECALL AND HE WOULD BE RESPONSIBLE FOR THE REPAIRS. THE DEALER STATED THE HEAT SHIELD DID NOT CAUSE THE FRACTURE. THE DEALER PULLED THE RECALL UP AND STATED IT LOOKED AS THOUGH THE CONSUMERS VEHICLE SHOULD HAVE BEEN COVERED UNDER THE RECALL, BUT THERE WAS NOTHING THAT COULD BE DONE. *JB UPDATED 06/28/11

DRIVING MY 2005 VW PASSAT WAGON WITH 50K MILES. ENGINE DIED SUDDENLY WHILE DRIVING AND WAS ABLE TO PULL TO THE SIDE OF THE ROAD. NO WARNING LIGHTS OF ANY KIND APPEARED ON THE DASHBOARD. CAR WOULD NOT RESTART AND WAS TOWED TO THE VOLKSWAGEN DEALERSHIP. PROBLEM WAS STATED AS FAILURE OF THE FUEL PUMP AND REPLACEMENT WOULD RUN $550.00. THIS ITEM WAS RECALLED ON PREVIOUS MODEL YEARS BUT NOT ON THE 2005 1.8T ENGINES. I FEEL THAT THIS ITEM SHOULD NOT FAIL ON A LOW MILEAGE ENGINE. DEALER NOTATED THAT NUMEROUS OTHER VEHICLES HAVE BEEN SUFFERING FROM FAILING FUEL PUMPS AS THE SUMMER HEAT SETS IN. *TR

WHILE I WAS DRIVING HOME FROM WORK ON THE HIGHWAY MY 2005 PASSAT (1.8T) SUDDENLY SHUT OFF. FORTUNATELY, I WAS ABLE TO MOVE QUICKLY TO THE BREAK DOWN LANE TO GET OUT OF THE WAY OF THE CARS BEHIND ME. THE PASSAT WAS TOWED TO THE DEALER WHERE THEY DISCOVER THE FUEL PUMP HAD FAILED. SO THEN I PAID THE DEALER REPLACED THE FUEL PUMP, SINCE THERE ARE NO RECALLS FOR THE 2005 MODEL (ONLY 2003).

HELLO, I BOUGHT VW PASSAT WAGON GLS BRAND NEW FROM VW DEALER IN OHIO DURING JUNE,2005. THE CAR MALFUNCTION INDICATOR LAMP IS COMING ON THRICE SINCE I BOUGHT IT NEW. I ALREADY MADE COMPLAINTS ABOUT THIS DURING MY SERVICE VISIT. EVERY TIME THEY FIX IT AT A COST TO THE CUSTOMER.BUT I DO NO KNOW HOW SAFE TO DRIVE IN A HIGHWAY WITH THIS MIL COMES ON SUDDENLY.VW NEVER ADDRESS TO THIS UNTIL. YOUR ACTIONS ARE APPRECIATED. *TR THANKS, MOHAN RAJAMANI

I WAS DRIVING DOWN THE ROAD AND THE CAR STARTED CHUGGING AND DIED. THE DEALERSHIP TOLD ME THE FUEL PUMP FAILED AND A NEW PUMP AND FILTER WERE REPLACED. THERE HAS BEEN A RECALL ON THE FUEL PUMP FOR THE 2003 VW PASSAT BUT THE DEALERSHIP WON'T RECOGNIZE IT FOR THE 2005. *TR

TL*THE CONTACT OWNS A 2005 VOLKSWAGEN PASSAT. WHILE DRIVING 60 MPH, THE CONTACT NOTICED THAT THE FUEL INDICATOR WENT FROM HALF FULL TO EMPTY. HE PULLED OVER TO THE SIDE OF THE ROAD AND SMELLED GASOLINE. WITHIN SECONDS, THE VEHICLE CAUGHT FIRE. THE CONTACT MANAGED TO SAFELY EXIT THE VEHICLE. THE MANUFACTURER OFFERED HIM A SETTLEMENT OF $2,700 BECAUSE THE VEHICLE WAS NOT ADEQUATELY REPAIRED ACCORDING TO NHTSA CAMPAIGN ID NUMBER 08V156000 (FUEL SYSTEM, GASOLINE: DELIVERY). THE INSURANCE COMPANY STATED THAT THE VEHICLE WAS DESTROYED. FIRE REPORT NUMBER E58424 WAS FILED. THE CURRENT AND FAILURE MILEAGES WERE 102,000.

THE FAILURE IS WITH (1) THE BALANCE SHAFT OIL PUMP CHAIN DRIVE SYSTEM ON THE VW PASSAT 2.0 TDI DIESEL AUTOMOBILE. THE FAILURE HAS OCCURRED NUMEROUS TIME TO OTHER VW OWNERS AND PRESENT AN IMMINENT THREAT TO VEHICLE SAFETY SHOULD SUCH FAILURE OCCUR IN HEAVY TRAFFIC. (2) CERAMIC GLOW PLUGS FOR THE TDI DIESEL ENGINE HAVE A TENDENCY TO BREAK OFF AND CAUSE CATASTROPHIC DAMAGE TO A RUNNING ENGINE. BOTH DEFECTS HAVE BEEN RECOGNIZED BY VWOA AS EVIDENCED BY UPGRADES MADE TO THEIR EUROPEAN CUSTOMERS. HOWEVER VWOA IS TOTALLY IGNORING THE AMERICAN CUSTOMERS AND RESULTING IN EXORBITANT REPAIR PRICES. VW CONTINUES TO VIOLATE EPA RULE BY NOT RELEASING ECU REFLASH DATA TO NON VW SERVICE FACILITIES, HERE AGAIN CAPITALIZING ON A KNOWN DESIGN FLAW. LET IT BE KNOW THAT ONLY THE SYMPTOMS OF THESE IMPENDING FAILURES HAVE OCCURRED AT THIS POINT IN TIME. JUDGING FROM REPORTS OF OTHERS WHO HAVE SUFFERED ALREADY THIS VEHICLE IS IN IMMANENT DANGER. *TR

DIESEL FUEL FILL BACK PRESSURE OVERFLOW. 2005 VW PASSAT TDI. *TR

TL*THE CONTACT OWNS A 2005 VOLKSWAGEN PASSAT GLS TDI. THE ENGINE BEGAN TO RATTLE VIOLENTLY IMMEDIATELY AFTER THE VEHICLE WAS STARTED. THE NOISE SOUNDED LIKE MARBLES ROLLING AROUND IN THE ENGINE COMPARTMENT. THE NOISE WAS LOUDER DURING START UP AND WHILE DRIVING LOWER SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER FOR THE FAILURE WHO REPLACED THE GLOW PLUGS AND FUEL FILTERS; HOWEVER, THE FAILURE CONTINUED. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC AND WHO ADVISED HIM THAT THE BALANCE SHAFT ASSEMBLY NEEDED TO BE REPLACED WITH A REDESIGNED BALANCE SHAFT ASSEMBLY. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 30,000 AND THE CURRENT MILEAGE WAS 70,000.