Questions and Answers

Volkswagen New Beetle Fuel Smells Q. I have a 2002 Volkswagen New Beetle with a 5 speed transmission. It currently has 19,000 miles on it. I purchased it new in July, 2002. Since it's purchase, I occasionally noticed a gas smell when passing by the rear of the car where the gas tank was. I assumed that maybe I had spilled some when refueling and quite frankly, didn't pay much attention to it.

The gas smell has become noticeably worse and I have taken the car to the dealer on several occasions. The first trip, they decided that the Engine Control Module needed to be replaced, so they replaced it twice only to be told by Volkswagen that they had misread the output indicating a problem and there really wasn't anything wrong with the ECM.

They supposedly tested the fuel system, smoke test, and did not find any leaks. The second time it went back, they replaced the gas cap. The "Check Engine Light" light has never come on indicating a problem. The smell is intermittent, but it is most noticeable after refueling and when the tank is ¾ plus full. The smell is coming from the wheel well of the rear passenger side, it does not smell in the area where you refuel.

On the previous trips to the dealer, the smell wasn't there, so the work they did was based on my word about the smell. Finally, this week, I drove to the dealer and they did smell the gas fumes, so at least they believe me now!!!! I am scheduled to take it back next week. Any suggestions on what they might look for would be helpful.

Thanks,
Martha

A. I never doubted the word of a customer when they say there is a problem that isn't apparent when they brought it in. Well, there was this one guy who came in with his head covered in aluminum foil and a silver suit on saying he had to get to Andromeda and his space/time drive was acting up. I gave him a lollipop and told him it was an fuel integrator unit and to put it in the fuel cell and it would clear up the problem.

There is a revised troubleshooting procedure for testing the Evaporative Emissions (EVAP) System. I have used it myself and it is very effective IF followed step by step.

Group: 20
Number: 03-02
Date: May 21, 2003

Subject:
Evaporative Emissions (EVAP) System, Checking Using the KLI 9210 EVAP System Tester

Model(s):
All with Leak Detection Pump (LDP) 1997 through 2003 (see Eng. Code Application Table)

Also, the possibility of an actual fuel leak can not be discounted. A check of the fuel lines and fuel pumps may reveal the source of the leak.