Golf IV R32 :: Fuel Vapor Smell And Faulty Fuel Lever Sensor?


Apr 28, 2011

During recent trip to WITW 2011, I started smelling fuel vapor after stopping and getting out of the car. The smell was easily noticeable near right rear wheel which is obviously at the fuel filler door and neck.

Also, at one time the fuel level showed tank 3/4 full, but after filling it up I discovered that it was nearly empty with appx. 3 Gallons left. After filling the car back up to full, the fuel level went back up showing full, however the fuel vapor odor stayed the same on the way back home.

I have scanned the car and no codes.

Inspected under the car for fuel leaks and found none.

Removed access cover over fuel pump under rt rear seat and did not see any signs of leaks.

Removed rt quarter liner to visually inspect, but did not see anything unusual.

Which component could cause vapors to escape if faulty? R32 now has 31k on it.

I searched and read about possibly faulty fuel sending unit causing faulty fuel level reading, so I will be checking that next. However, no mention about fuel vapor problems.

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I thought this strange occurrence I am about to describe was maybe happening because of a faulty air-fuel oxygen sensor, that I knew was bad do to a code test that was done, when my check engine light came on. However, after changing the air-fuel oxygen sensor, doing a reset on my check engine light over the weekend, this same occurrence is happening, to spite the check engine light remaining off. Here is what is happening.

When I start and drive it to normal driving temperature then put the car in "Park" with nothing turned on, the car will shake the idle speed will move up and down until it will eventually kill.

Special Note: It does not always have a idle drop and kill the engine every time. If I turn the A/C on in "Park" it idles up higher and does not ever kill. Could it be a bad Idle Air Control Motor?

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#1 where would you reconnect this "whatever it is" line on carb or manifold
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Golf IV / Jetta IV :: Car Won't Crank / Start - Faulty Fuel Pump

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One day out of the blue the car would not crank or start. Checked and found that fuse #14 was blown and would blow the instant another fuse was inserted. Checked all the typical locations for wiring issues usually associated with the comfort module because it had all the symptoms of a faulty module (the power windows did not work and the fuel pump didn't pressurize the system when the driver door was opened, the alarm didn't set, automatic door locks also inoperable).

I checked the dome light, trunk hinges, rubber boot between doors and body and found nothing. Put a jumper wire into the neutral start relay and was able to crank the car. I then replaced clutch safety switch, neutral start relay and installed new (junkyard) comfort module and the car cranked up, started and everything was working normally again...for about 3 weeks. Then it did the exact same thing again. Fuse #14 was blown again and would blow the new fuse as soon as it touched the terminals in the fuse box.

I reinstalled the jumper wire in the start relay in order to be able to drive the car for the last week, and then last night out of the blue the car would crank, but not start. I turned the engine over several times and could hear the fuel pump pumping and even smell fuel, but no start. 3-5 minutes later after random tries to start, the car stumbles to life as if it wasn't getting fuel, and then drove 10 miles home with no issues. I returned the 'faulty' comfort module Monday and got another one but haven't installed it yet because I fear the same thing happening with this one as the other one.

Last night after I got the car home, I plugged in the comfort module and everything worked like it was supposed to. Can a faulty fuel pump damage the control module? I'm trying to get to the bottom of this and fix the problem and not the symptoms so I'm looking into anything that could potentially cause the problem.

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I have tried looking online to no avail except for one site selling ford part that has this line for almost 300 dollars. It is just a plastic line that leads to a metal line. Even the Ford Parts site doesn't carry it! That's insane! I was thinking of cutting the plastic line off where it meets the metal line and using rubber fuel line with hose clamps on the line and the plastic fitting on the tank. I just dont know if this will be good enough.

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Golf IV / Jetta IV :: Smell Of Oil And Fuel Burning

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My car smells of fuel in the exhaust and when checking the oil it is mixed. I have a cel and it says the o2 sensor is bad, not sure if a bad o2 would be causing all of this or not. The air filter is clean and I have done a few oil changes also. The oil is low also after so many miles but cannot seem to see any leaks.

Car also has over 200,000 miles. Is it necessary to change the gear oil in the vehicle?

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Today I went out to swap crank sensors but only tried for a little while and cant really get my hand up there. So, I disconnected the battery for a while, went back and connected it, and it started. Up until this point I have had the same 2 codes, over/under boost, but the car has always ran with them present. I scanned today and got a p1545 Throttle position sensor code...But only got that one time. Ive been messing around with disconnecting and reconnecting the battery and among one of these times, the EPC light came on and would not rev passed 1k rpm. turned it off, turned it on, and it was fine after that.

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I called VW customer care and they informed me this recall of the fuel tank ventilation valve was performed back in 2009 but the symptoms explained in the recall are exactly what I experienced. I verified the recall was done using my VIN number search on NHTSA's Safer Car site.

I can imagine that although the recall was done 7 years ago, it's still possible for this ventilation valve to fail. Especially because the recall states high ambient temps are a factor.

I have a legit VCDS but have not scanned it yet. Wife is off today so I took her car. I plan to go home, scan the car, and try to reproduce the issue before taking the fender liner out again. I have the means to do my own work but if I have to do something like drop the fuel tank I'll probably take it in.

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After checking and testing, I can confirm that the fuel vapor smell is coming from the charcoal canister and not anywhere else on the engine. The smell gets worse as the tank drains: Full Tank - Almost No Smell; Half Tank - Strong Smell; 1/4 Tank - Very Strong Smell.

Here is all that we have tried.-Replaced Fuel Cap (Genuine Ford)-Visually inspected the Evap Lines - Look Good-Visually inspected Fuel Line and Fuel Filter - Look Good-Checked the Fuel System for Leaks - None-Pressure Tested the Fuel System - No Leaks-Ran Multiple Smoke Tests on Evap System - No Leaks-Checked the Computer for Codes - No Codes-Replaced the Charcoal Vapor Canister (Genuine Ford)

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