Hi, Michael,
Headscratcher!
I disagree. Don't believe the "leak" is consistent with the issues you've been describing (spewing fuel vapor and fuel when gas cap opened) -- with no codes (MIL).
Difficult to build pressure with a leak, especially when fuel vapor whooshes out of the filler pipe with some liquid fuel.
Also, after reading Brian's documentation, I?understand your van uses pressure to test the evap system.
No codes means the evap monitor (that runs on every key-on engine-on cycle) completed successfully each cycle by monitoring pressure drop in the system.
(A leak would have to be smaller than 0.002 inches?(mandated for vehicles starting in 2000) so the evap monitor would pass the evap test.)
The "leak" on the fuel tank may be legit, but it would be surprising if it's the root cause of your van's symptoms.
Did the tech use a scope and dealer scan tool with a pressure transducer (or an upper-end scan tool) when using the smoke?
Maybe a balloon on the canister vent pipe?
Were there any pending codes set?
Am more inclined to believe there's a? physical issue affecting the evap system or even buggy MAF, ECT, and O2 sensors.
Whatever it turns out be be there were no related TSB's by VW re the issue you've described (only anecdotal info from other van owners).
Good luck, sir! :-)
