Malfunctioning High Pressure Fuel Pump. Client Uploaded videos of condition and shared videos with me. Car started up at dealer fine. Drove into shop, computer scan, no codes stored. Uploaded videos and computer scan to VTA. As per VTA consultant’s recommendations, removed intake pipe from airbox/grille, and placed in trunk under carpet, in stowage compartment. Previous repair order, updated intercooler kit was ordered, parts block, not here yet to install. Releasing car back to client.
Installed updated intercooler kit. Note: when removing charge air cooler discharge hose, I found a good amount of condensation, which poured out onto shop floor. Cleaned related hoses prior to reinstall as per technical bullet. After installation of new cooler components, ran car in shop for 10 minutes. Computer scan using self diag to quick check work performed, no codes. Roadtested, when driving out of shop on dealer’s driveway, car stalled abruptly. Would not restart. Towed back into bay using golf cart and tow strap. Inspected work performed for updated intercooler. No malfunctions detected why car would stall. Removed boost pipes, car will not start. Inspected for blockage in intake using borescope, none found. Tested operation of fuel pump appear ok. Inspected fuel filter, filter is full. Inspected high pressure pump for metal flake, none found, screen and bowl are clean. Contacted VTA, as per consultants recommendations, removed 4 glow plugs and inspect/check for fuel atomization. Removed 4 glow plugs, found to be dry. With aid of another technician, cranked car, no fuel came out of glow plug ports. Cracked fuel line to rail and found fuel spray. Tested fuel injectors for power and ground, noid light does not blink when car is cranking. Fuel pressure tested too low on fuel rail to turn on injectors. As per xxxx from VW, tested fuel tank pressure at pump, tested .47bar, tested ok. Tested fuel pressure at aux. pump under hood, tested 57psi/3.9bar, tested good. Tested fuel rail pressure read data block 1, fuel rail pressured tested 80bar. Because ecm needs to see minimum of 250 bar, the injection is not started by ecm. Removed fuel filter and inspected housing, appears very clean, no metal flake. Xxxx released high pressure fuel pump, and I ordered new bolts and fuel line for replacement of the high pressure pump. Replaced high pressure pump using new hardware and fuel feed line (this connects fuel pump to fuel rail). After replacement, purged fuel system using basic settings 35 three times. Car started up fine and test drove 1 mile. Car to be driven overnight. Roadtested overnight, total of 40 miles. Car drove very well. Computer scan in morning, no codes stored. Releasing car back to client.
Parts:
- 1 03L-130-321 Pipe
- 2 N-107-145-01 Screw
- 3 N-911-8030-01 Bolt
- 1 MSX1075 Material
- 1 03L-130-851-AX Pump