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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old November 3rd, 2010, 14:51   #1
Join Date: Nov 2010
Location: pa
TDI(s): 02 TDI
Default 02 TDI Jetta Fuel Flow Problem

Ok time to ask for some help from the experts on here, you guys have seen or heard just about everything. I have an 02 TDI Jetta that will not run more than lets say 20 minutes, exactly when the fuel filter is emptied. I have replaced the fuel filter and same thing it will run aslong as trhe fuel filter has fuel then it will not refill the filter and stalls out for lack of fuel. I have replaced the injection pump about 5K miles ago along with new fuel injectors and nozzles. Any help here would be greatly appreciated.
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Old November 3rd, 2010, 14:53   #2
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Join Date: Dec 2001
Location: St Louis
Fuel Economy: fantastic

Put a sender unit/pickup module in. May be clogged up with crap. Sometimes you can clean them out.
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Old November 3rd, 2010, 15:06   #3
Join Date: Nov 2010
Location: pa
TDI(s): 02 TDI

Ok, I tried that already. There wasnt anything that would cause it to not suck fuel up to the filter in there. I did exactly the same symptoms when i cleaned the sending unit.
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Old November 3rd, 2010, 19:04   #4
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Join Date: Jan 2005
Location: Indianapolis IN

Did you drill out the check valve and grease the o rings? You have an air leak or something clogged. Thanks Steve
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Old November 3rd, 2010, 19:13   #5
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Join Date: Apr 2010
Location: Scotland
Fuel Economy: No idea

I know it's probably a stupid question, but is there any chance the send and return fuel pipes could have been put on the wrong way round?
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