04 Passat anoth no start after FF change

[cudabnu]

Changed and primed the new FF(meyle), once it starts it will run for awhile then die, If the Tee is taken off I hear a suction sound and the level is below the tee inlet, if I fill more fuel into the FF and put the tee back on, crank for awhile, it fires back up and runs for awhile again before the same thing happens, I change the stock clamps and installed a new tee.

I do have a vag-com, but have not used it in years since my 97 passat TDI so I don't know what to look for.
(this is my brothers 04 that we are working on, but it has me stumped)

The inlet on the original Tee did break in the line, is it possible that some plastic piece could have gone down the hose? If holding the Tee and flow is right to left, it would be the right side, I could've swore we got everything pulled out, but not sure what else may be causing this.

 

[cudabnu]

just took it on a 15 mile trip on the freeway, wanted to die once, but if I floored it, then it would catch itself then keep running. However did notice that when you really give it gas at spped to get upto about 70-80mph, then it starts to stumble a little, but when you left off to about 60 it seems ok.

 

[DanG144]

Please forgive my ignorance; I have had little experience with Passat's, and do not have a manual for them.

This scenario sounds as if it is a PD engine with a failed fuel pump, and 2004 would be about the right time for the Passat to get a PD style engine.

So, do you have a PD engine, or a rotary injection pump?

 

[s4phillips]

Snip...This scenario sounds as if it is a PD engine with a failed fuel pump, and 2004 would be about the right time for the Passat to get a PD style engine.

So, do you have a PD engine, or a rotary injection pump?

Yes, this is a PD style engine with lift pump.

 

[MOGolf]

from reading this it leads to the question of your procedure for fuel filter change.

Did you remove fuel lines from the T, and thus break the T? Or did it just break pulling the T out of the filter (with lines attached)?

Your description is one of the break being on the return to tank side of the T. This won't cause a no start, nor stumble.

Are there new VW (black and blue) o-rings on the T? or two aftermarket black o-rings? Are they damaged from the install/remove/install/remove...?

Did you install the T in the correct direction? Well you pretty much have to to get the clip in place.

Do you have the blue marked lines on the T, and white marked lines on the filter?

Is there any sign of fuel leaking from the fitting on the bottom of the filter?

 

[cudabnu]

OLD Tee broke in the fuel line when trying to remove it to replace, we had to squeeze the line to brake the part left inside the line to remove it.

Had 2 black O-rings on the replacement, we ended up using the old O-rings and that appears to have worked better.

only 1 way to put the Tee in and be able to use the clip, we even removed the Tee again to make sure there was no blockage, and removed the pump return line and blew it out just in case. We let it sit overnight and it fired right up in the morning, so my brother drove it back to Arizona. He did say at full throttle trying to get to speed it still would studder, but when he was at cruising speed all was good, but as soon as you gave it more than 60% throttle it would studder.

After reading alot my next guess would be the pump. I'm in the aircooled VW restoration parts biz, so I have connections for all the parts, but still don't like the trial and error way of fixing a car, but when we pulled off one of the lines and cycled the key, a good amount of fuel was comming out.

Blue marked lines are both on the return side, and both white marked lines are on the inlet side.

The only other things we did were to replace the valve cover because the gasket was leaking , the left driveshaft and both trans mounts, but I would think any of those would effect what he is describing.

 

[heykw]

my guess is that you have an air leak at the T fitting

 

[DanG144]

On a car with a lift pump, an air leak at the tee usually squirts fuel.

 

[cudabnu]

Under pressure while the car is running there are no fuel leaks at the fitting, that was the first thing we were looking for, we thought if air could get in, then fuel would surely get out.