All Stop

[davioil]

It was all going so well making good progress towards the Airport at high speed, Then without warning complete loss of power

pulled over onto the side of the road and crawled up the side of the Motorway with no response to throttle, dipped the clutch then the engine stopped and would not restart, all insruments read normal, electrics seemed normal, no CEL warning, lifted the bonnet, definately fuel related, both fuel lines from the filter to the pump full of fuel.
Desparate, loosened the unions to the injectors cranked the engine but no fuel came out.
One very expensive car recovery trip to home later, checked fuel filter clear, no blockage in tank, no VAG COM to check computer or Fuel pump. Car has 146,000 miles, engine turning over at approx 3,900 rpm when failure took place
My car was in good order prior to this, water oil levels checked, could it be a sensor failure, but then no CEL, checked the fuel cutoff valve on the pump which was OK, checking this threw a fault code! Help, Can anyone suggest what I do next

 

[Keiller]

I'll give this a bump. Maybe someone will have a good suggestion. Maybe a lost electrical connection? Could a blown fuse do this?

 

[MTjake]

For me it was a loose connection to the fuel shutoff valve, a zero $ fix. Searching here will provide some other possible sources for your trouble, like the 109 relay. If you have a '96 B4, you can possibly diagnose with the blink code sytem that uses the CEL.

 

[rdkern]

Sounds like Relay 109 - $20 and 5 minute fix. Fuel shutoff valve could also do it, and as noted by MTjake, it could just be the connection to it.

 

[davioil]

I agree this sounds more like electrical, checked for fuses but only ref to fuel is CIS pump, sounded like petrol to me.
I'll need to dig for wiring diagrams, (Audi 80 Series 4[94])
The main connections to the pump via a circular plug, any clues as to what the pins carry? or do I not even want to go there with the multimeter!

 

[davioil]

Hi all, Just had a call from the repair shop I gave the pump to check over, apparently there has been some contamination at some point in the system and a partical of this has caused the pump to jam & the vane! pump has sheared off the shaft? It can be repaired at a cost of approx £415.
The recommendation is I carefully clean all lines from the Fuel filter & change the filter.
Noting earlier posts during filter changes & avoiding running the pump when dry how do you go about filling a fuel filter with clean diesel?

 

[Diesel Dude]

I use a mini-vac pump to pull fuel through the filter. Install the filter and just hook up the inlet line, the thermostatic "T", and the mini-vac to the line going to the fuel injection pump. A few pumps and the filter is full and can be hooked back up. This process ensures that all the fuel going to the pump is filtered. Good luck.