cherrybomb
Active member
2003 Beetle 1.9L ALH./ AT. Bought car with 186K miles, discovered a diesel leak in lower chamber of IP. Changed all fluids & filters and worn items. Replaced both Seals (O-rings) and reset IQ using VCDS Lite. Car ran great all summer. Changed fueling stations from (Al to Tn) and car began to take several trys to start and run. This was intermittent and continued for a while. Bought & installed a new Thermo Tee, but still slow to start upon cranking. Finally discovered the leak by diesel dripping at base of pump head. Obviously there was no problem with the original Tee I replaced. Resealed the Pump Head successfully using procedure suggested in many articles. Used a 12v. pump inline to prime the IP and lines, then proceeded to crank engine over and it bled nicely and ran. During the IP Head repair, we used a Strap Wrench Tool to turn crank pulley to get pump stroke at Max. Discovered the Serpentine Damper bad so replaced it also. Alt. Pulley was good and belt appeared new so it was reinstalled. Working in are of filter, we considered we may have disturbed the lines,Tee & clip so we removed and lubed the o-ring and reinstalled. No reason to suspect the lines,(rubber or metal) damaged and had been good prior to the Pump Head repair. The car runs great after it starts and will sometimes take excessive cranking to start now. Must be the Tee. Would like to bypass the entire filter assembly and temporarily install a inline diesel compatible filter to isolate the problem. Plan to use 5/16 clear filter and a 5/16 barb (return line) to eliminate the existing filter. Generally are the plastic Tees cracked or just the o-rings damaged? Have another new Tee with o-rings on order, but would like to ID the reason for this problem. Suggestions welcomed.