Fitting PD lift pump into Mk3 - bit confused!

[ourkid]

Got my lift pump today from Ryan (thanks mate!).The old level sensor had a large arrow embossed on the top that pointed to the front of the car.When i removed it i compared side by side to the PD pump.I positioned it so that the float rods were in the same relative position but this puts the arrow in a different place.So should i rotate it so that the arrow points forward?.does it really matter?

Oh,i haven't connected it up yet so i don't know how it's going to read.I've heard that i may have to bend the float rod slightly,is this the case or should it be fit and forget?

 

[keaton]

i dont know the answer to your question, but before you install the pump you should do PD fuel pump mod, just to be on the safe side

http://forums.tdiclub.com/showthread.php?t=208968

 

[G60ING]

You need to swap the resistor board from the ahu fuel sender to the pd fuel sender. The mk4 sender's use a completely different resistance range then the mk3 and earlier cars.

 

[IndigoBlueWagon]

Lug_Nut got mine to work in my A3. I don't think he had any trouble with resistance and the gauge, the big deal was getting the float positioned correctly so the gauge read right. Trial and error: Empty the tank, set float, add 2 gallons, set float, add two more, and so on.

EDIT: I may be wrong about the resistance board. We did experiment with other ones to get the gauge to read right. But I thought we ended up back with the A4 one that came with the pump.

 

[G60ING]

I'll bet money on the board needing to be swapped

 

[ryanp]

The failsafe mod has been done, I'm letting you do it first Ade and then i'll fit one to mine and my bro's, haha! take a load of pics for me.

 

[Little Pickle]

Mine just went straight into my 1z setup. Installation was pretty easy.

 

[ourkid]

I got the wiring sorted this morning (ended up mounting the relay next to the battery,signal from the pump then one fused wire under the carpet to the back - no probs).The only way i could tell it was running is a few seconds of gurgling with ignition on.The sender read halfway but i knew from the old sender that the tank was quarter full so the float was resting on a hump somewhere.So i just slackened the clamp and slowly rotated until i got 1/4 again.This puts the arrow pointing out to the side.
I'll see how it goes when i fill up as it may still be out of calibration,if so i'll swap the boards over
I reckon it revs up faster but it's probably not - just because i read it on here first!.It did spew a ton of air bubbles through for the first few minutes though.

 

[cog]

did you grease the fuel iines up before putting them back on . when i greased my lines up i had no air bubbles whatsoever

 

[G60ING]

the problem I had when i used a corrado fuel sending unit with a mk4 tdi cluster was that the ohms for a full tank on the corrado sending unit was what the mk4 cluster used for empty and the empty ohms on the corrado sending unit was what the mk4 cluster had for full. The resistance ranges were opposite. This is something that several swap people have run into. The b4 tdi cluster worked fine with the corrado sending unit.

Just my experience and why I think you might run into a problem.

 

[ourkid]

Just to report back on this and say that G60 is correct (not that i ever doubted you of course),after a few runs and fill up at the station,my gauge is going backwards!

Luckily i have a Mk3 sender so i'll swap over at the weekend.

 

[ryanp]

take a couple of pics of the orientation too!!

 

[G60ING]

here is the link to my photo album of my swap. There are a couple pictures of what I had to do #131-#139

 

[mk1-83]

Have more users have problems with broken liftpumps I broke 2 pumps in 6 months.
The pumps just died after few months of driving maybe the pump can't handel the vp.
The pump get's hot and the electric engine died...
Please help with this. maybe a fuel bypass when the fuel pressure is above 0,5 bar ???

 

[G60ING]

Sorry about that here is the link to the photo album: http://share.shutterfly.com/action/welcome?sid=8CZtXDdy5asmM

Also I did was swap the mk4 resistor board into my Corrado fuel pump's sending unit. You will have to do the opposite and install the Mk3's resistor board onto the mk4's sending unit. It requires creativity and the desire to put the square peg in the round hole. Good Luck.

 

[ourkid]

Thanks!,i'll let you know how i get on

 

[Adamski]

i swapped my boards and the float over and it worked fine!

 

[kooyajerms]

This is not friendly to the b4v tdi tank.

It won't work unless you swap to a vr6 wagon tank and do some modifications to the pickup and the long lines. Not just the resister board because the tdi b4v fuel sender is 3" versus the 5-6" units EVERYONE else uses.

http://forums.tdiclub.com/showthread.php?t=309402

 

[Mark@MaloneTuning]

I have a (new to me) MK3 Golf TDI and I'm fitting a PD lift pump (with the failsafe mod).

The MK3 originally had a 1.8L 8v gas engine with a ~3 bar / 43 PSI lift pump.

Will the MK3's existing pump relay/wiring fry the ~6 PSI PD lift pump? Just thought I'd ask here before I whip out wiring diagrams and a multimeter

Thanks,
Mark

 

[m1ketdi]

Being a pump it should only draw the power it needs surely? It won't have a high voltage source or anything.