Jetta Stalling dying need GURU's help

mrbowtieguy

Active member
Joined
Nov 18, 2006
Location
North central Texas
TDI
99 Jetta
I have a 99.5 jetta that has been intermittently cutting out and stalling.
If I wait 20-30 min it will restart. Some time it doesn't die on the road if I keep the
Clutch engaged in gear for 5-10 seconds while it's cutting out
It will then resume like nothings wrong. It's been getting more
Frequent. Use to start after about an hour of cruising but now it's
Doing it on short trips around town. The pump timing fluctuates
From about 54-70 and is not stable like my other 2 tdi's.
Could this be a sign of the injection pump going out. Is there a way
To check the pump with vcds? No leaks on the pump.
Are these rebuild-able? The fuel quantity runs at 3.4 at idle.

I replaced the relay 109 and it still stalls and dies after about 5 min of driving. I can get it to start again after about 5-10 min and then it stalls and dies again a few minutes later
it has fuel in the return line no bubbles, fresh filter.
one time I crack one of the injection lines open and cranked it over and it just dribbled out seems like weak pressure.
I has 290k and the pump has had gas ran in it a couple of times a few years ago, although it doesn't leak at all.

I checked the case relief valve as described in this post

http://forums.tdiclub.com/showpost.p...10&postcount=7

and although the retainer wasn't fully seated it made not bearing on the stalling problem. I rescanned and checked the timing and no codes and timing was as set previously. tried another 109 relay and nothing still stalls.
I'll check the ground under the battery box to make sure its bonded good tomorrow, and I'll switch the fuel cutoff solenoid to eliminate that. I ran all the active solenoid tests and they all click but who knows if there actually moving the valve.
 
Last edited:

flatlanded

Veteran Member
Joined
Aug 1, 2009
Location
Saskatchewan
TDI
2002 Jetta
You should be able to pull the fuel solenoid and hit it with 12v and it should click. It's either air, fuel, or computer issues. Have you checked to see what your EGR is doing? When my ECU was on its way out it stalled often, it had the EGR cranked open. Since there's no codes, I'd rule out the ECU.

You might be on to something with the pump, but it should throw a code.

I'm out of ideas at the moment, but hopefully someone will chime in while I think.
 

mrbowtieguy

Active member
Joined
Nov 18, 2006
Location
North central Texas
TDI
99 Jetta
mileage and egr

car has 288k on the clock, intake, Egr valve, all inter cooler and related components have been cleaned less than 600 miles ago. egr has been deleted but no other codes. I cleaned re-bonded all the grounds under the battery.
installed another fuel cutoff solenoid. but I must have mess up the fuel quantity adjustment because it idles like crap now after pulling the top off the IP to get access to the solenoid. a 23mm wrench was to small and a 24 was to big. I used a 15/16 socket, that's why I took the top off the pump.
There was a small amount of fine metal shavings on the underside of the regulator assembly.
is this pump trashed?
 

kiva822

Veteran Member
Joined
Mar 17, 2010
Location
Chico, CA
TDI
'03 Wagon
I know, super simple, but when was the last time you changed the fuel filter? Do you know for sure the fuel is good? Probably not fuel quality, as it's been slowly doing it more over time...but a filter could slowly clog?

However, it does sound like a pump. Maybe call the guys at DFIS and see if they have any suggestions?
 

alphaseinor

TDI Innovator, Gone but Not Forgotten
Joined
Jul 30, 2006
Location
Denton, TX
TDI
'03 Jetta TDI 780,000 miles (totaled out), 01 Audi TT 225 Quattro 230,000 Miles (runs great!), 00 Cabreetle Beetle dash, ALH & MK4 harness Swap
I was going to say Engine speed sensor, but since you don't have a code for it... probably not.

I don't think this is an injection pump issue, but it definitely seems fuel related, or possibly something with the antishutter valve misbehaving.
 

mrbowtieguy

Active member
Joined
Nov 18, 2006
Location
North central Texas
TDI
99 Jetta
Update!

If you ever remove the top off the IP don't mess with the fuel quantity limit mechanism. It took me 8 tries to get it back like it was. I also removed the sender fuel pickup assembly to check for algae or anything that could be restricting the flow It was all clean, I checked the supply and return hose to verify flow, I checked the fuel pump by removing the return hose to the filter and cycle the pump by turning on the key and turning the key to the on position. it only runs for a few seconds each cycle on-off-on with the clutch depressed. unless the motor is running, I guess this is normal. I did get fuel running out the return hose to the filter so I figure ever things good there. As I mentioned in a earlier post there was a minute amount of fine metal shavings clinging to the underside of the quantity adjustment solenoid I guess because it was magnetized from being energized. Anyhow I did a test run and it didn't stall or die once in a 10 mile road run. You don't suppose the fuel tank could be creating a vacuum and starving the fuel? This never happen before I did the TB, Clutch flywheel, New turbo, cleaned intake and all inter cooler and ducting repairs . But My son lost the fuel cap so I replace it from one from rock auto at the same time as these repairs. I assumed all caps have some sort of check valve for venting purposes. I told my son if it does stumble and stall to leave the cap loose to where it can breath just to see if that's what could be causing the problem.
Just trying to rule out all possibilities before springing for an IP.
 
Top