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Thread: In Tank Fuel Pump - Allroad 2003 TDI

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  1. In Tank Fuel Pump - Allroad 2003 TDI 
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    Hi. This is my first post on this forum so looking for a little bit of help. I cant see anything specifically mentioning this problem on other posts but apologies if I have missed one.

    Car is a 2003 Allroad 2.5TDi AKE - Serial number indicates its a lift pump in the tank. VDO branded

    Having recently changed the timing belts etc, I had to disconnect the fuel filter in order to gain access for the cam locking tool. Now I have the usual problem of the car not starting as there is an abundance of air in the system. I have bled the system properly with a vacuum and with each injector being loostened in turn. The injection pump itself is fine and is providing good pressure at the injectors, however once the filter has been emptied, no more fuel is being provided to replace that which has been drawn forward by the main injection pump and the level can been seen dropping in the clear fuel tube section. This leads me to believe that the lift pump in the tank is playing up which I know is sometimes the case when the sealed system is interrupted.

    Everything appeared to be tight hose wise. I checked the fuse, relay, connectors etc and all look fine with readings as expected and continuity. 12V directly to the in-tank pump connector ran the pump but no fuel was being delivered forwards towards the filter. Following this i replaced the in tank pump, however I still have the same issue with no fuel being delivered forward on cranking, or with 12v directly the pump. I have removed the pump and tested it successfully, however this is where I need a little help.

    Once the fuel has been drawn in through the bottom of the motor, it exits the top tube which then travels to a T ish shaped connector with the easy release clips. This then connects to a line in the tank which leads to a 3 or 4 way green plastic block/valve. There is a green hose attached which appears linked to the side of the tank but the other port is open with no hose attached. If fuel is moving along these channels how does it get into the tube to the outlet port on the top of the filter. From tracing lines of flow I cannot see how the fuel from the pump works its way into the outlet line and down towards the filter. The pressure coming through is great but there is no flow at all from the outlet so im wondering if there is something not connected that should be.

    Can anyone give me a pointer on this one or a diagram to work from.

    P.S the engine and timing are all ok as it runs nicely when using a hand bulb to manually draw the fuel forward, and unfortunately I dont have long enough arms to pump by hand and drive at the same time.
     
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  2. Re: In Tank Fuel Pump - Allroad 2003 TDI 
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    No help as to pipe arrangements in there as I've not had mine apart

    Mine is pumped from tank and will prime from empty tank with no interference at all, you just have to leave it sitting with ignition on and not running and it'll get the job done.

    Going by the same results with old and new pump, could there possibly be a divert in the connecting block you've described that is preventing correct routing of fuel delivery. Rather than hook up pipes (assuming they were left alone) is there something in there that could fail I'm thinking, ie an over pressure route that just circulates round inside the tank when the engine line is full.
     
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  3. Re: In Tank Fuel Pump - Allroad 2003 TDI 
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    The in tank fuel pump essentially does nothing to provide the VEP with fuel, all it does is to fill the in tank swirl pot with fuel and keep it full so the engine driven pump can draw fuel from the pot.
    Anthropogenic climate change, the biggest con inflicted on mankind since religion...

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