Starting issues.... Looking for advice and even a solution

[McKiwi]

Hi ya all - hope some one can help with this problem.

Car is a 2006 Passat 1.9 TDI Estate - 175000 miles - generally very reliable and serviced regularly

3 weeks ago the car broke down - appeared to run out of fuel even tho there was 15 miles showing on the fuel range meter (I have often run it lower than that due to country living). Called recovery, they came out and kicked the fuel tank, applied copious quantities of easy start, got it running and advised filling it up and putting injector cleaner in it, which was duly done, no worries!

Again (foolish perhaps) I ran it down to about 15 miles in the tank and had the same problem - appeared to run out of fuel. Went and got a gallon of fuel (now >50 miles in tank), gave the fuel tank a good kick but nothing. Recovery called, they tried the same as before but still no go - trying to start but wouldn't run. Recovered it to home and started investigating...

Fuel pump in tank is making a rumbling noise when the ignition is turned on so checked fuel filter and found the fuel pick up "stem" broken off - great - easy fix or so I thought. Got a replacement (2nd hand) filter housing and swapped over the pick up/ relief valve part and hit the starter.... Still no go. Took fuel line off, fuel is pumping up to the filter from the in tank pump, took the fuel line off at the engine pump and getting fuel there so kinda stuck now. (My diesel experience is on older engines with the old injector pumps on the side of the engine not these "common rail" types....)

I have tried to bleed the system by taking off fuel lines and running the in tank pump repeatedly (it only runs for a few seconds) and am getting fuel through but, there is not a lot of it . How much there should be I wouldn't know. It also appears to come out of both fuel lines leading to the engine - I had assumed one would be the return line?

So basically I am after a bit of advice please - I have never noticed the fuel pump noise before but to be honest I have never listened out for it before, especially with the seal and padding up. So.....

Do they normally make a rumbling noise?

With the fuel filter top off should the pump run constantly (i.e. with no back pressure)?

Is there some more bleeding of the system required that I'm missing?

Should the in tank pump really pump it out or does it just provide a small trickle? (i.e. is the pump motor *******?)

Unfortunately I don't have access to a diagnostic unit but if this is the best option I will try to arrange it.

Any advice or thoughts would be appreciated - gratitude in advance

Ian McComb :1zhelp:

[martijn v o]

If it is an 2006 1.9 TDI than it is an injector pump engine and not a common rail.
Do you have a high oil level now?
I suspect that the fuel pump in the diesel as well as the tandempump aren't working properly now.
If its starts with starting fluid spayed in to the intake duct very easy, then it must be a fuel flow problem.

The pressure from the tandempump schould be 7,5 bar at 4000 rpm.

[Doctle Odd]

There's no pump in the old sense in a 2006 PD engine. It's a bad idea to let a car run so low on fuel it can pick up all sorts of debris. The tank in the pump pulses so you wont get a steady flow, it usually makes a "squelching" sound when you turn on the ignition. You don't need to remove the return pipe. As the OP said start by checking your oil level and have a good sniff for diesel. Check everything is ok at the tandem pump. Check the fuel filter is clean and airtight and all the lines are secured. Explain kicking the tank, the imagery is interesting!

[McKiwi]

Thanks for the input -

Re kicking the tank: it involves lying on your back and kicking the tank bottom to get the fuel pump working - both recovery guys tried it!

Was told it was probably a common rail set up but I'm not sure as never worked much on modern diesels. Oil level looked ok but didn't check for diesel smell - will do so tomorrow. The easy start worked first time but not the second....

The fuel pump definitely makes a rumbling noise so is it worth taking out and checking? To me there just didn't seem to be enough fuel coming up from the fuel tank

Ian

[martijn v o]

let me check the prescribed fuel flow.
What is de code of the engine (BXE?).


If you not have VCDS:
Connect the fuel pomp in de tank to a charged battery with a switch. (VCDS: select the fuel flow control button)
disconnect the fuel line on the fuel filter in to a measuring cup of minimum 1,5 liter
Switch on the fuel pump for 30 seconds.

The fuel flow has to be at least 1 liter.
Fuel pressure on idle 0,5 bar
Fuel pressure on 2500 rpm 0,25 bar.

[McKiwi]

Cheers Martin

Thanks again for the input.

Engine number is BKC A30901 - is that what you meant?

Will try the fuel flow method described - not sure why the fuel pressure would increase from an electric pump when revving the engine (even if I could get it started :confused:....)

Regards
Ian

[McKiwi]

It lives......

Ran a separate electrical feed to the fuel pump so it could be run continuously, disconnected the return fuel line from the engine, ran the pump until it flowed freely from there, then with the pump running, chucked a bit of easy start at it and a few tries later SUCCESS! Reconnected fuel pump plug (range now says 2000 miles but I'm sure that'll sort itself out) and took it for a run to the local garage. Filled it up with diesel and it seems to be OK.

Hopefully it was just an airlock caused by the broken fuel pick up, exasperated by many attempts to start it before finding the problem...

Thanks for the advice given - great website/forum - just got to sort out the near side front door which has stopped opening from the outside.... thankfully I have previously sorted the drivers door so think I know what the problem is!
Beer O'clock me thinks.... :beerchug:

[Doctle Odd]

Keep at least 2 gallons of diesel in her at all times :)