Problems again =(

[86gti]

nah, havnt checked yet Grant. Dont have a manual but a bentley Manual and the bosch K-jet Manual have been ordered!! going to try and find someone with some knowledge of K-jet around Launnie tomorow..
its just bloody annoying, haha my alcohol and cigarette consumption has gone up 300%...

[joshyd-mk2gti]

ive been reading vwvortex looking for answer. theres lots of threads on the topic, have a search. theres not always the same cure thou, unfortunately.

next time its hot unplug the coolant temp sensor and see if it starts.

[86gti]

yea, went through vortex back in dec when it last did it.....found allot more on
www.vwfixx.com...
what i really need is a fuel pressure tester. got a price on one today but it will have to wait a couple of weeks.
roccodingo gave me a few tips on testing a few things so I will get onto that on sunday i hope :-S. just trailered it home tonight....
If i dont have any luck Pertroject (automotive sevice solutions) put me onto a few people on the Launceston area who are familiar with the system.
we just wait n see what happens..to make matters worse my zooki just started playing up too...i think its just fouled a plug...i hope...not having any luck latley, haha

[gtimk5]

I can probably lend you a tester Benny for a very short period. You have a manual I hope? Did you check for voltage at the pump when it wouldn't go? Relay?

[86gti]

ok, got the guage of Andrew (thanks heaps!!!)...
made up an inline fuesd switch in the pump relay and
did a few tests first ,that all checked out..
(1)intank pump test was 13.5oz in 10 sec..i got it in 8 sec so pum is fine (should be its new)
(2)control pressure reg had continuity but i had no multi meter to test resistance (should have one tomorrow)..
(3) cold start valve checked out ok
(4)thermo time switch checked out ok

all that was fine. car still not starting at all at tht stage.

but........ i couldnt hear the main pump at all..no pressure at cranking, and no noise! it wasnt going. so i pulled the pump out and submersed it in some fuel and hot wired it off the battery, and it was pumping fine!!!! let it pump away for about 10 mins and was whirring away nicley.
..so. refitted it to the car and flicked the switch i had made up to bypass the relay and it was working again....
soooo. i reconnected the coil lead and the relay and it fired up allbeit very rough.

managed to get theese readings on pressure.
im gathering from the manual when it says close valve on the pressure line
that would mean off

System Pressure while running from dead cold valve closed (press guage) went straight upto 70psi and the car would cough and die whenever it got there. did the same thing 5-6 times always at just on 70psi.

with the valve open (on guage) it would run at 50psi but took along time to get there and was still running rough. till stalling after around 3-4 mins still at 50 psi but fluctuating a bit. also backfired cupla times through the a/f meter while trying to start.

turnned motor off and was holding between 45 to 48psi of residual pressure.(valve open) car cold...wouldnt run long enough to get warm..
manual says between 49-55psi when warm.

ran the pumps and it went down to 25psi and returned to 48 when the pumps were turned off.(valve open).


couldn't do control pressure because the car will not start again.
the car would try to start for a second whenever i turned the pumps on and off while turning the car over, but still no go.

so i then tryed fuel pump delivery rate.
in the manual it says 675cm3 at 12volts in 30 sec.
i aroundabout worked that out to be about 22oz in 30 sec.
in 30 sec it only pumped 11oz.

anyway..few pics below...all in one file so may take a lil while to load.

[gtimk5]

Keep going Benny, I'm off to Melbourne this week and I don't need the manual straight away.
Anyone had this problem before??

[Golf Loon]

Sounds like a tired main pump.

[86gti]

yea, i was thinking main pump too, pressure was ok, but flow test left allot to be desired... so far everything else checks out..
its also weird that the main pump didnt run till i took it out and put it back in again. checked all the wires etc. all fine. the pump went, the car started going and then got real rough in the idle and back fires through the inlet when you stomp on it. after 5 mins it never went again....im still running backwards and forwards between here and the garage swigging on a bottle of jonnie walker red just to keep me saine!!!! if i had one wish in the world it would be for the damn thing to go! oh maybe a hoist.....

if i cant sort out whats wrong by tomorow u mite see my funeral notice or a busted golf for sale

[roccodingo]

System Pressure while running from dead cold valve closed (press guage) went straight upto 70psi and the car would cough and die whenever it got there. did the same thing 5-6 times always at just on 70psi.

Pressure is there but from what you say further down the flow rate isnt which = lean mixture to cause engine to stall.

turnned motor off and was holding between 45 to 48psi of residual pressure.(valve open) car cold...wouldnt run long enough to get warm..
manual says between 49-55psi when warm.

ran the pumps and it went down to 25psi and returned to 48 when the pumps were turned off.(valve open).

did it drop to 25 with the engine running , or just the fuel pumps??

so i then tryed fuel pump delivery rate.
in the manual it says 675cm3 at 12volts in 30 sec.
i aroundabout worked that out to be about 22oz in 30 sec.
in 30 sec it only pumped 11oz.

IMO the main pump is definately taking holidays from these figures

think yer best option is to fit a new main pump, Got mine from a mob called ASV here in Perth, bout 1/2 price of petroject quote ( both "bosch pumps")

dunno bout Mk2 tanks, but the MK1 has a screen filter ( strainer) in the tank that was pretty gunky after 26 years of use, took it out and gave it a damned good clean..Etka tells me there is one in the tank..

[Golf Loon]

Yeah main pump. As grant says engine is running lean as its not getting enuff fuel.

Your clean up of the pump made it go for a min, but it is rooted.

Slap a new one in, car should roar.