Engine Specific Info and Questions > IDI Engine

1.6td won't draw fuel

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oblique:
So more fueling trouble with my mk1 Jetta...same time last year I replaced the pump with a Giles unit because the fuel pump inside the IP was shot.

Car runs fine for about 1o or 20 seconds then starts to lose power, throttle position does nothing. After a bunch of cranking the car will restart and the process begins anew.

Also with a full tank I had a lot of diesel dripping out of the vent drain under the car. Not sure if this is related or if its just expansion.

Anyway I blew out the supply and return lines with shop air and they were clear. Both the return and supply nipples at the fuel tank gushed diesel with no sign of blockage.

Swapped fuel filter and filled it up. Used mighty vac to prime and car will start and run from what seems like the fuel inside the filter and then sputter out because after I'll remove the fuel filter and down to 1/3. Next I tried to prime the pump and basically I drew all the diesel out of the fuel filter and after that I could not get any fuel out of the tank despite confirming the hard supply lines were clear (did not check the rubber line from behind engine to fuel filter but does this clog up?)

What are the possibilities?

rabbid79:
Just to attribute the problem squarely to the IP or to the fuel tank/lines/filter, I'd run fresh clean diesel fuel straight out of and back into a mason jar.  See if it keeps running ok.  If it does, then move the mason jar lower toward the ground to see if the IP has any problems drawing fuel up a few feet.  If that all checks out, then go after the tank/lines/filter.  Not a lot of fun playing in diesel fuel, but at least you'll have a pretty good idea of where the problem is.

ORCoaster:
(did not check the rubber line from behind engine to fuel filter but does this clog up?)

What are the possibilities?

Someone had that man a cubby doll, or a beer.  If you didn't try running the pump on a bottle or jar eliminating the tank and normal fuel system then I would bet a dollar to a doughnut, I love those things, that you have a gummed up rubber line.  That is where I have seen most of the gubbers collect. 

Pull that line off and verify it is clear.  Look at the banjo fittings as well.  Sometimes they get a ring of junk in them. 

It sure sounds to me that you are just developing a vacuum on the line and starving the pump for fuel.  A jar with a line for fuel in to the IP and one out of the OUT bolt back to the same jar should get all those issues out of the way.  Then you can figure out if you have a leak in seals and loosing ability to draw fuel in or see air being put into the system from seals going bad.

oblique:
Thanks for replies!

I am losing sleep that Ive ruined another pump because I cannot afford to replace and that would mean putting the car to sleep.

I will check that upper rubber line. Also how do I blow air through banjo fittings? I want to check the fuel filter bracket.

Is this upper rubber line still available for purchase? I cannto find it anywhere. Also do I have to make my own fuel filter > IP supply line if I want a clear one?

ORCoaster:
Oblique no need to loose sleep on this.  That is for Obtuse to do that.

I don't think you have ruined another pump.  A plugged line or filter just puts a vacuum on the system and it stops the car after awhile.  No fuel delivered, no engine rotation.  Sorta simple there.

I have had a hard time getting that line off the metal line in the past.  I think I even ended up just cutting off the end and then cutting down the metal line to get the piece off.  That stuff is like iron once it sits there for that many years. 
I don't know that you can do anything other than blow air back into an open line connected to the banjo fitting.  Again it might be necessary to cut it off.  I do a visual inspection holding it up to the sun to see an open hole. 
I would caution you on the filter bracket as well, Those things also are solid on there.  The 17 mm nuts get tight for whatever reason and they are in a position that assures your knuckles are going to be bloody if the wrench slips.  So be prepared and wear some gloves.

I think the line going into the filter is standard 1/4 or 7 mm metric.  Just get a new piece from your local auto store and be sure it is fuel rated not some goofey stuff from the hardware section or Home Depot.  I know, people have used it and claim all sorts of great things.  But face it, it is a critical piece of the fuel system.  Not something you want to have crack on you in the dark of the night years from now on a deserted highway, with no cell connection. 

Some have installed one of those lawnmower type fuel filters before the pump as those are clear and about the same diameter line.  There are even ones with glass outer shells that have a replaceable filter inside.  A little more cash for them than the prior one.

Good luck. 

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