Jetta Mk2 GTI. 1989. Fuel pump appears dead.

[Clive Roberts]

Hi,

Several experts have failed to get a fuel supply to the engine of my old Jetta - and I'm no expert(!) After two years' worth of failure to get the bottom of the problem, the car has now sat forlornly in my drive for 18 months.

But it seems such a shame to sell my Jetta when there must be a solution to the repeated failures of both after-market and refurbished original fuel pumps. Several people here have offered to buy it, as they have the know-how and yards to strip it down and make a beauty of it. But summer is here, so I'd like to restart from square one for myself. Such a shame to admit defeat.

I understand it is possible to convert the two-pump fuel system, (tank riser and pressure), to a single pump system. This may well clear out any lurking residual problems with any of the pumps and petrol leads. Also, some new electrical loom may eliminate that problem.

If it's possible to convert to one fuel pump, and if anyone has information about such a conversion, I would be grateful.

Thanks,

Clive.

 

[Crasher]

PB engine? How can anyone fail to fix that, it is so easy...

 

[Clive Roberts]

Well Crasher, if it were the engine to be fixed ... .

The engine is fine, but no engine in the world can run until fuel of some form arrives - in this case, petrol by means of a pipe, electricity, and pumps which do not keep failing.

So my question is, can I convert to one fuel pump?

 

[Crasher]

The system is very simple, a relay triggered by the ECU runs both pumps from a junction under the back seat. You could convert, as I have just done on a customers project car, to a Golf 3 fuel tank with its internal pressure pump and only a fuel filter on its own under the car but that would also mean fitting the fuel tank vapour recovery system. Is your hazard warning light switch on the dash or on the steering cowling?

 

[Clive Roberts]

The system is very simple, a relay triggered by the ECU runs both pumps from a junction under the back seat. You could convert, as I have just done on a customers project car, to a Golf 3 fuel tank with its internal pressure pump and only a fuel filter on its own under the car but that would also mean fitting the fuel tank vapour recovery system. Is your hazard warning light switch on the dash or on the steering cowling?

It's on the steering cowling.

(The conversion seems interesting).

 

[Crasher]

The hazard switch is an easy way to see which electrical system it has and it shows you have the ECS 3 fuse box shared with the Golf 3 and that yours is a type 1G rather than the earlier type 19. The Golf 3 tank fits straight in and is a couple of gallons larger, which is why I have fitted it to the 3L VR6 turbo I am building. You would want the tank, straps, lines and vapour tank (which bolts directly into a spot under the air filter) and to get the tank from a late model that used a 3 Bar pump as opposed to 4 Bar which would cause you over fuelling problems. The “catch”, sorry in joke, with the vapour tank system is how to command the valve. There are established factory Digifant Golf 2 methods not involving the ECU but my mind is wondering off into finding a late 8v Golf 3 GTI and not only fitting the tank, but the engine, management, cat etc and making it cleaner. That’s just me though, I can’t stop modifying....

 

[Clive Roberts]

Thanks Crasher. That is the level of detail that I need to decide whether to go ahead. Know before you go!

I have to bear in mind that I ain't on the same planet as you and many members of this forum when it comes to stripping and replacing a car's vitals. But I have to see this Jetta on the road again, and it's worth another try.

But I won't be replacing the engine etc. That would be madness for me.

 

[Crasher]

Yes we’ll do bare in mind that I am rather odd and slightly bonkers...

 

[Clive Roberts]

Yes we’ll do bare in mind that I am rather odd and slightly bonkers...

Never doubted it for a moment (!)

I wish I could find such a rather odd and slightly bonkers person around here to spend a few days on my poor old Jetta.

 

[Sam&Anne]

Never doubted it for a moment (!)

I wish I could find such a rather odd and slightly bonkers person around here to spend a few days on my poor old Jetta.

I am from Lisburn and at 69 I am also odd, bonkers and heavily medicated, come to think of it most over 60's with an auto engineering background here are exactly the same.
The same galaxy as Crasher? NO is the short answer.

 

[Clive Roberts]

I am from Lisburn and at 69 I am also odd, bonkers and heavily medicated, come to think of it most over 60's with an auto engineering background here are exactly the same.
The same galaxy as Crasher? NO is the short answer.

Sam,

Well, we're the same age, and my main medication is a stiff whisky (nowadays, of course, also a whiskey) and cigar.

I am no auto engineer, but worked with engineers all of my working life. We are near neighbours, it seems. Well, anytime you and Anne fancy a cup of tea, do drop in. But beware - I'll try to pick your brains about where to start with my Jetta.

But you can also see my three motorbikes - and for a real treat, I'll even let you see my new shed!

 

[Sam&Anne]

Sam,

Well, we're the same age, and my main medication is a stiff whisky (nowadays, of course, also a whiskey) and cigar.

I am no auto engineer, but worked with engineers all of my working life. We are near neighbours, it seems. Well, anytime you and Anne fancy a cup of tea, do drop in. But beware - I'll try to pick your brains about where to start with my Jetta.

But you can also see my three motorbikes - and for a real treat, I'll even let you see my new shed!

Bikes of all makes and capacities since 1964.
PM me Clive and we will have a chat.
Sam.

 

[Clive Roberts]

Hello,

Well, I have not been on this forum for a very long time. Because, after trying everything to get the Jetta running, despair set in. Three visits to a garage, two trailer uplifts, and a tow, several fuel pumps (all failed), and I nearly sold the car, for peanuts. But then I did what I should have done first - look for the simplest problem. So I leaned under the rear of the car, took off the 'manifold' which is spaghetti junction for the fuel supply, and labelled each pipe and connection.
It is a 1989 car. I guarantee that the litre sized, aluminium 'barrel' which is the fuel filter had never been changed in its 138k miles and thirty years. It was failing every fuel pump I fitted, for the simplest of reasons.

So a new filter, a blow out of the fuel lines, and the pumps are no longer failing. The engine leaps reliably into life, after sitting outside for several miserable wet winters. Now I'm going to restore this plucky little Jetta. Lesson learned.

So now I need to source a few more cosmetic items. I need the plastic 'tray' which covers the wiper assembly etc just under the bonnet. It is WXE 192 819 415 A. Does anyone know of a website which may carry this item?

Many thanks,

Clive.

 

[Sam&Anne]

Greetings Clive and well done for getting a result and printing it which may help another owner.
I shall call again to see you as soon as I am allowed.
Hoping that Davy has some news about your bike issues.
Take care
Sam.

 

[Crasher]

It is just 192 819 415 C, new I have no idea and on felaBay they are going for silly money even in tatty condition (£100 ish) but they do clean up easily if they are the later much thicker versions.

 

[Clive Roberts]

Crasher,

Many thanks for the updated part number. It's crucial. With the old part number, I was quoted £170 second hand from breakers. Gulp! With the new part number, even VW parts Germany quote €95. Euros! Less than half-price - including delivery!

My existing water deflector has a third of it missing, so is not repairable. I may well accept the one from Germany - although when I tried to order my smokes from Holland, Border Force intercepted them and said I would be prosecuted for smuggling! So a bit nervous about ordering from the Continong in the present climate; so I will search the UK with the correct part number first.

Strange we used to have a 'Police Force', and 'Customs and Excise'. In Brave New Britain, we have a 'Police Service', and a 'Border Force'. Bonkers!

And I have signed the petition 556842. These bozos in Westminster are just following voters, whichever way the wind blows; whatever seems to keep them in office, however misguided. (When all vehicles are electric, where will the power come from? Not to mention electric Airbuses and Boeings?

 

[Crasher]

Be careful ordering this from the continent, it is right hand drive specific. Don't let them fob you off with a 191, it must be 192.

 

[Clive Roberts]

Many thanks Crasher.