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This 2004 Volkswagen Jetta TDI was driven down to our shop by a customer who said that the car wouldn't start for him at work it just cranked and cranked. A co-worker recommended covering the exhaust with a rag to see if that would help and then the vehicle started. He drove the vehicle over 60 miles back home and had to plug the exhaust again to bring it down to our shop. I tried to start the VW Jetta a few days later and found that the car would not start. I cycled the key a few times, cranked and cranked but the TDI engine wouldnt start. I then shoved two rags into the muffler and the engine started up and after a few revs the engine smooth out and ran good. It seemed like air was entering the fuel system or the engine was starving for fuel so I hooked a fuel pressure gauge into the line after the fuel filter. After I had a fuel pressure gauge hooked up I started the engine and checked pressure. I has about 8-9psi and the service manual called for 13 psi on the TDI with BEW engine code. I ordered a new pump and in this video I show how to change the pump and the fuel filter. After the pump and fitler replacement I cycled the key many times until I couldn't any air bubbling in the fuel tank while the pump was running. I started up the engine and then shut it down to inspect for leaks. With no leaks found I started it back up and checked the fuel pressure. It no has 13 psi. I think the hard start was a combination of a weak lift pump and a leaking oring on the fuel filter allowing air to enter the fuel system.
Fuel Pump - www.ecstuning.com/b-vdo-parts...
Fuel pump gasket - www.ecstuning.com/b-genuine-v...
Fuel Filter - amzn.to/2QLonRN
Basic Fuel Pressure gauge set - amzn.to/2OBp2Uc
Deluxe Full Fuel Pressure gauge set - amzn.to/2NsRlHV
Fuel pump wrench - amzn.to/2OAJ6Gs
shop rags - amzn.to/2PG22V1
Gloves - amzn.to/2Ni7USL
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