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2G Fuel Starvation

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Mham2k

15+ Year Contributor
306
57
Feb 8, 2008
Dallas, Texas
After a few years of tinkering once or twice a month I have my car running pretty good. However, I still have one issue i have never been able to figure out. its a 1996 TSI AWD

Problem: I have never been able to drive my car any distance using only the pump in the tank. While driving it starves for fuel at random times and sometimes cuts off. I have gone through 2 Aeromotive 340's and can assure you they are working as designed.

Work Around: The work around is having a surge tank with a bosch 044 under the hood that is fed by the Aeromotive 340 in the tank. This lets me drive around and boost happy for about 1 hour then the 340 seems to have a problem keeping the surge tank full. If i pull over and let it full the surge tank up I can run and boost happy for another 30 minute to an hour.

This happens on a full tank of gas and I have the fuel returning to the surge tank then returning from there to the fuel tank.

What is wrong here?
  • Is the fuel tank having issues keeping the baffle full?
  • I called aeromotive and they told me the pump is probably sucking the baffle dry and can't get it to fill back up fast enough.
  • Will a sump on the tank work?
  • Help Please!
Don't know how to solve this problem... This is the last of my ghosts in this car... Any thoughts help.
 
Is your 340 in the stock tank rewired? I run a 340 as well, and while I don't stress it at all, it's been flawless for me since I put it in 4+ years ago.

Only thing I can think is it's losing voltage stability as things heat up and its efficiency is tanking :idontknow:

P.S.- my aeromotive is rewired and my battery is relocated, so I have an very short 10 gauge run powering my pump, and I've monitored voltage after a long drive and I have less than .2v drop at the pump connector.
 
It almost sounds like your fuel filter is getting clogged up when its under a heavy load, that or the pump is heat soaking and slowing down, an amp draw when your driving it would tell alot when its acting up.
 
Is your 340 in the stock tank rewired? I run a 340 as well, and while I don't stress it at all, it's been flawless for me since I put it in 4+ years ago.

Only thing I can think is it's losing voltage stability as things heat up and its efficiency is tanking :idontknow:

P.S.- my aeromotive is rewired and my battery is relocated, so I have an very short 10 gauge run powering my pump, and I've monitored voltage after a long drive and I have less than .2v drop at the pump connector.

My battery is in the trunk and pump is rewired with a 20amp fuse in line. I probably have 2 feet between the pump and battery.

I will check the voltage to see what happens.
 
It almost sounds like your fuel filter is getting clogged up when its under a heavy load, that or the pump is heat soaking and slowing down, an amp draw when your driving it would tell alot when its acting up.
So while it's acting up see if it pulling more amps than normal? It only happens after driving a while so the heat soaking makes sense.

What would cause it to heat soak? Dirty pump sock?
The fuel filter is after the surge tank now so it's something before that.
 
Sounds right, how'd the tank look when you put it in? Mine was pretty good but I cleaned it fastidiously anyway.

Dirty filter sock or maybe a a hole in the line between the pump and bulkhead? Once it warms up it opens up? Stretch but idk.
 
You want a small pump or low lift to the surge tank, you only want to keep it just full not over filling the tank,

Right hand corners make the tank pump stop sucking, so you can do a better baffle setup or add a foam inside. But i would also check your filters or see if you got a bad earth on the battery or pump side of things incase its breaking up causing it
 
Sounds right, how'd the tank look when you put it in? Mine was pretty good but I cleaned it fastidiously anyway.

Dirty filter sock or maybe a a hole in the line between the pump and bulkhead? Once it warms up it opens up? Stretch but idk.

Tank isn't clean, I have put 3 socks on the pump. Anyway you clean it without dropping it?
 
Tank isn't clean, I have put 3 socks on the pump. Anyway you clean it without dropping it?
Drop it. It will be way easier than any of the other "easier" procedures. When it comes down to it, there really isn't any efficient shortcut.
 
Yeah dropping it is by far the easier way. More time consuming maybe, but factoring in the PITA of doing it in the car, makes sense to drop it.

If you've been through that many socks then I'm sure that's a major contributing factor for your issue.
 
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