'95 TSI fuel/starting issues

[TSIflyer95]

Hey guys,

Yes I am new here, I have been searching but I just can't seem to find anything that is definitive.


I recently bought a '95 TSI with a 6 bolt swap. It has some mods too it. 1g rods, 2g pistons, he claims it has BC272's but I don't believe it as they are SUPER quiet, S-AFC, and it had a walbro 255 in it.

Well when I bought the car I knew it had an issue. I was pretty darn sure it was the fuel pump. He said it was about 2-3 years old and the problem was that when going into boost, around 5 PSI it would start to miss.

Well I was positive that it was the pump as my buddy was having the same issue in his car.

I took out the fuel pump and checked the filter, it was black as black gets. FILTHY. So I got a new one and then when trying to boost it would now go up to 12 psi then start missing.


So this is where I am at now:


I was driving today and the car just crapped out. It wouldn't stay running. If I got the car started and had about %50 throttle it would run but not idle. It would die out.

So I got my new 255 today. I was in the parking lot changing it where it broke down. The pressure line ripped so I replaced that.

Well now, with the BRAND NEW pump in, I turn the key, and the pump no longer primes, no noises, no nothing. I try to turn the car over. It turns over perfectly. But WILL NOT FIRE.

I am thinking the full pump relay shot due to over running the old pump. I am unsure.

I need help asap. This is the only car I have that is road worthy right now.


Also, I am newish to DSM. I work on cars a lot but have never owned a DSM.

 

[TSIflyer95]

That said, it sounds like the pump isn't getting power,weak,dead, or dumping entirely too much fuel because of the stock fpr and fouling your plugs in the meantime...with that 255 your going to need an adjustable either way so I would invest in one anyway. Check power,ground, make sure you installed everything you needed with the new pump, and I'm sure you'll find something...you have an extra stock fpr to throw in just for sh*ts and giggles??

Yeah I thought maybe she is dumping fuel too. I also have EVO 560 injectors.... the guy said the EPROM was tuned and he had someone use the S-AFC to "tune" it finer... I don't know.

I do not have a wideband, yet. I am getting one in tomorrow. He had a narrow band. Which scared the piss out of me.

And I do not have another FPR, but it looks like I might try to find one.

Also, I even tried to put the old pump back in and still nothing. So it must be some wires somewhere... I'll be checking tomorrow.

Would you know about how many volts I need to see?

 

[98spydereugene]

S-AFC only works while its installed in the car, it still there???I'd definitely invest in dsmlink if you can(you'll love it)..and try the other things I've mentioned..

 

[TSIflyer95]

The S-AFC is still there. I love it . It looks cool.

And yes, I do plan to get link. But 500 bucks is a stretch right now. I still need to register the car. haha.

 

[98spydereugene]

Get v3lite, think its $395..well worth it...ya then I'd go with a problem with power to the pump, or a pressure problem...good luck man hope you get it worked out

 

[GSXTasy005]

Ok, I'm going to sound like a broken record here, but test for power to the pump while cranking.

No power - go to 1
Power - skip to 2

1. If there is no power
A. Check your fuses.
B. Pull off the center console cover on the passenger side, and you'll find 1 relay on your 95.
C. When you turn the key to "on" you should hear/feel it click once. when you crank, you should feel it click a 2nd time. If it doesn't do this, you may have a bad relay, or a wire got hacked somewhere in your wiring harness
2. If there is power
A. Remove the fuel pump assy again and check wiring inside it
B. If everything checks out there, then check your ground at the pump. A simple test light will help with this one, but a multimeter would be preferred to be sure you're getting healthy voltage at the pump, just hook/touch one side to the power wire, and the other side to your ground wire, don't just use any ground on the car. You want to be sure the ground wire can handle it.
C. If you're getting less than 12V, try another ground. If you still see less than 12V, consider the battery as a possible source of the problem.

P.S. if you don't have a Fuel Pump rewire done, you should definately invest the $30 and a couple hours to do it... it will make a huge difference in fuel pressure and consistancy with your engine. Vfaq has a good write up, or there is a lot of info on these forums about it. If you do the rewire, i'd recommend getting an afpr FOR SURE. Get an aeromotive or fuel lab regulator, NOT a cheap one... (do it right, or do it twice)


Sent from my T-Mobile G1 using Tapatalk

 

[TSIflyer95]

Thanks man. Like I said, I am not new to cars, just DSM. And I despise wiring issues. haha. Hopefully it can be found very easy. Otherwise I'm just going to take it to my mechanic and have him deal with it. I have to have this fixed by Thursday before I go back to work.

And I need to get it right so I can start putting money back into my RB25 240 .

I did try looking for the relay but was unable to find exactly where it was. I didn't know if it was under the center console by the seat or farther up front per se.

 

[98spydereugene]

Doesn't sound like it'd be too much of a pain to find out...If you weren't so far away I'd help ya

EDIT:definitely post up what was wrong, I'm curious to know if anything I suggested actually was going in the right direction...good luck

 

[TSIflyer95]

I really appreciate it. I am okay with anything but wires. I never mess with them. . On my 240 I spent the $550 on a premade harness cause I didn't want to mess with all the wires. haha

 

[98spydereugene]

I grew up wiring stereo's and electronics so that gave me a good prelude to working on anything else...It can be intimidating, but I don't think it's anything to crazy with your problem considering your prior pump worked...

 

[TSIflyer95]

Good deal. I'm gonna give my self a few hours to get it fixed tomorrow. Hopefully I can find something simple. I don't want to have to order anything .

 

[98spydereugene]

Hopefully not..keep fingers crossed

 

[TSIflyer95]

for sure.

Also, I don't know if its air or leaning out, but sometimes when I boost lightly in 2nd at about 8 psi then dump the clutch to neutral, the rpm's go all the way down and I stall out?

 

[98spydereugene]

That could be a bad ISC, or a fuel pressure problem as well....

 

[Tyeler18]

Is your BOV recirculated?

 

[TSIflyer95]

Okay. So I am here now sitting in the car. The fuel pump now turns on and makes noises when I crank the motor. I checked the plugs. They are a little dark. The car still turns over fine but still won't fire. I've tried starting it 3 times now.

The BOV is not recirulated as the guy said it has been tuned that way.

My only problem now is that the motor won't fire. I'm going to have to assume it's my fpr. I need to get this thing running today.

 

[Tyeler18]

Take a vice grip and clamp the fuel return line off the fpr. Plugs COULD be fouled, may be worth replacing, what kind are they? Recirculate that BOV, it's definitely not tuned for that, unless you're running a GM maf or speed density.

 

[TSIflyer95]

I will try to clamp the hose, they are bpr7es plugs. Bought them about 3 days ago. I dont believe he has the gm maf, I know my buddy was able to run just fine without being recirc. He just ran rich between shifts. Which really just made the car pop flames .

Also, at the pump. Which line is the return. I have two small lines then the feed line.

 

[GSXTasy005]

OK, sorry for the lack of information.

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This is a diagram of where components are, where you're looking for is "Y"

This post shows what your relay should look like, and where the bolts are to take it out (if you want): http://www.dsmtuners.com/forums/newbie-forum/263224-mfi-mpi-relay.html

It also explains how to test (if you do find out that it could be bad)

if there is still confusion, this pic should show you a little better:

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It's a pic of a 1G, but it's still the same basic location, you'll have to look behind the metal brackets to find it. it's bolted in

 

[98spydereugene]

The pump is turning on and pumping it sounds like so I doubt it's the relay...your plugs were dark???after 3 days?

 

[TSIflyer95]

I pulled out one plug just now and it is black, and dry. I have EVO 560 injectors...

The pump does turn on so I know it has power. I just can't get the damn thing to fire.

I'll see if maybe I change the plugs if it helps. They may be cooked. I'll snap a pic really quick.

 

[98spydereugene]

Are you showing fuel pressure at your gauge??

 

[TSIflyer95]

0 PSI at the gauge.

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Sorry for the crappy cell pics. That's the plug.

Everything is attached to the pump as I took it off. All the lines, the lock ring. All of it. It's like it won't pressurize though.

And that happened a few days ago. It would have 0PSI at idle but would still turn over and start. And it would be 40-50 psi at idle.

 

[98spydereugene]

Then maybe you do need to check relays, and power to pump, it may be turning on but not have enough power to build enough pressure...if your showing 0psi that pumps not working somehow..check the relays GSXtacy mentioned and definitely grab your multimeter and test power and grounds.

 

[TSIflyer95]

I know it has enough to move fuel because I tried to crank the motor with the pump half way out of the tank to see if it would squirt fuel everywhere and it did. Lol. Shot like a 3 foot stream.

 

[98spydereugene]

fpr took a dump then??

You could've sucked air in and have a gnarly air pocket blocking fuel as well, I would think it'd kick that air out, but thats beyond my knowledge I've never had this much of a problem with fuel..