HELP. 2.0 TDI BKD just cut out and wont start!

Westy · Jun 16, 2014

Hi guys,

The Mrs' car (a 2008 Golf GT TDI 140) has been totally fine all weekend. We've done about 150 miles this weekend without an issue. This morning she sets off to work, gets 2 miles down the road, it starts to jerk then just cuts out and won't restart.

RAC come to recover her. The guys scanner shows no faults at all. Apparently the RAC guy sprayed "something" on "something" lol. I've just got home and the mrs pointed at the air intake and said he sprayed something in there to get it started but it wouldn't stay started!

It all sounds like a fuelling issue of some sort. So I've scanned the car with full VCDS and there are no faults, none at all out of the norm! I've had injector issues before on my old car and I know they log lots of info when a fault is detected with them. So I checked all the fuses and can't find any blown. Battery is fine, dash, lights, radio etc. all working fine. Car turns over fine but just won't fire.

So I need suggestions please. Due to no Injector faults I'm thinking the fuel pump may have died but the car has only done 80K on a stock map so I'd be very surprised if it was that tired. I've also read about injectors on the newer engines (mainly 170ps) just packing in, and when 1 goes they all short out!

Anyone had this before or got any ideas for what I could try?

Lewis583 · Jun 16, 2014

Check the measuring blocks to see if you can log fuel pressure and watch it when cranking. That will give an indication of whether you have adequate supply from the fuel tank.

The break down guy just sprayed some easy start into the intake. It's a good indication of where the fault lies, if it runs on easy start then the issue is likely with the fueling side.

Edit: Also check the engine speed and the camshaft speed (If available) when cranking to make sure the ecu is seeing a reading from both via VCDS.

Westy · Jun 17, 2014

Cheers Lewis. Any idea which measuring block numbers?

r15wne · Jun 17, 2014

ive had that on my audi a4 2.0tdi engine exactly same situation no codes..just cut out whilst driving..
my friend auto electrician came round and activated the fuel pump from his diagnostic machine a few times ,
car came back to life..
i guess i got lucky it was just sticking and not permanent fault..
its not happenede again been around 2 months..
hope you get sorted..

Lewis583 · Jun 17, 2014

I don't I'm afraid Westy, not done much logging with the 2.0TDi unfortunately.

Westy · Jun 17, 2014

Just spent some time diagnosing the problem and it appears to be the in tank pump that's packed in!

The pump doesn't prime at all when the key is turned an I checked that power is getting to it so I'll be getting a price for a new pump tomorrow then I'll look forward to the messy job of fitting it.

smurfworth · Jun 17, 2014

i was gonna say, could have tried the old fashioned way of pulling the fuel filter out in the engine bay and seeing if theres any fuel being supplied to it, if not then theres a problem between the tank and the filter and if there is then there'd be a problem after the filter.

Westy · Jun 17, 2014

smurfworth said:
i was gonna say, could have tried the old fashioned way of pulling the fuel filter out in the engine bay and seeing if theres any fuel being supplied to it, if not then theres a problem between the tank and the filter and if there is then there'd be a problem after the filter.

I thought i'd go straight to the source! Rear bench out, fuel pump cover off, got mrs to turn the key and the pump is totally silent. I tried the same on my A3 just so I knew that the pump should actually make a noise and mine does plus I can feel it vibrate with my hand on the top. I then popped the electrical connector off it and my multimeter saw 12v when the key is turned so it is definitely getting power.

Bit annoyed that it's died after only 80k miles when my remapped A3 is on 150k and my old S3 only started to show signs of tiredness at around 120k!

Johnny Bravo · Jun 18, 2014

Yea... the old pumps had a tiny hole that allowed the tandem pump to draw fuel directly in case it fails and you could drive almost normal. The only problem was when starting the engine after a long stay, it would start difficult until the fuel would reach from the tank.
The newer pumps don't have that hole. If it fails is game over. You won't be able to start the engine.

Here is the most comprehensive discussion about the TDI PD fueling system I found on the internet:
2005 BEW PD lift pump operation and internals - TDIClub Forums

Westy · Jun 18, 2014

I'd expect the pump to have been a new part as the car is a 2008 but it's got the same BKD engine as my 2004 A3 so perhaps not! Hopefully the replacement pump will be a revised part?

Johnny Bravo · Jun 18, 2014

According to the topic from my link, the older cars had lift-umps with that... fail-safe feature. The newer cars, although with the same engine, come with a revised pump which is supposed to be better an which doesn't have that fail-safe feature.

Westy · Jun 18, 2014

Johnny Bravo said:
According to the topic from my link, the older cars had lift-umps with that... fail-safe feature. The newer cars, although with the same engine, come with a revised pump which is supposed to be better an which doesn't have that fail-safe feature.

Any idea when the new pumps came in?

Johnny Bravo · Jun 18, 2014

Unfortunately no! I just removed ETKA from my computer and I can't check.

Westy · Jun 18, 2014

Johnny Bravo said:
Unfortunately no! I just removed ETKA from my computer and I can't check.

I've got ETKA I just be bothered to fire up the shonky old laptop it's on

No worries, I'm ordering a new pump tomorrow.

Westy · Jun 21, 2014

New pump in, can now hear it priming and feel it vibrating but car still won't start. Turned it over and over in case air was in the system but nothing. Fuel is in the filter so I'm now suspecting either HPFP or injectors! MY next door neighbour fixes planes for a living and he said that his jeep can sometimes take over 5 mins of cranking after a fuel filter change to bleed the air out! I refuse to keep cranking it as I don't want to wreck the starter!

Anyone got any ideas before I get a mech to take a look???

Phil-1 · Jun 21, 2014

I might be wrong. But I thought you have to use VCDS to prime the system after a fuel filter change. This might be the same as you have changed the pump. But as said I could be wrong.

Westy · Jun 21, 2014

Phil-1 said:
I might be wrong. But I thought you have to use VCDS to prime the system after a fuel filter change. This might be the same as you have changed the pump. But as said I could be wrong.

Thanks for the suggestion Phil. I've used VCDS to turn the fuel pump on in the basic settings but no change.

Westy · Jun 21, 2014

It's alive! Used some easy start to give it a helping hand. A huge black cloud of smoke came out and then it was fine. Cheers guys.

Phil-1 · Jun 21, 2014

Glad you got it sorted

Andytrucker63 · Jun 27, 2017

Hi I have an Audi A4 2.0tdi 170bhp it was cutting out no error codes .I changed the crank sensor worked ok for a few days then stared happening again. I went and bought a genuine crank sensor from Audi and have had no problems. Hope this help anybody

Marek196c · Jun 30, 2017

I will add that if you remove the fuel filter or don't got the fuel in it, you will need to unbolt the bolt on top to take air off and put into accessory position key to turn up the pump for few seconds, put the screw again and then cranking might take up to 40 seconds before it fire up.

HELP. 2.0 TDI BKD just cut out and wont start!

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