ke5in

Hello,

My wife has a 96 jetta that won’t start. On my 92 jetta I can hear the fuel pump kick-in when I turn the key but, currently, I do not hear her fuel pump kick-in when I turn the key to the on position on her car. Should I be able to hear it on the 96 jetta like I do on the 92 jetta? (I ask her if she had heard it in the past and her reply was “Fuel Pump?”) I even had her turn the engine over while I put my ear against the fuel pump cover and I did not hear anything.

So I removed the electrical connector from the fuel pump cover and put my multi-meter on the connector. I capture a max of 11.2V. This is reasonable since I know she cranked the engine more than a couple times and drained the battery some, plus the battery is about 5 years old.

I’m pretty confident that it’s the fuel pump but I was told to check with you guys first.

Also, could you give me some advice on actually removing and replacing the fuel pump (if you think that’s my problem)?

Here is a link to a photo of the pump cover:
http://ke5in.com/96_Jetta_fuel_pump.htm


Summary Info:
1) 96 jetta 2.0L automatic

2) Won’t start in driveway

3)Sounds fine trying to crank over (i.e. I can hear the starter engaging the engine and it all sounds normal) but just won’t start.

4) Can’t hear the fuel pump but I get 11.2v at the connector.


Thanks!
-Kevin

Tacuvito

Well here is what I learned on how to remove the pump from the gas tank. Hope it helps you.
1. disconnect the negative battery cable.
2. Fold down rear seat and pull back the floor cover along with the insulation. Remove the access panel from above the fuel pump.
3.Disconnect the harness connector, the supply line, and the return line from the fuel pump. By the way these two line will be color coded The black line is the supply line, the return line will be blue in color.
4. Unscrew the fuel pump retaining ring or fuel pump cap nut however you want to call it. lift the fuel pump assembly slowly, empty pump of fuel still in it. And that is it! to install, reverse everything I have just said, but make sure to check all the seals specially the one between the fuel pump and fuel pump flange (the top part of the pump where the return and supply line come out of. Make sure to inspect the filter screen which is at the bottom of pump ,I would replace it.
Enjoy all the fumes around the place or if you are not of the mind expanding type, make sure you are working in a well ventilated area. hope it helps you out.
Tacuvito.

ke5in

Tacuvito,

Thanks for the reply. But I believe I can see the fuel pump access cap from inside the trunk. Do I really need to go through the back seat? (its a 96 jetta)

Here is a link to a photo of the pump cover. I took the picture from inside the trunk:
http://ke5in.com/96_Jetta_fuel_pump.htm

Tacuvito

Well, its for easier access, If you can get to it and nothing is blocking your way, go to town on it.
Tacuvito.

ke5in

Tacuvito,

Thanks! I never knew that the rear seat folded down. And that made changing the fuel pump a lot easier.

-----
But I am wondering if I still have a problem... After I took the old pump out of the tank, I connected the new pump to the harness connector while it was _outside_ the tank. I turned the key to the on position just to see if I could hear the new pump briefly turn on like it does on my 92 jetta (described above). It did not turn on.

So then I started to think that maybe my old pump was not bad and that I should return the new pump and get my money back. Then I figured, well maybe the 96 jetta does not turn on the way the 92 does for that brief second. (when I took old pump off for the first time I noticed that there was a little pressure in the hoses.)

Here is the strange thing: I disconnected the new pump and then connected the old pump to the harness connector while it was still OUTSIDE the tank. The two fuel lines, supply and return, were not connected to anything. I turned the key ALL the way ON just to see if the old pump would work AND THE ENGINE STARTED!!!!! The fuel lines were not connected to anything!!!!! Now I am really puzzled!!!!! The car had not started in days and now suddenly starts without the fuel lines connected to anything! So I put the old pump back in and hooked it all up thinking to bring the new pump back to the dealer. I started the car up and it ran ok. Just then my dad drove over got out of his car and said to me "Sounds like your engine is running a little rough." Honestly, I did not think so but he convinced me to put the NEW pump in the car. So I did. He claims that the engine now sounds better to him but I don’t hear anything different, however, I will say that I think the car does have more power now.

I would really love to know if I truly fixed the car by replacing the pump. Mainly because this is my wife’s car and I don’t want it to fail on her while she is driving. Why would the car start after I unhooked the fuel lines??? How likely is it that my “no start” problem described in my first post is related to the fuel pump given this new information? Was it a good idea to replace the pump anyway? (The car had 90,000 miles).

If you read this entire message: Thank you!

-Kevin

Tacuvito

Isn't it great to discover new things in your old car! Now you will have more cargo space back there by collapsing both rear seats. As for you concern, I have to say that it could have been a problem with you lines having air in them. Sometimes if you park your car on an incline surface and you have less then a quarter tank of fuel, it might make the fuel pump suck air instead of gas causing it to create air bubble in your lines. When you disconnected the lines it cleared the blockage. Also it could be your fuel regulator. As far as the expense of replacing the fuel pump, just look at it like this. You won't have to worry about the fuel malfunctioning for good time. If you feel the need to replace the regulator, test the old one by swaping it with one from the junk yard if you can find one. It would be alot cheaper then buying a new one. If you notice a difference, then either use the one you got at the yard or just buy a new one.
hope this helps you.
Tacuvito.