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Low Fuel Pressure Sensor Replacement
 
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Pelican Technical Article:

Low Fuel Pressure Sensor Replacement

Steve Vernon

Time:

45 minutes45 mins

Tab:

$40

Talent:

*

Tools:

23mm or large adjustable wrench

Applicable Models:

VW GTI (2006-09)

Parts Required:

New low fuel pressure sensor

Hot Tip:

Work on a cold engine

Performance Gain:

Car runs like normal again

Complementary Modification:

Replace fuel injectors

The Volkswagen GTI MkV has two separate fuel pumps; one in the tank and a high pressure pump mounted on the engine. Fuel pressure is critical on most engines but even more so on the direct injection motors. If you are getting an error code that you have low fuel pressure to the high pressure pump changing your sensor is the first step in trouble shooting.

You are going to be working on the fuel system so be prepared: Work in a well ventilated area. Keep a fire extinguisher near you at all times and know how to use it correctly. No sparks or open flame around and if you smoke now would be a really good time to quit: at least for the half hour it might take you to perform this job.

Just as with the fuel filter, injectors, or any other component of the fuel system, it's best to relieve the fuel system of any pressure before you go opening it up. The engine should be cold while doing this so open the gas cap while the motor is cooling down and help relieve the vacuum in the system. Also, be sure to use some protective gloves and goggles whenever you're working with fuel.

If you do not have an after market air induction system you will need to remove the engine cover.
Figure 1

If you do not have an after market air induction system you will need to remove the engine cover. Please see our article on engine cover removal for additional assistance.

You are going to want to run the fuel out of the system.
Figure 2

You are going to want to run the fuel out of the system. Begin by opening the access panel on the left side of the dash by using a trim removal tool and gently prying the panel out from the dash (red arrow).

Use the fuse removal tool on the back of the panel and remove the fuse for the fuel pump (red arrow).
Figure 3

Use the fuse removal tool on the back of the panel and remove the fuse for the fuel pump (red arrow). Make sure to check with your owners manual to locate the proper fuse. With the fuse removed try to start the engine; if it does start it will die quickly from fuel starvation. Usually a couple turns of the key will do it.

There is a Schrader valve located on the pump housing (red arrow).
Figure 4

There is a Schrader valve located on the pump housing (red arrow). You can unscrew the cap and use the valve to relieve any residual pressure. Have a rag or cloth handy to catch whatever remaining fuel that will come out.

The plastic hose (yellow arrow) that is part of the emission system runs directly over the sensor (red arrow).
Figure 5

The plastic hose (yellow arrow) that is part of the emission system runs directly over the sensor (red arrow). These hose get very brittle so it is better to carefully remove it that risk breaking it trying to work around it.

Gently squeeze in the tabs (red arrows) on the ends of the hose.
Figure 6

Gently squeeze in the tabs (red arrows) on the ends of the hose.

Squeeze and wiggle the hose off.
Figure 7

Squeeze and wiggle the hose off. You can see the ridge area you use to squeeze the hose.

Unclip the wiring harness (red arrow) from the sensor (yellow arrow).
Figure 8

Unclip the wiring harness (red arrow) from the sensor (yellow arrow).

Use a 23mm wrench or large adjustable wrench and remove the sensor, be prepared to catch a little fuel that may spill out.
Figure 9

Use a 23mm wrench or large adjustable wrench and remove the sensor, be prepared to catch a little fuel that may spill out. The large "nut" end of the sensor is made out of a softer metal so use care not to round it off. There is a small O-ring (red arrow) on the sensor, if you are reinserting the old sensor make sure of the condition of this O-ring. Installation of the new sensor is the reverse of removal.

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Comments and Suggestions:
Problems Comments: I have a 2007 golf 1.9tdi cuts out whenever it reaches temperature I'm getting no fault codes iv swapped camshaft sensor crankshaft sensor temperature sensor still no joy I'm beginning to think it's the high pressure pump or injectors failing when hot as is misfires for a second and then cuts off and will not restart Untill its cold again
October 26, 2016
  Followup from the Pelican Staff: I can't help without knowing what is missing from the system when you are trying to start it. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume, quality and engine compression. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose.
- Nick at Pelican Parts
 
Greasey Rider Comments: Love how well you document what you do in photos , I am looking for how a EMC is held down securely in a 2007 VW Touareg 3.6 v6 engine. any help would be appreciated .
September 18, 2016
  Followup from the Pelican Staff: What do you mean by EMC? - Nick at Pelican Parts  
skoot Comments: Golf 5, 2.0 started to be sluggish when I'm on the road, sometimes it gets hard start. Replaced the presure pump in the petrol tank, but its still sluggish. What should I do. Please help
September 7, 2016
  Followup from the Pelican Staff: Is the check engine light on or flashing when the problem is present? Sounds like an engine misfire. I would check spark, fuel and compression on all cylinders. - Nick at Pelican Parts  

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