Empty Tank Problems: Troubleshooting & Solutions

Hello,
Last week, my fuel gauge completely misled me! It showed about halfway to empty, but the car was already hard to start in the evening. The next morning, it wouldn't start at all. I had to go to the gas station, get a canister, etc....
After a while (several minutes) of gurgling, it started up again (I always thought it would self-bleed and start up much faster!).
Since then, this has happened to me three times: I was stopped at a traffic light, for example, and the engine suddenly stalled! Each time, I had to struggle with the starter for about 20 seconds to get it started again.
What could be the reason for that?
I suspect there are still some air bubbles trapped in the fuel filter.
Or did I destroy my fuel injection pump during that operation?

Volkswagen Golf 3 AFN, 153,000 km.

It's quite likely that your ESP is sucking in a lot of air instead of diesel... there's been a lot written about this already.
-> Search function

Best regards, Rainer.

Rainer K. wrote:

It's quite likely that your ESP is sucking in a lot of air instead of diesel...

Hi Rainer,

The symptomatology suggests this direction. But how and why can so much air still be sucked in, even "long" after the refilling, causing the engine to stall?

In order for this to happen, the pump needs to be approximately half empty, as I know from repeatedly opening the pump and previously "siphoning" out the diesel.
Once more than about half of the diesel fuel is in the tank, it starts up as usual and runs smoothly.
The engine will briefly "stumble" at idle only when the internal pressure in the pump reaches its normal level (i.e., when all the air has been purged), because the fuel injection timing then needs to be readjusted.

Can running a fuel system dry lead to leaks that later continuously draw in air ?

To me, the "empty tank-refill-sludge-swirl-filter seal" theory seems more plausible so far.
Only then would a significant lack of performance be noticeable .

Hi,

I'm leaning more towards a leak in the fuel system, which would be more noticeable when the tank is relatively empty.

Best regards, Rainer.

ulf wrote:

To me, the "empty-travel-night-refueling-sludge-swirl-filter tight" theory seems more plausible so far. Only then would a significant lack of performance likely be noticeable

.

Hi,

I can also confirm that . There can be quite a bit of buildup in the tank, so you should replace the fuel filter .

I can also confirm the leak theory . If I only have about 4 liters left in the tank, then large amounts of air bubbles go to the ESP .

My fuel gauge (Passat 1Z 1995) also shows incorrect values, approximately 10 liters off: Then, the next question is, how does one adjust the fuel sender ?

Best regards, Christian.