Hey everyone, I’ve got a 2002 Jetta TDI that’s been playing stump the mechanic for the past two weeks. I’ve had about $800 worth of work (most of which had error codes and were necessary), but given that the next suggestion is to replace the fuel pump at a cost of ~$2k, I figured it was time to ge…

Your ignition relay is shorting out. One of the contacts is shorting against the metal case of the relay. For some reason the relay expands just enough to where there is a short. Happened on our 87 Jettas (we had 2) and especially dangerous on the freeway driving 70, middlelanes. . Relay on our 87…

Has anyone checked the fuel filter on this car?? Diesels are very sencitive about dirty filters as they are also water seperators.

I find it hard to believe a good mechanic can’t fix this, if he has seen it happen. Does he, by chance, own a boat or a house on a tropical island someplace?

OP, We even had the computer module changed. It is the relay.

Check the new relay to insure there is enough clearance. You will see it.

It sounds like your mechanic is on the case. Those are all the thing’s I’d have thought of. I probsablyu wouldn’t have changed them out until they were proved to be not working, but that’s a judgement call. Pay att’n to what @longprime is saying, seem sto be speaking from experience. If it’s not…

$2K for a fuel pump! That’s high even for a diesel. I’d certainly follow up on the relay possibility and before you give the OK on the fuel pump make sure the mechanic checks the fuel line pressure. How many miles on your Jetta? It should go at least 250K before needing replacement.

There absolutely must be no air bubbles in the fuel line of a VW diesel, TDI or IDI. Get that air leak fixed first. Then post on TDIClub.com if you still have the starting problem. Many more diesel experts and owners there.

it I remember, Our Gas Jetta, had 2 pumps. and yes we changed the gas tank pump.

2002 Jetta TDI Won't Start When Engine is Hot

Maintenance/Repairs

GSragtop October 24, 2012, 6:03pm 5

As a follow up a Diesel motor is very basic when it comes to running as there is no ignition system… ALL you need is Fuel and Compression… The issue as you are finding out is there are a few reasons for poor fuel pressure. One can be the pump, but like I said above make sure someone has checked those filters. This is more true if they have not been changed…

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2002 Jetta TDI Won't Start When Engine is Hot

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