I have a greasecar conversion kit and have had a hell of a time lately. I've been chasing air leaks and other ghosts, and wonder if my diesel lift pump may be bad. I've reconnected the stock fuel supply and return lines to the stock fuel filter and cannot rev over 3000 rpm. However, if I disconnect those lines and dip them in a container full of fuel, it runs and revs just fine.
As part of the greasecar install, I had to cut into the blue with red stripe wire going to the fuel pump, then connect in the red/brown wires. I removed this connect today and put it back stock, but it still exhibits the same behavior. I tried having a test light on that wire and cycling 'on' to 'off' on the key - the light comes on and stays on (contrary to GC instructions which say it should go off after a few seconds) and I do not hear anything.
How can I go about testing the in-tank lift pump for proper functionality - and if it's dead, how would i replace it? I tried turning what looks like a cap, but could not budge and didn't want to damage it.
Did you ever figure out why the fuel pump went bad? I've experienced the exact same problem and waiting for my ne pump to arrive. Don't want to ruin another one. - rob@mrrickshaw.com
search on tdiclub.com and you'll find the 2004's were notorious for going bad. This one lasted about a year and also died. I contacted BoraParts.com and found out that they were not a real company. Some employee of KermaTDI was redirecting their customers to his own little side business. I contacted KermaTDI, who graciously accepted my dead one and sent me a new one at no charge.
