dereko

As Topic states, 2003 Carrera 2, Car had deeply discharged battery, so flat not even interior lights or dash lights went on, Car is very rarely driven and battery approx 4 years old, so no big surprise it finally died, i'm surprised it made it this far.

Bought a new Battery from Costco, fitted, tried to start today, starter cranks as normal but will not start.

Tried jump starting with other car, in case the cranking current on the new battery they sold me was insufficient, car cranked harder and faster, but still no start.

Checked fuses C1 - C4 for fuel pump etc, all OK

Pulled out fuel pump relay, seems to test OK.

Jumpered the fuel pump terminals on relay socket, pump is definitely trying to pull current, as jumper arcs and can hear a click from fuel pump, but no pumping whirring noises.

I had replaced the fuel pump only about 18 months ago with a brand new one, I'm suspicious it has seized. I do rarely drive the car and I'm wondering if this is aggravating it, if its the pump again.

It does have all the same symptoms as when the pump died last time, however I'm just suspicious as its occurred immediately after a very dead battery, as was fine prior.

What should I do next, can I remove the fuel pump and run some sort of test outside the car? I'm reluctant to just order a new pump just yet as this one is seriously quite new, and done less than 1000km

Is there anything you have to "reset" when you have a dead battery?

Ahsai

You can try e-gas calibration: turn key to the last position before crank and leave it there for 60s, then turn key to OFF and wait 10s.

However, if the fuel pump does not run when jumped at the relay terminals directly, it is seized.

dereko

Thanks Ashai, I'll give that a try

You were the one that stepped me through the diagnosis last time with the fuel pump, I am very grateful.

From memory, I should be able to hear the fuel pump whirring where the ignition is on?

Just a bit sus as the pump is quite new

Ahsai

You're welcome. Yeah, you should hear the pump for about 1s when you turn the key to the last position before crank. Regardless, jumping from the fuel pump relay is the most direct way so if you dont hear it, it's most likely seized. Be careful jumping a seized pump though. It may blow the fuse due to large current. If you see spark and don't hear the pump, it's definitely not running.

Did you replace the whole assembly with an OE unit?

dereko

tried e-as reset, no joy

Should I pull the pump out and have a look at it?

dereko

I replaced the fuel pump with a new VDO OE unit last time, didn't replace the sender assembly

dereko

When I jump the relay, with the ignition on, I do get a good spark, can hear a bit of a clunk from fuel tank when I first make contact, but no whirring pump noises

Ahsai

Yeah, sounds like the pump is stuck. Seems the only way is to extract it.

Ahsai

Actually ignition does not need to be ON because the fuel pump power at the relay terminal is always hot. You used a fat wire to jump it, right? Just want to make sure the pump gets enough current.

dereko

Yes, used 1.5 sq mm wire

dereko

Is there a safe way to test the pump once I remove it from the fuel tank?

Mike Murphy

Was the filter replace?

Macster

Test it in the tank. Disconnect the pump from the car's electrical system and then connect 12V power directly to the pump. The pump should run and run with no problems.

If it runs the no start problem lies elsewhere.

If it doesn't run the pump is bad.

808Bill

It amazes me how many problems occur due to a dead battery...

dereko

Good idea Macster, do you know what the connections are on the electrical header without pulling the pump out

There are 4 terminals 1. Thick Green/white 2.thin purple 3. Thin brown 4. Thick Brown

From memory the thick brown is generally ground. Two of them will be the level sender