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Author Topic: Mk5 GTi stage 1 fuel pressure problems  (Read 725 times)

Offline Lassebongo

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Mk5 GTi stage 1 fuel pressure problems
« on: August 28, 2025, 12:15:19 pm »
Hi!
Im new here so if the thread is posted in the wrong section let me know.

Ive got a 2008 Gti mk5 stage 1 with fuel pressure problems.
On hard pulls it jerks and in the VCDS logs the pressure drops from 110 bar to 7(with the new HPFP, the old one went up to 129 bar and dropped)
A local company loaned me a HPFP which is swapped but didnt solve the problem.
Fuel filter swapped last year.
The cam follower is also new, doublechecked and its in pristine condition.
There are no leaks from what i can see, atleast around the visible fuel rails and HPFP.

So whats left is the in tank pump and im pulling it out today but i dont know what to look for  :scared:

Could there be anything else causing this problem or can i just swap out the in tank pump and the problem should be solved ?
Can the in tank be repaired ?
Is a 4 bar pump enough?

Offline ZoliWorks

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Re: Mk5 GTi stage 1 fuel pressure problems
« Reply #1 on: August 29, 2025, 01:23:41 am »
Check the part number of your old pump and buy based off of that. IIRC you need a 6 bar pump and a 6.6 bar filter.

Log the low pressure side with vcds next time you go for a drive so you can check what the pump is doing. Could be the pump, could be the controller or could be a worn out HPFP lobe. Even just a slight bit ow wear on th elobe can mess with the regulator open/close times and in turn mess up your fuel pressure.
Mk5 Jetta 2.0 TFSI BWA | Manual | Mk6 GTI Front | BorgWarner K04 Turbo | Sachs X-Tend Clutch Kit | Ta-Technix Air Intake | Ta-Technix Cat-less Downpipe | Ta-Technix Sandwich Intercooler | OEM S3 Injectors | Vis Motorsport 175 bar HPFP | 319hp 491nm


Offline Lassebongo

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Re: Mk5 GTi stage 1 fuel pressure problems
« Reply #2 on: August 29, 2025, 10:03:43 am »
Ty for the reply
I did the filter swap myself last year and did check the pressure requirements beforehand so the filter is the correct one.
Here are the logs:
https://log.tunezilla.com/s/bbQzxooI

I'm doing tests on the n80 today and checking if the charcoal canister is clogged because there is a hiss when opening the fuel cap.

How do I test the controller on the fuel tank lid?

Offline ZoliWorks

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Re: Mk5 GTi stage 1 fuel pressure problems
« Reply #3 on: August 29, 2025, 03:46:20 pm »
Holy, yeah look at your low-pressure side, that's basically dead. I'd say in-tank pump, controller or maybe the filter but unlikely. Your low pressure side is basically starving your engine completely. It should never really drop under 4.5 bar on full WOT.



Try logging the in-tank pump duty cycle as well. I forgot the exact VCDS param for it. Auxiliary fuel pump or electric fuel pump? something like that.

If you're going to replace it, there are a few threads here with people and the pumps they used.
Mk5 Jetta 2.0 TFSI BWA | Manual | Mk6 GTI Front | BorgWarner K04 Turbo | Sachs X-Tend Clutch Kit | Ta-Technix Air Intake | Ta-Technix Cat-less Downpipe | Ta-Technix Sandwich Intercooler | OEM S3 Injectors | Vis Motorsport 175 bar HPFP | 319hp 491nm


Offline Lassebongo

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Re: Mk5 GTi stage 1 fuel pressure problems
« Reply #4 on: August 29, 2025, 09:18:53 pm »
Yea as I feared I ordered a new pump and controller. The new pump will have a newer revision, 1t0 DB i think it was, same with the controller. It's weird though because its a low milage for its age. 130k
Yea I did log the duty cycle att some point, lost the file, it did max out at 95% if I remember correctly.
Thanks for the insight, I'll post the results after the swap!
« Last Edit: August 29, 2025, 09:24:27 pm by Lassebongo »

Offline ZoliWorks

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Re: Mk5 GTi stage 1 fuel pressure problems
« Reply #5 on: Yesterday at 01:03:33 pm »
100k is about the expected lifetime of these pumps tbh. They will last more but can break at any moment.

95% is basically dead. IIRC even under WOT it should be around 65 max. I think I deleted my logs but I dont think I've ever seen it go above 70 and that was when when I was pushing it for 370hp
Mk5 Jetta 2.0 TFSI BWA | Manual | Mk6 GTI Front | BorgWarner K04 Turbo | Sachs X-Tend Clutch Kit | Ta-Technix Air Intake | Ta-Technix Cat-less Downpipe | Ta-Technix Sandwich Intercooler | OEM S3 Injectors | Vis Motorsport 175 bar HPFP | 319hp 491nm


Offline Lassebongo

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Re: Mk5 GTi stage 1 fuel pressure problems
« Reply #6 on: Yesterday at 06:00:06 pm »
Alright good to know! Also found that cylinder 4 misfires, not much but still. How long does the injectors last you think? Recently replaced all the seals on the injectors but it didn't fix the misfires, so I'm suspecting they are on their way out as well.

Offline ZoliWorks

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Re: Mk5 GTi stage 1 fuel pressure problems
« Reply #7 on: Yesterday at 06:15:12 pm »
The injectors themselves have a general lifetime of no more than 100k km. They'll work more than this, but under 100k is when they still operate in factory params. Then again, you cant trust sh*t nowadays cause i installed 4 brand new oem injectors in mine and one failed after a month...

Injectors generally fail by leaking or getting stuck open/closed. They are engineered with very small tolerances so once they get dirty inside, that's the end of them. you also cant really clean petrol injectors because of mechanical wear. To get a matching set of 4 injectors that all spray in the same pattern and the same volume, you need to refurb about 14 injectors at least.

Another thing that fails about them is the filter at the top. It literally disintegrate and get's sucked into the injector. OEM filters last about 60k km or less so most people opt for mesh baskets instead.



Now regarding misfires, it could be caused by many things. My misfires under WOT were caused by a sticking injector while my current misfires at idle are caused by mechanical wear inside the engine. Specifically, my camshafts are rusted and pitted. During idle, cyl 3 misfires 90% of them time.

Other likely causes are spark plugs, ignition coils, valves that arent sealing properly, carbon buildup on the valves and in the intake, faulty pcv system, faulty maf, or a vacuum leak. Plus billion other things...

My advice is, as long as it runs and doesnt have issues during WOT, dont try to fix it lol
Mk5 Jetta 2.0 TFSI BWA | Manual | Mk6 GTI Front | BorgWarner K04 Turbo | Sachs X-Tend Clutch Kit | Ta-Technix Air Intake | Ta-Technix Cat-less Downpipe | Ta-Technix Sandwich Intercooler | OEM S3 Injectors | Vis Motorsport 175 bar HPFP | 319hp 491nm