Anyone have this problem? Add in 1 gallon of gas and it starts. Runs fine otherwise.
thanks,
Dave

 

Mine did that after pump replacement

 

the pump must be removed and inspected. New pumps aren't cheap, unfortunately. Search this forum for "fuel pump" and you will find a lot of info on how these things work.

 

I had the same problem, had to replace the whole fuel pump. Not cheap, but nothing on these cars is.

 

You also CANNOT test this pump on a bench. It must be submerged.

 

Local shop needed a couple of tries to get my pump replacement just right.

 

Having done my own fuel pump after it burned out due to a flood (along with the TCU, ECU and Several coils), I can tell you that there are several quick disconnect lines throughout the system and if any of them becomes disconnected, the whole suction system becomes faulty. Also there is a line which dumps fuel into a "cup" in which the fuel pump sits. If this cup feed line becomes dislodged, then your fuel pump is no longer submerged and sucks air...no fuel... Most of the fasteners are remarkably flimsy so this line could become dislodged and cause the problem. The fuel pump itself either works or it doesn't...sort of. If your lines are all OK and your pump is in the process of dying, then it is possible that it no longer has enough oooomph to keep the return stream from the far corners of the tank priming the cup.

Simply put, the pump is not at the lowest part of the tank, but sits in a plastic baffle and this suction system keeps the cup filled and the pump submerged.

I think I had the most miserable fuel pump replacemnt process known to man - a worst casee scenario where I had to weld up a special foot long hole saw and cut out the fuel pump assembly around the retaining bolt. Search "Das Boot" and you will see what I mean, The catch 22 is, replacing the fuel pump is EASY, once you know how.

When you replace a fuel pump put in a gallon or two to an empty tank, then pop the cover off the fuel pump relay and lay a rubber handled pliers on the contact to hot wire the pump. Buy a banjo fitting to attach to the High pressure output and add three feet or so of fuel hose. Let it pump into a fuel can. If it starts strong then after a few seconds begins to aerate and spit...its is wrong...try again..once it pumps out all but ..say...a half gallon or less.. you ae good to go. This is a hell of a lot better then the Audi reccomended method of "Go for a drive and run out of gas" Good luck. Random thoughth...WD-40 makes the tough job of getting the rubber gasket back in EASY.