VW Bora Fuel Pump Failure: Symptoms and Solutions

I had a similar situation with my VW Golf from 2003, and having some experience with fuel system repairs, I can share my insights about the automotive diagnosis process. The symptoms you describe match what I experienced, poor starting, rough idle, and increased fuel consumption. My workshop first performed a fuel pressure test to verify the gasoline delivery system was the culprit. They also scanned for error codes and checked the fuel filter and electrical connections. Turned out the main issue was just a faulty connection to the fuel pump. The plug had corroded over time, causing intermittent electrical contact. The repair involved cleaning the connections and replacing the damaged wiring, costing 95€ for parts and labor. Car performance returned to normal immediately after fixing the connection. Before jumping to a full fuel pump replacement, you might want to have them check: Fuel pressure, Electrical connections and wiring, Fuel filter condition, Relay and fuse status Could you share: What error codes are you getting? When was the last fuel filter change? Does the problem get worse when the fuel tank is below quarter full? Are there any unusual sounds from the fuel tank area? This information would help determine if your issue matches what I experienced or points to a different fuel system problem.

Thanks for all that feedback. Just had the car error codes read at last service 2 weeks ago. The fuel pressure test showed readings well below spec and the fuel pump was making a whining noise. Got quotes between 450€-700€ for a complete fuel pump assembly replacement including labor. The car performance issues persist especially during hot weather when the pump seems to struggle more. The fuel injector testing showed consistent spray patterns, so the workshop is confident the pump is the main culprit. They suggested a known aftermarket brand rather than OEM due to significant cost savings. My mileage is now at 146247km and wondering if this is a common failure point for the fuel pump on these models?

Following up on my previous reply about the electrical connection issue, your situation does sound more serious than what I encountered with my Golf. The whining noise and low fuel pressure readings are classic indicators of a failing fuel pump, unlike my simpler connection problem. At similar mileage on my Golf, I actually ended up replacing the entire fuel pump about 6 months after fixing those initial connection issues. The automotive diagnosis process was similar to yours, low pressure readings and pump noise. The fuel injectors checked out fine in my case too. For the fuel pump replacement, I went with Bosch aftermarket and paid around 500€ including labor. The gasoline delivery system has worked flawlessly since then, with normal fuel consumption returning and no more starting issues. The hot weather correlation you mentioned matches typical fuel pump behavior when failing, heat makes the worn components struggle more. This is exactly what I experienced before the replacement. Regarding your question about common failure points, these fuel pumps typically last 120000-150000km, so your mileage is right in that expected range. I would agree with your workshop that a quality aftermarket pump is a smart choice. The price quotes you got are in line with what I paid for the repair. Have you noticed if the problem gets significantly worse during longer drives when the engine is fully warm?

Good observations and recommendations. Those fuel pressure readings and whining noise definitely confirm my suspicions about the fuel pump failing. Based on the workshop's diagnosis and your experience with a similar repair, I feel more confident about proceeding with the replacement. The automotive diagnosis process seems thorough, they checked both the fuel pressure and injectors which rules out other potential issues. The car performance problems do get worse during extended drives, especially in traffic when the engine stays hot for longer periods. After hearing about your positive experience with an aftermarket pump, I will likely go with their recommendation rather than the more expensive OEM option. The 450-700€ range seems reasonable considering the labor involved in accessing and replacing the complete fuel pump assembly. Thanks for confirming this is a common failure point around my current mileage. Will schedule the repair soon before the pump fails completely and leaves me stranded. Hoping this resolves all the starting and stalling issues I have been experiencing.