VW Bora Fuel System Fault Causing Stalling and Power Loss

Had similar symptoms on my 2004 VW Golf with the 1.6L gasoline engine. The check engine light came on after changing the fuel filter, followed by rough idle and stalling issues. The problem turned out to be more complex than just the fuel pressure regulator. The fuel rail pressure sensor was faulty, causing incorrect readings and making the engine run either too rich or too lean. When diagnosed, multiple trouble codes showed up related to fuel pressure regulation. It needed a complete fuel system diagnosis. The technician found that debris from the old fuel filter had contaminated the fuel rail and pressure regulator. The entire fuel rail assembly required cleaning, and both the pressure sensor and regulator needed replacement to resolve the rough idle issues. This was a serious repair requiring specialized diagnostic equipment for the fuel system. The job involved: Fuel system pressure testing, Cleaning the fuel rail, Replacing the pressure sensor, Installing a new fuel pressure regulator, Clearing all system codes Best advice is to get it properly diagnosed with a VW-specific scan tool. These symptoms almost always indicate fuel delivery problems that worsen over time if left unchecked.

Thanks for sharing your experience. What you described sounds exactly like what happened with my Bora last month. The rough idle was driving me crazy, and I was also losing fuel efficiency badly. Did the repairs fully solve your issues? Curious about the final cost since I ended up paying around 450€ for my fuel system overhaul. Also wondering if your fuel pump showed any signs of wear during the inspection? My mechanic mentioned it could be a potential future concern.

Thanks for asking about the follow-up. The repairs completely resolved all the issues with my Golf. After fixing the defective fuel pressure regulator, the engine runs smoothly with no more engine misfires or stalling problems. My total repair costs were much lower at 45€, which just covered fixing the error code entry after the fuel filter change. Seems like your case required more extensive work with the complete fuel system overhaul. The fuel pump on my car showed no signs of wear during inspection. The main culprit was definitely the fuel pressure regulator causing irregular fuel delivery. Since the repair, fuel efficiency has returned to normal and the engine maintains steady pressure at all speeds. The initial symptoms were concerning, but getting the proper diagnosis and fixing the specific issue with the pressure regulator proved to be the right approach. No warning lights or performance problems have returned in the months since the repair.

I really appreciate all the feedback. Just wanted to update everyone on how things turned out. After checking multiple shops, I found a certified VW specialist who really knew their stuff about fuel system diagnostics. The check engine light issue turned out to be exactly what described. My mechanic found similar problems with the fuel pressure regulation and some contamination in the system. The complete diagnosis revealed a failing fuel pump along with the pressure regulator issues. The final fix included: New fuel pump installation, Fuel system cleaning, Pressure regulator replacement, Full system diagnostic reset Total cost came to 450€ but worth every cent. The rough idle is completely gone, no more engine misfire, and the car runs like new again. Fuel economy has improved significantly too. For anyone facing similar symptoms, definitely get it checked by a specialist. Waiting would have likely caused more extensive damage to the fuel system.