VW Crafter Fuel System Nightmare: Stalling and Misfires

I experienced similar fuel system issues with my 2015 VW Transporter diesel. As someone with moderate experience in car maintenance, these symptoms strongly suggest fuel pump problems, which matches what you're describing. My vehicle showed identical warning signs, rough running, stalling, and increased fuel consumption. The auto repair shop diagnosed a faulty electrical connection at the fuel pump assembly. The check engine light was also illuminated in my case. The repair involved replacing damaged wiring and a corroded plug connection to the fuel pump. Total cost was 95€ for the repair, which was relatively straightforward once properly diagnosed. The car performance returned to normal immediately after fixing the connection issues. To better assist with your specific case, could you share: Any unusual noises from the fuel tank area? When did these symptoms first appear? Have you recently filled up at a different fuel station? What error codes is your vehicle showing? These details would help determine if your Crafter is experiencing the same fuel pump electrical issues I encountered. Proper diagnosis is crucial since similar symptoms can sometimes indicate other fuel system problems.

I had my last service just 2 weeks ago at 160640KM. The automotive diagnosis showed normal readings back then, which makes the sudden fuel pump issues even more concerning. After reading your response about electrical connections, I checked and heard a faint buzzing near the fuel tank when turning the key, definitely not the normal fuel pump sound I am used to. The engine stalling started 3 days ago, and fuel consumption jumped from normal to extremely high practically overnight. The error codes point to issues with gasoline delivery pressure, but since everything was fine at the recent service, I wonder if something got damaged during that inspection. The engine performance problems seem too severe for just a wiring issue, making me think the entire fuel pump assembly might need replacement. Did your repair shop perform any specific tests before concluding it was just the electrical connection? Want to make sure I am not missing any crucial diagnostic steps before potentially paying for a complete pump replacement.

Those readings at your recent service make this situation quite unusual. The abnormal buzzing sound combined with the error codes related to fuel pressure strongly suggests this goes beyond just electrical connections in my case. After facing similar symptoms, I learned that auto repair diagnostics should always include pressure testing of the complete fuel delivery system. My mechanic performed a fuel pressure test that revealed inconsistent readings, leading us to discover that while the electrical connection was faulty, the fuel pump itself was also failing. In my case, we ended up replacing the entire fuel pump assembly for 780€ including labor. The mechanic explained that modern fuel injector systems are sensitive to pressure fluctuations, which explained the rough running and increased consumption. The previous buzzing sound you mentioned mirrors my experience exactly, it started as a subtle change in pump noise before developing into full performance issues. A professional fuel system diagnostic would be worth the investment to pinpoint whether your gasoline delivery system needs a complete overhaul or if there might be salvageable components. This sounds more extensive than my initial wiring fix. Given the symptoms and timing, I would recommend getting a second opinion focused specifically on full fuel pump assembly testing rather than assuming it is just a connection issue like in my first repair attempt.

Thanks for your detailed follow-up. You really got me thinking about the service timing too. Just checked the codes again: P0087 and P0093, which are now also showing low rail pressure warnings alongside the original fuel delivery error codes. Since hearing about your repair cost breakdown for the fuel pump assembly at 780€, I have been calling around local shops asking about comprehensive fuel system diagnostics and parts costs. The buzzing has actually gotten louder over the past day, and now the engine barely starts at all. The service records from 2 weeks ago show the fuel pressure was tested and normal at 4.5 bar, so something definitely failed rapidly. Found a reputable shop that specializes in diesel fuel injector systems who can do pressure testing and scope diagnostics tomorrow morning to verify if its the pump or something else in the fuel delivery path. Will update once I know more, but based on the similarities with your case and the rapid onset of problems, I am expecting to need the full pump assembly replaced. At least knowing your repair costs helps set realistic expectations for what I might be facing. Thanks for sharing your experience, it helped narrow down the likely causes and necessary diagnostic steps.