VW Lupo Fuel Pump Failure Guide & DIY Diagnosis

I faced a similar fuel system issue with my 2004 VW Polo diesel. As someone with moderate experience in auto repair, I understand your concern about the fuel delivery problems. My car showed almost identical symptoms: hard starting, rough idle, and increased fuel consumption. The fuel pump was initially suspected, but when I took it to the workshop, they found the actual cause was a faulty cable connection to the fuel pump sensor. The repair process involved: 1. Running a complete diagnostic scan 2. Testing fuel pressure 3. Inspecting electrical connections 4. Replacing damaged wiring and connectors Total repair cost was 95€, which was much less than replacing the entire fuel pump. The car performance improved immediately after fixing the connection issue. Before jumping to conclusions about needing a new fuel pump, I suggest having these checked: Fuel pressure readings, Electrical connections to the pump, Fuel filter condition, Wiring harness condition Could you share: Current mileage of your Lupo? When was the last fuel filter change? What specific error codes are showing? Have you noticed any unusual noises from the fuel tank area? This information would help determine if your issue matches what I experienced with my Polo.

Thanks for sharing your experience. My Lupo has 56649km and had its last service 3 months ago, including a new fuel filter installation. The error codes are P0087 and P0191, suggesting low fuel rail pressure and fuel rail pressure sensor issues. The clicking sound from the fuel tank area started recently, particularly noticeable when turning the ignition on. Your suggestion about checking electrical connections makes sense, especially since car performance issues developed gradually rather than suddenly. Will have a professional check the fuel system connections and pressure readings before considering a full pump replacement. The wiring inspection seems like a smart first step in the automotive diagnosis process.

Thanks for providing those additional details. The clicking sound from your fuel tank area combined with those specific error codes actually aligns more closely with a failing fuel pump than my initial wiring issue diagnosis. I recently had the identical codes on my Polo before the fuel pump completely failed. The clicking noise is typically the fuel pump struggling to maintain proper fuel pressure. In my case, the gradual car performance decline also started with occasional clicking sounds. After my wiring check showed no issues, the workshop performed: Fuel pressure test showing 2.2 bar (should be 4-4.5 bar), Fuel pump current draw test, Fuel system pressure loss test The tests confirmed a failing fuel pump assembly. Total repair cost was 480€ including: New fuel pump unit, Fuel tank removal and installation, System purge and testing Post-repair improvements were significant: Instant cold starts, Stable idle, Normal fuel consumption, Error codes cleared and never returned Given the similar symptoms and error codes, I strongly recommend getting the fuel pump tested. The clicking noise combined with P0087 is particularly telling of fuel pump deterioration in these models.

The error codes and symptoms you describe match exactly what I was experiencing. Your suggestion about getting comprehensive fuel system testing makes perfect sense. The quoted repair cost of 480€ for a complete fuel pump replacement also helps set realistic expectations. I scheduled an appointment with my regular workshop for next week. They will run the pressure and current draw tests you mentioned to verify if the fuel pump has indeed failed. The clicking noise has actually gotten more noticeable this week, which seems to further support the fuel pump failure theory. Will update the thread once the automotive diagnosis is complete, as this information could help others dealing with similar engine stalling and fuel delivery problems. Really appreciate the detailed breakdown of your repair experience and the specific test values that helped identify your pump failure. If anyone else has dealt with P0087 and P0191 codes in similar diesel models, please share your experiences with fuel system repairs. Having more reference cases helps evaluate repair options.