VW Sharan TDI Stalling: Fuel Regulator Warning Signs

I had almost identical issues with my 2002 VW Passat TDI. As someone with some automotive repair experience, these symptoms immediately pointed to fuel delivery problems. The rough idling and engine misfire symptoms were exactly like yours. Car maintenance records showed regular fuel filter changes, but the problems persisted. The check engine light was constantly on, and fuel efficiency dropped significantly. After two diagnostic sessions, my workshop identified a defective high pressure fuel pump as the root cause. They found metal particles in the fuel system, which meant the pump was deteriorating internally. The complete repair included: Replacing the high pressure pump, Cleaning the fuel system, Installing new fuel lines, Replacing all fuel filters Total repair cost was 1510€, including parts and labor. The car ran perfectly after the fix and fuel efficiency returned to normal. Before suggesting this is definitely your issue, could you share: Current mileage, Service history, especially fuel filter changes, Any diagnostic codes pulled, When the symptoms first appeared, Whether the problems get worse in cold weather This information would help confirm if your Sharan is facing the same fuel system problems my Passat had.

Had my last service at 74297km, and they performed diagnostics but found no immediate issues with the fuel system. After reading your detailed experience, Im convinced we might be dealing with similar problems, especially given how the symptoms match exactly. The diagnostic codes pulled during my recent service showed P0401 and P0100, which seem consistent with fuel delivery problems. The interesting part is that these issues started showing up gradually over the past month, getting worse during cold starts. The rough idling becomes particularly noticeable when the engine is cold, and the check engine light started flickering before staying permanently on. Its worth mentioning my fuel efficiency has dropped noticeably, from normal consumption to about 20% higher than usual. Would you mind sharing if your repair included any sensor replacements? Also curious about the workshop time required for such an extensive fuel system repair.

Thanks for those additional details. Your symptoms and diagnostic codes align perfectly with what I experienced, especially the cold start issues and increased fuel consumption. My repair did include replacing the mass airflow sensor along with the fuel system components. This was necessary since the faulty fuel delivery had caused irregular engine performance and affected sensor readings. The complete fuel system overhaul took about 8 hours of workshop time. For reference, my car started showing these car maintenance issues around 80000km, very close to your mileage. The initial rough idling seemed minor, but the fuel economy kept declining until it became unbearable. One detail I forgot to mention in my previous response: after the repair, our workshop recommended switching to a higher-grade diesel fuel and shorter fuel filter change intervals to prevent future high pressure pump issues. This has helped maintain consistent performance without any return of the check engine light or rough idling problems. A tip based on my experience, have them check the fuel injectors while doing the repair. In my case, two injectors showed minor wear and replacing them during the same service saved on labor costs later. The total workshop time for my complete repair was: System diagnosis: 1 hour, Fuel pump replacement: 3 hours, Fuel system cleaning: 2 hours, Injector testing/replacement: 2 hours If your symptoms continue matching mine, expecting similar repair scope and timing would be reasonable.

Thanks for sharing those workshop times and additional repair details. Your experience really helps clarify what Im likely facing with my Sharan. After seeing how closely our situations match, especially with the fuel injection and sensor issues, Im planning to book a comprehensive inspection next week. Based on your feedback, Ill definitely have them check both the high pressure fuel pump and injectors during the diagnostic process. The car maintenance costs you outlined help set realistic expectations for my budget, looking at around 1500€ seems reasonable given the scope of work needed. The cold weather connection makes perfect sense now, as my rough idling and check engine warnings definitely got worse during morning starts. Good tip about the higher grade fuel too, Ill implement that recommendation after the repairs are done. One last question Id have asked would be about preventive measures post-repair, but you already covered that with the fuel filter intervals suggestion. Really appreciate the detailed breakdown of your experience, as it gives me a clear path forward for addressing these fuel regulator and injection system issues.