HELP! New Fuel Pump broke twice within a year!

[porsche996tt_tpe]

Car is 2002 996 TT. I replaced the fuel pump with a brand new one in 2013/2 and it broke again on 2013/6 and had it replaced with a brand new pump. Now 6 months later it just broke again, now in the garage...

I did a little search and didn't come up with much. Has anyone had repeated fuel pump failure in their TT? Could the incoming power frying up the pump motors?

Also, the local mechanic said he's had many calls recently with failed fuel pumps in his shop, so he's asking me to post this to see if similar problem is occuring elsewhere...

Thanks a lot for your help!

D.

[Loren]

Make sure they are putting in the latest part number fuel pump as there have been at least 3 changes.

Latest fuel pump part numbers (as of Dec 2013)

LHD 996-620-107-02

RHD 996-620-108-02

[porsche996tt_tpe]

Thanks, Loren, for the quick reply.

I am at the shop and the new part they have is 996-620-107-02

The mechanic and I are both worried if there are other issues (the relay, for ex.) that may cause pre-mature failures. Have you seen this happening twice within a year?

Thanks again.

[Loren]

I have not - but there is a reason they have changed the part at least three times.

It could be a coincidence - just a bad pump. Either way it should be under repair warranty.

[porsche996tt_tpe]

The gas filter has been replaced as well.

During hard accel, especially on 2nd gear, I hear a momentary break in the engine roar. It's very brief. Does this mean anything to the fuel system?

Thanks.

[Silver_TT]

Wouldn't have anything specifically to do with 2nd gear but, yes, if the fuel system isn't properly delivering fuel then you would experience a "break" or interruptions, especially under heavy load (acceleration). The engine needs properly delivery of fuel to run optimally.

[porsche996tt_tpe]

yes, has nothing to do with 2nd gear. It's just the 1st was too quick too loud, the 2nd allows you to hear the engine more clearly, and 3rd was too fast too much wind noise... I have Tip.

[Silver_TT]

Right. Loren does have a very relevant point. Part has been revised multiple times, makes it less surprising. Should be a free replacement under warranty as stated.

To clarify your question about the fuel system, as I mentioned, this very possibly could be related. Should be no hesitation under load with the 996TT-- quite the opposite.

[wross996TT]

The biggest issue with the previous version pumps was the ridiculous hose. Mine ruptured multiple times....until I had a custom rupture proof hose made. I don't believe the pump itself is any different. Are you sure the pump is actually bad or is it a bad hose?

Edited December 31, 2013 by wross996TT

[porsche996tt_tpe]

Yes, the pump won't turn when given a direct 12V supply. Both occasions, the car just suddenly lost its power.

[porsche996tt_tpe]

I left the car in the shop for a week. I want to update on what happened. The shop owner said the fuel pressure valve is 3.8bar at idle. He did however replace the fuel pressure valve. He didn't say why he did that...

He's still unsure if there are other causes leading to the premature pump failures, so he gave me an old, but working pump for now. He didn't want to put in a new one just so it would fail again. I'm driving the car in great fear that it will die on me some where on the road...

I want to check if there's another suggestions or places to check. I'd welcome any comments.

Thanks!!

[porsche996tt_tpe]

Is it possible that the mechanic could have mis-installed the pump to cause early failure? The car was driving fine and fuel consumption seems normal...

[JFP in PA]

Is it possible that the mechanic could have mis-installed the pump to cause early failure? The car was driving fine and fuel consumption seems normal...

Rather doubt it as the fuel pump is pretty much a "plug and play" installation.

[porsche996tt_tpe]

Want to give an update...

 

Since last Jan, the shop-owner put in an used "C4S" fuel pump into my TT, the pump has been working problem-free. Last month the shop-owner told me that something similar has happened again! A guy had his TT's fuel pump replaced new only to find it break down in less than 6 months. This guy then came to my friend's shop and replaced the pump and to find it break again in less than 4 months! Both repairs, the latest -02 version of the pump has been used...

 

I had mine replaced twice and they broke in less than a year!

 

So, the shop-owner asked me to NOT replace the working C4S pump in my TT...

 

Any one heard of this crazy pump problem???