Fuel pump.


The original fuel pump for the Passat g60 Syncro is this:

Swirl pot: 357 919 051 H

With this, avionic quality, two stage, (3-4bar, less current consumption, more power with lower rpm, less noise, less wear), pump:

1HO 919 651 Q
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specs (red rectangular)
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The stainless steel, heavy duty, main impeller.

The 293.000 km collector. (Here one of  low km).

The only deficiency: the elastic parts, membranes and hinges, last less, (than 25 years):

Pump bottom with destroyed membrane..

The destroyed upper membrane.

It seems that the membranes are used to seal the two stages, in order to avoid the 1/4 syndrome, when a car stalls with only the 1/4 of the fuel capacity.
The same problem is apparent in fast right turns, even with more than 1/4 fuel, if the membranes are broken.

The question arises when the time for change comes: replace with the same, heavy duty, having, proved, 25 years of life, (or ~ 290.000 km), die-hard, pump?



So... I decided against the original solution thinking that it is better to have, potentially, a lower expectation  about MTBF, (mean time before failure), but a crystal clear image about what is going on. 

I believe that it is better to have a fuel pump which  immediately and clearly gives all the necessary information about what is going on, even if will last less, than one which works perfectly, for a very long period of time, but has elastic membranes, which you do not know when are going to deteriorate, causing symptoms similar to many other failures. 

Saying these, my decision went for a single stage 4 bar  Bosch fuel pump, with a new swirl pot, since it is not compatible to the original one.


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And as a kit with the swirl pot:

with the necessary for the installation 


without membranes

A made in Brazil product....Time will saw if this has  it's negatives.

After a thorough cleaning of the fuel tank, (much more cleaner than it expected after ~ 25 years of use, found parts of the diluted elastic membranes and a minuscule amount of metal raspings),   installation procedure:

#1 The top part of the original pump must be used, since the BOSCH swirl pot comes without it.

#2 The original signal sender must be used, since the BOSCH swirl pot comes without it. But unlike the top part, this must be modified and adjusted, (slope), in order to be operational.

Previously, I had to do something to the senders lamella whose the platinum contacts found finished:

The solution to renew this essential part was to flip over it, adjusting both, the pretension and the azimuth, smoothing the rear side of the contacts to be ready for their new duties:

Here goes the sender:

 A siting base was necessary...

...and two screws.

Adjusting the slope of the sender.

By the trial and error method found that the multi meter must give values between 270 - 300 Ω. 
Setting it to 270 Ω gave a final measurement of 300 Ω after the installation. 

The arm must not touch the bottom of the fuel tank otherwise than  the intended pad.

Ready for the installation.

First impressions:

#1 The no membranes swirl pot has some braces for the pump which look fragile...

#2 When the pump is priming, you can here the noise... (o.k., helpful as an instant operational check). 

#3 So simple architecture... (why the Pierburg is so more complicated)...

#4 Very well and tight fit into the fuel tank. Better than the original's.

#5 Perfect operation, no hesitations of any kind when driving, even with a very low fuel level, even at high rpm.

And the strange:

The above document is from the 2008-2009 BOSCH of Australia. The specs for the F 000 TE0 111 repair kit, (and for the inner pump), are 400 kpa, (=4 bar), and 100 l/h, values which are identical to the original Pierburg's.

The pump inside the kit has this code number: 0 580 453 606

The next is a document from the 2010 BOSCH do Brazil:

Here we can see the 0 580 453 606 pump of the specific kit as giving  4 bar but at 90 l/h.

But, from the same, do Brazil, document we can see:

So the kit with the code number: F 000 TE0 111, here has other specs which now are 3 bar and 105 l/h!

Starting from the same point, for the same product, with the same code number, there are three different manufacturer's...opinions!

BOSCH announces:

          (translated from the Italian)