GTI 337/20th Anniversary :: Fuel Cutoff When Tank Gets Less Than 1/3 Full


Jul 31, 2011

I am the original owner of a 337 with 292,800 miles, that's correct. I recently have had a fuel cutoff problem when the fuel tank gets less than 1/3 full. So I replaced the fuel pump and fuel filter thinking that would solve the problem. It still stalls with a low fuel tank. It runs fine with more than a 1/2 tank. I have a Vagcom and no issues there.

Mystified at what could be the cause. Possibly fuel pressure regulator or vacuum line, is there a check valve somewhere in the fuel system that could be sticking, or what about an issue with the EVAP system? By the way this car still looks great, has been to the track many times as well as autocrossed, and still has the original clutch. Way to go VW. My race car is a spec miata.

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This van has had a couple of fuel pumps, no surprise there, and i need to look through my paperwork and find out how many miles the current one has on it, but it has the STRANGEST habit I've ever had on any vehicle. Starts fine, runs fine, no fuel pump noise when van is running, and when you turn it off, the fuel pump creeks on and off for several minutes.

I mean a strange creaking noise almost like a shorted electrical device or a vehicle's brakes when you park it on a hill and the breaks creak as it settles into place. I'm probably doing a lousy job of describing this but i don't know how else to describe it!

ALSO, if you lay under the van and wait til it stops creaking, you can tap the bottom of the tank and it will creak for a few more seconds. You can tap repeatedly and make it creak more. Is it about to explode? Can i trust it on a road trip?

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This has happened to me 4 times now in the 7 years I've owned my car. It happened so infrequently I thought the problem was the pump's sensor was not working properly. However now it's happened twice the last two times I've tried to fill up. On Friday my son was supposed to fill the car and could only get 1 gallon in and the fuel pump kept clicking off as if the car is full of gas. The bars never moved and I thought the problem was the pump. Then today, Sunday 2 days later, I decided to go ahead and fill it up. I have 250 miles to drive and want a full tank of gas. The tank shows 3 bars. I started fueling and it clicked off at 1 gallon. So I pulled the pump trigger again and tried to force more fuel in and it stopped and wouldn't add anymore than 1.7 gallons.

So now I have a long drive tomorrow and I can't figure out why the pump is clicking off as if the tank is full yet it can't be because I drove 250 miles since my son tried to put gas in and it's showing I have 3 bars.

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I filled up my very first tank yesterday (dealer gave me a full tank when I bought it) and the miles remaining display said 424 miles after I filled up. Does it display 424 on all Priuses by default?

The first tank gave me right around that many miles before I filled up - the miles remaining display said I had 9 miles left so I got too scared to see if I could go farther. But when I filled it, I only filled just under 10 gallons - does that mean there's more miles for me to drive, despite that remaining miles meter?

And...am I getting pretty bad fuel economy?

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All has been well in just over a month of driving the car and about 3300 miles logged. The 12v, Aux battery was dead from the car sitting on the lot for so long (I replaced with a new OEM Toyota 12v battery) After a week of the car experiencing dim headlights, and various other electronics

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Now that the 12v battery has been replaced, the car runs exceptionally well, aside from an intermittent fuel gauge issue where it only reads full bars (completely full) if I let the tank get to empty (Flashing single bar) or close to that. If I fill the tank from s

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That was odd so I just figured there was some air in the tank or in the hose, so I tried adding some more fuel. I got about a half gallon more added when it clicked off again. Well, I know you're not supposed to top off the tank so I tried to add more. Got about two gallons added when it clicked off. I stopped fueling at that point for fear of causing damage.

My fuel gauge now shows a little less than half full. How can that be? Is there something I can do to fix this?

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The dealer could not figure it out and I still have this issue. It seems the smell is more in the front of the cabin then the rear. It just could seem that way since the smell is very strong. I have to park the car with the windows open.

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The needle sits at E, but it still says about 20 miles till empty on the MFD. When I left the house this morning, it said 5miles till empty.. by the time I got to work, it said 20. Kinda odd..

I will hook up the vagcom when I get home tonight, any area I should scan for? or just a complete scan? There is no CEL error on the dash though. What I could look at to fix this?

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Assuming it must be an electrical issue - I dropped the tank and tested the gray power wire / 12 volts. But to be thorough / in case I made a mistake / I stripped and re crimped all the connections, heat-sealed the sleeves and wrapped in all in electric tape. Tested the pump - she hummed like a kitty. Re-installed the tank and she fired up like a champ. Drove around a couple of days - stopped and filled the tank with gas. Same thing - wouldn't start right there at the pump. i poured fuel in the intake - she would start and run until the fuel burned up.

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