Stalling issue

[GLICWH]

I have a 2003 VW GLI with approx 227,000 miles.
I've been having an issue with what (seeming like) running out of gas when the gas tank is below 1/2 tank or less. Sometimes the car will just "sputter" & then re accelerate. When the tank is lower (1/4 or less) the engine will die completely. When it die's, I pull over...wait anywhere from 30 seconds to 3 minutes & the engine starts right back up. (There are usually repeated attempts to re-start the engine & it will not fire) Once it does...I am then able to travel multiple miles again (till the next stall out) Once I fill the tank to full again....no "interuptions" occur again till the above scenaro comes about.
I have changed the fuel pump, fuel filter, O2 sensors (ft & rear), mass airflow sensor, crank speed sensor, master motor relay, fuel pump relay, & had the tank completely "peered into" to look for foreign matter. This issue has been occuring for at least A YEAR!

Any ideas?

Thank you in advance,

Chris
Denver,CO

[silverstonevr]

fuel lines?
any codes?

[jaso028]

can you get someone in your area to scan it with VAG-COM??

[apstguy]

Weird, I've had the exact same thing happen to me many times. Hasn't happened for months though. I haven't changed any engine parts so I have no clue what made it stop.

[jaso028]

have you changed your Gas latley? like where you have gotten it from...
just throwing that out there....

[apstguy]

Nope, same gas. It seems to only happen on cold mornings. I have run some 100 octane since though, car seems to run better with a little 100 in the tank every once and a while

I never did have any codes either. Weird!

[turbonium89]

i have just been going through the same ish this past couple months. i work at a local vw dealer and have had the techs all stumped until today. . . .

i have had an engine light for the past year and a half and its always come up rear o2 sensor no activity. well after getting deeper into the diagnostic, it shows the o2 sensor is working but way off the charts and i have been running 18% lean. WTF! so we replaced the fuel pump and filter as trouble shooting goes and for the first time in months i had no engine light for the first 90miles. turned the car off two times and then after driving a few miles . . bam! engine light is back with same code. and running 18% lean. so we went up to the INTAKE MANIFOLD. and sure enough the bearings are shot on the intake manifold change over rod. both seals on either side are loose to and you can physically push the rod side to side and hear the air getting sucked in while the car is on.

so i'm getting the gruven parts intake rod gaskets, vw oem rod, seal kit, and drive unit.
hoping this is gonna be the answer.

[vtlbuddal]

This seems like a common problem. I'm having the same issues with my car. It has been in and out of the mechanics for a month.

[apstguy]

I've had a code for the front 02 sensor come up the first week it did it, and nothing since. Only code I have now is for a bad cat. I've replace the intake manifold change over valve bushings, but they don't seal the rod. Only way to get the seal is pick up the whole drive unit ($120+). So I have avoided it. I did break my breather hose and replace most of it with rubber tubing. Maybe I had a vac leak???

[pure85gti]

Just an FYI...
I have the same problem with my MK2 VR6. I just fill up every 150 miles, as anything more than that it sputters, and sometimes dies (which I can restart and keep going). It feels like it's struggling to get the gas from the tank to the engine.

I just keep it topped off. I'll fix this problem next spring.

[MachtSchnell]

I have changed the fuel pump, fuel filter, O2 sensors (ft & rear), mass airflow sensor, crank speed sensor, master motor relay, fuel pump relay, & had the tank completely "peered into" to look for foreign matter. This issue has been occuring for at least A YEAR!

Any ideas?

Fuel Pressure Regulator maybe?

[diathermic]

Did you ever get this solved? I have the same exact problem with a 2002 24V GTI VR6. Any help would be appreciated!