my Volkswagen Golf MK5 (2004-2008) won't start after filling up with gas, what's wrong?

Solution

1. Preparation

• Gather necessary tools and parts.
• Ensure the vehicle is on a flat surface and the ignition is turned off.
• Disconnect the battery to avoid electrical shorts.

2. Check Fuel Pump

• Remove the access panel (if equipped) to the fuel pump.
• Disconnect the electrical connector from the fuel pump.
• Use a multimeter to check for power supply to the pump (should be around 12V).
• If no voltage is present, inspect the wiring and relay.

3. Replace Fuel Pump (if faulty)

• Relieve fuel system pressure by removing the fuel pump fuse and running the engine until it stalls.
• Disconnect the fuel lines from the pump using a line wrench, collecting any spilled fuel in a container.
• Remove the fuel pump assembly from the tank.
• Install the new fuel pump assembly and reconnect all lines and wiring.
• Reinstall the access panel.

4. Check Fuel Pressure

• Connect a fuel pressure gauge to the fuel rail.
• Turn the ignition to the "ON" position without starting the engine and check the pressure (should typically be between 50-60 psi).
• If pressure is low, verify the fuel filter is not clogged and replace it if necessary.

5. Reconnect Battery and Test

• Reconnect the battery terminals.
• Start the vehicle to ensure proper operation.
• Monitor for any leaks around the fuel system.