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I had an issue where my key would not go in my 2005 Jetta ignition. I literally looked around the stuff in my car to check that I was in the right car. A locksmith came out to try to fix it, but they weren't able to. Ultimately, I had to get my car towed. The dealership quoted me around $700 to replace the ignition lock. I have no idea what was going on with my car? Was it something I did to somehow break it?
I have a 2003 Jetta VR6: and my friend a 2002 Jetta, both cars stall if fuel level is at or under ¼ tank. After many Web search results I see many stories like mine, car stalls on Highway, traveling at speeds from 50 to 75. Sometimes I can feather the accelerator and will save from stalling but if not I have to pull over put the car in park and it will restart.
This has been trouble on both cars for over 2 years, we never let the fuel get below ¼ tank. The tanks get flushed and filter replaced every two years but same problem. VW had done many tests but can’t figure it out. Someone said the fuel pump could over heat and shut off, that the gasoline keeps it cool, it makes sense when the gas is below ¼ tank that the pump is more above the fuel than under. If the manufacture had the pump designed with a low heat tolerance than maybe all the OEM replacement pumps and aftermarket pumps would react the same causing same failure and confusion after replacing one.
In conclusion, I believe there are multiple diagnoses posted that are correct. More than one specific failure could cause the same symptom. I’m told by VW a faulty crank shaft sensor would typically cause a computer error code, they are either working or not unless it has poor connection. The tank is clean so I am going to try replacing the fuel pump with a more superior one pump like BOSH and not an OEM part.
I’m curious as to the person that posted they used the BOSH pump and seems to have worked if this stall had resurfaced or not.
Lets be clear, this car is over 10 years old and not worth a whole lot. It makes no sense to pour money into this 'problem' you describe.
Personally, I would not waste much time nor money on this 'issue'. Since you have already diagnosed the problem as happening ONLY when the fuel-tank is less than quarter full.
Hence, you have already figured out how to resolve the 'issue'. JUST KEEP THE FUEL ABOVE QUARTER FULL..
End of problem, worries and no money spent.
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