On Thu, Oct 15, 2009 at 5:32 PM, Paul Chubbuck <paul@takingflight.net> wrote:
.....

> I have been told by two different seemingly competent shops that the problem
> lies in a part numbered Bosch 0 438 101 005, which I believe is called a
> fuel flow meter or a fuel injection pump. �Not sure of that...I'm not a
> mechanic, as must be obvious.
>
> The first shop to work on it had it back at least 5 times before they gave
> up. �They tried cleaning and adjusting that component to no avail. �They
> couldn't get a new part and tried replacing with a used part and said the
> other used parts performed worse than my own. �They also replaced the O2
> sensor.
>
> The 2nd shop said replacement of that part would cost me $2000 because the
> part is not made any more. �They offered to do an engine conversion to a
> Suburu for $12,000!
>
> Can you tell from the symptoms if this part is really the culprit? �Is there
> any way to replace this part at a reasonable price?
>
> Thanks very much in advance.
>
> Paul Chubbuck in Fort Collins
>

Googling the $2000 (installed $ presumably) Bosch PN as 0438100100 gives me this

http://www.gmpperformance.com/index.cfm?PG=detail&PID=111539

More searching tells me that unless you find a known working good used
part, you are likely dealing with getting a rebuilt part. IF that part
is at fault.

If you haven't already done so, take your ride to a VW specialist that
knows electrical really well. Have the engine electricals checked out.
The surging could be something as simple as a loose wire or other
connection.

And not that you asked but......   ;)

IF current engine fine otherwise, (good compression, no smoke/leaks
etc.) consider changing from CIS engine management to Digifant. In
comparison to CIS, Digifant is a much more modern engine management
system. And I bet this would be much less money than the quote for the
Suby swap..... if done right the first time.

Or..... swap in a later model year 1.8 8 valve that already has Digifant.

Neil.

-- 
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines