[JettaRed]

Thanks. I have disabled the system entirely for now. I had the crap scared out of me this morning at 5:00 when I left for work. I had filled the washer tank yesterday, but the low fluid light came on this morning. There was no fluid on the drive and I could only guess that over night it had pumped 3 quarts into the intake. I suspected that the fluid drained back into the intake piping and not the engine because I had started the car before the light came on. So I spent the next hour and a half disconnecting the lower pipes and checking everything out--no fluid anywhere.

The only thing I can figured that happened is that the 3 gph coming on at 7 psi and maxing at 15 psi was tooooo much--apparent by the misfires. Coincidentially, the fluid was at the borderline low level and the light came on. I drove about 35 miles this morning with the system disconnected and had no idling problems or O2 DTCs. So, this afternoon, I will connect things back up, but set the initial threshold at 12 psi and max at 22 psi.

Should I go with a smaller nozzle? The calculator says I need about 3.x gph at 100 psi. With the pumps operating at 150 psi, should I go smaller, like 2 gph?

thanks