Advice after I put petrol in my TDI by accident!!

[Diesel_vert]

Fingers crossed for no damage. Looks like the most vulnerable part is the HPFP, which could fail now or earlier than usual.....

Who has seen an HPFP survive a full on misfuel? - TDIClub Forums

According to this article, it's the aluminium bore of the HPFP that fails resulting in metal particles in the fuel system.
dweisel's HPFP Analogy of a Failure - VW TDI forum and Audi TDI forum - myturbodiesel.com

Have now got 2 diesel cars so stay away from the petrol pumps now and partner refuses to refuel in case she makes a mistake.

---------- Post added at 09:03 PM ---------- Previous post was at 10:33 AM ----------

Here is a post showing damage to HPFP after 3 minutes on gasoline:

TDIClub Forums - View Single Post - CR engine HPFP analysis

Lol, way to rub it in!

But seriously, yeah, don't fill 'er with petrol unless it's -50°C outside.

[bluey]

Well, if it's possible that a misfuel can cause damage to the HPFP, it would rather make sense to do something to keep on top of the potential problem, rather than wait for a who knows how many thousand dollar repair if it does fail. (USD8000-9000)

One would have to consider the simple options of:
1. replace HPFP
2. install filter to prevent metal particles from causing downstream damage - TDIclub members have been working on such a solution
3. periodic inspection of HPFP and filters to detect metal particles early
4. pretend that nothing ever happened and claim on warranty
5. ostrich

I wouldn't be laughing, I'd be solving the problem.

Other diesels are more forgiving of misfuels than the diesel-lubricated CRD HPFP made by Bosch for VAG.

[Diesel_vert]

I'd go for option 4, cross fingers and hope it fails within the warranty period.

If the TDIForums are anything to go by, it should happen in no time.

Woohoo! Free HPFP!

[popeclement]

Apart from my VW Bora & M5, I also run a Nissan Xtrail diesel (renault M9R motor). Had the misfortune to fill up in the dark at BP in Geraldton - tired and put 30l into the 60l tank using the dark blue hose next to the diesel one!! Got all the way to 40km before Leeman on the Indian Ocean Drive and it simply stopped - a bit of chugging but it sat on 110 easily - I thought it might have been dirty fuel. Got a tow into Leeman when I realised my error.

I had it trucked from leeman back to perth and then drained the tank(s) - the Xtrail has a saddle tank design and two caps to access - no drain valves. Flushed the lines, replaced the filter, filled with fresh diesel, and so far so good.

PS stopped of course where there was no mobile reception - Murphy's Law.

[NiekSavio]

Diesel Mis-fuelling Device | My RACQ | RACQ

[popeclement]

Well, if it's possible that a misfuel can cause damage to the HPFP, it would rather make sense to do something to keep on top of the potential problem, rather than wait for a who knows how many thousand dollar repair if it does fail. (USD8000-9000)

One would have to consider the simple options of:
1. replace HPFP
2. install filter to prevent metal particles from causing downstream damage - TDIclub members have been working on such a solution
3. periodic inspection of HPFP and filters to detect metal particles early
4. pretend that nothing ever happened and claim on warranty
5. ostrich

I wouldn't be laughing, I'd be solving the problem.

Other diesels are more forgiving of misfuels than the diesel-lubricated CRD HPFP made by Bosch for VAG.

Well - my HPFP in the Xtrail was not alright and symptoms were stalling when hot when idling & about to move off. The HPFP is a Bosch unit and for replacement and bits n pieces and labour I was quoted $8k by Nissan. To cut a long story short I removed it myself and took it to a Bosch diesel specialist who refurbished it for just over 1k. I reassembled and have done over 1,000kms with no issues. Moral of story - don't believe the dealers - mate of mine who is a long distance courier driver with a VW Transporter did the same and was quoted 11.5k by VW - He seems to have got away with it without having to replace the HPFP probably because his mix was not 50/50 like mine.

[bluey]

quoted $8k by Nissan. ... quoted 11.5k by VW

Wondering what you had changed. I thought a HPFP failure resulting in metal particles going downstream clogs injectors. So the larger quotes should include replacing HPFP and injectors and any other bits downstream from the HPFP. I thought the HPFP was worth about $1500. Saw one apparently still available on a US forum for $500 (paid $1250).

[popeclement]

The 8k quote was only for the pump and some HP lines, not the injectors. The retail for the pump was 5k, the'other' bits approx 1.5k and the rest labour. I looked at pumps off the web but the Bosch specialist was very reassuring about their capability to refurbish - they offered an exchange for 2k. (My mate was quoted the same sans injectors!!)

I received three pages of computerised test results on every aspect, the most important being the ability to hold a very very high pressure - I hear it's around 1600bar & of course a 12 mths wty. The main part replaced was the metering valve assembly which was 'contaminated'.

Once I had done a few hundred k's, I took the car back to the dealer who kindly put their diagnostics on for no charge and noted no error codes and more importantly did a 'low flow recal' when hot - this is the only means to set up the idling speed band given that all these cars now have electronic throttle control (should also be done when a fuel filter is replaced).

They also made some comment about 'having the knack' in reference to me doing this myself - I suggested they could recommend to punters who have a similar issue, that a 'phased' fix may be the go - ie do the filter and flush lines/tank, next the pump, and finally the HP lines/injectors, provided the customer understands it will take time and is a process of elimination.

[Transporter]

It's good you got it fixed.

However a 'phased' fix, is not the best one/safest one, and it could be more expensive than doing the proper check of all the components that could be affected and replacing what need to be replaced asap.

[popeclement]

However a 'phased' fix, is not the best one/safest one, and it could be more expensive than doing the proper check of all the components that could be affected and replacing what need to be replaced asap.

It may be the most risk averse way to guaranteeing the fix by 'shotgunning' all and sundry, but it puts the cost in an area where many might even decide to trade in their vehicle, get a loan etc.

The 'damage' in this instance has already been done and it really is a straightforward process to eliminate each component in the chain, till it works. It took me no more than a total of two hours to remove and install and that was without any service manual. Even allowing for some computer diagnostic time, it comes nowhere near the 1.8k cost they quoted me on labour unless they are on $300/hr + !

From three decades in the engineering field, I prefer a pragmatic approach.

[wfdTamar]

You think you would never be so stupid as to do this. Obviously it's easy to do in a moment of absent mindedness. This is all driving up the insurance premiums for diesel owners. A $60 ounce of prevention can prevent it, so get a misfuelling device even if you think you'd never do it!

You'd think manufacturers could put them in by default.

[Transporter]

From three decades in the engineering field, I prefer a pragmatic approach.

So, you should know that, if you leave just one damaged componnent in the chain of devices, you can render whole system useless again.

Anyhow, it's good to have your feedback and it's good that you fixed it yourself.

[popeclement]

So, you should know that, if you leave just one damaged component in the chain of devices, you can render whole system useless again.

Anyhow, it's good to have your feedback and it's good that you fixed it yourself.

Start from the source and work down the chain - the components that are damaged not likely to get better by themselves, hence the process of elimination - cleaned the tank, sender, low pressure fuel pump, lines all up to the HPFP. If the injectors were or have been damaged I will find out in time. However all idling issues now resolved so unlikely but yet possible - I am not sure of the long term effect of petrol on piezo injectors. However the point I was making by the phased approach is that when the anticipated costs are enough to break out a sweat, it may be an option to put to customers.

I agree with comments about the misfuel device - this episode occurred after four years of owning the vehicle and when dark & tired. My first thoughts after 30kms of driving was a dirty batch of fuel. Only realised when I looked at the docket. Checked my insurance policy and they are quite specific about misfuelling and specifically petrol into a diesel which is on the list of exclusions.

Another recommendation for anyone else unfortunate enough to do this, is to take your vehicle to an accredited (Bosch) diesel injection specialist - they are doing most of the work for the dealers anyway - they also have facilities such as dynos which can be very useful when testing diesels under load. One of the questions I asked the dealer was if they had the facilities to test the HPFP which of course they don't have.