GTD HPFP failure at 65,000km

[Macca6571]

Hi guys,

My golf GTD recently stopped running with no warning lights on the dash. I assumed it may have run out of fuel even though the fuel light only came on a few minutes before the car stopped (it actually said I still had 45km to go). I filled it up but it still wouldn't start so I had it towed to VW dealer as i have extended warranty. They call me a couple of days later and say that i ran the high pressure fuel pump dry causing it to put metal fillings throughout the fuel system and I would have to pay $8200 to have it fixed. Now I have driven with the fuel light on quite a number of times and I have never run out of fuel. They are saying that they can't diagnose the problem properly until the car is running so I have to pay first to get the fuel system fixed because I "ran out of fuel". Does this sound like normal protocol or are they trying to have a lend of me? Also not sure if this makes a difference but it has only been 500km since they did the 60k service on it.
Any advice will be greatly appreciated

[Guest001]

Why run it to the bitter end and get all the crap in the bottom of the tank.
I would say you are the author of your own misfortune.
I never run a tank below a quarter for that very reason. Gauges are not known for absolute reliability either.

[The One]

Unlikely. Who's your extended warranty with? I'd assume not through VWA and probably through a company like Allianz etc... If that's so Allianz and other companies usually do a cap $ per claim and will usually only allow certain things to be claimed. Chances are the dealer is trying to avoid using the extended warranty so that they don't have to cover the excess repair cost that the extended warranty wont pay. Or simply put, they're trying to make bonus out of you. If I was in your position (I wouldn't be because I fix them myself) but theoretically if I was, I would be walking into your dealership with 20-40L of diesel, putting that into your car, priming the HPFP/fuel system several times with VAG COM, getting into your car, and driving away. Do not forget to do a 'front wheel drive burnout/skid' while you leave this dealership.

In all honestly, you probably just have air in the fuel system because you let the tank run low, I don't know why they wouldn't just charge you for 20-40l of diesel and maybe 30mins-1 hour labour to prime the fuel system and test it again, as opposed to saying they found metal filings blah blah to try and make more money.

Edit: I would have also checked that they have installed the fuel filter seal correctly, I have seen three instances in the past where the fuel filter seal was kinked causing the canister to not seal 100% resulting in the HPFP sucking in air. Also once before that the filter seal was incorrectly installed, causing diesel to leak onto the drivebelt causing it to deteriorate and shoot itself into the lower timing cover jamming between crank gear and timing cover causing the belt to skip several teeth, that car got an engine.....

But yes as above aswell, never a good idea to run any car, especially diesels low on fuel. Especially when the diesel is also a lubricant for the HPFP itself....

[brad]

Hillbilly, if the DTE said 45km then he's still got 5L in the tank. I know I can run mine down to 0km remaining and it only takes 52L including filling up the filler neck.

Last time I looked the inlet for the lift pump is in a fixed position so it is equally likely to suck up rubbish when it's full or empty. Also, whenever I've looked in a fuel tank in the last 15 years (especially the plastic tanks) I've always been amazed at how clean they are.

OP: I think the workshop is having a lend of you.

Does your extended warranty stipulate you have to go to VW? If not, then take the car elsewhere because $8200 is almost half the value of the car.

Suggest you start reading the T&Cs of the extended warranty.

[Lucas_R]

The HPFP failing on the diesels is actually quite common. Id be fighting it.

Have a look here - another diesel with a similar situation just a few days ago: http://www.vwwatercooled.com/forums/...me-106938.html

[Guest001]

Hillbilly, if the DTE said 45km then he's still got 5L in the tank. I know I can run mine down to 0km remaining and it only takes 52L including filling up the filler neck.

Last time I looked the inlet for the lift pump is in a fixed position so it is equally likely to suck up rubbish when it's full or empty. Also, whenever I've looked in a fuel tank in the last 15 years (especially the plastic tanks) I've always been amazed at how clean they are.


OP: I think the workshop is having a lend of you.

Does your extended warranty stipulate you have to go to VW? If not, then take the car elsewhere because $8200 is almost half the value of the car.

Suggest you start reading the T&Cs of the extended warranty.

I dont really care what he does. He said he has run it down quite a few times which to me is foolish. Gauges arent always right. I have run out in a petrol car when it should have still had some left.

At the price it costs to get fixed on these things I try never to do anything to help it do damage.

His car his money but I prefer to spend mine otherwise.

As far as fuel is concerned we were not allowed to fill the buses up for 2 hours after the tanker filled the underground tank.
Same with a servo easy to get dirty fuel the same way

[ParaBul]

The HPFP failing on the diesels is actually quite common. Id be fighting it.

Have a look here - another diesel with a similar situation just a few days ago: http://www.vwwatercooled.com/forums/...me-106938.html

Thanks Lucas - I was reading this thread and thinking it was exactly the situation you highlighted in my thread.

I also can't help thinking that catastrophic failure of a fuel pump by running the tank dry would open the door for "not fit for purpose" type of arguments.

Forget the dealer - In my opinion, they're either incompetent (at best) or outright fraudulent (at worst). If you can't find somebody at VW Australia with a brain, get on to consumer affairs in your state.

[ParaBul]

I dont really care what he does. He said he has run it down quite a few times which to me is foolish.

You're entitled to consider him foolish. Others are entitled to consider you foolish.

[Macca6571]

Thanks for the advice guys, I have to go to a VW dealer because of the insurance. I will wait to hear what they have to say before I go to consumer affairs as they have always been helpful in the past.

[Ryeman]

$8200 to have it fixed!!
What's that for - a new engine?!

[ParaBul]

Thanks for the advice guys, I have to go to a VW dealer because of the insurance. I will wait to hear what they have to say before I go to consumer affairs as they have always been helpful in the past.

Do some browsing of the problem that Lucas linked above, and gather some information to take back to VW. There's a lot of evidence to suggest it's an inherent flaw, and this type of catastrophic failure has nothing to do with running the tank dry.

Select 5 or 6 reports that match yours, take them to VW and calmly state that

• you don't accept that the failure was due to running the tank dry
• you believe it is a valid warranty claim
• you believe the failure was caused by an inherent problem (either design or manufacture - who knows?), and
• you would like VW to provide good will assistance with the repairs.

If they try to argue, stay calm. Becoming agitated or aggravated, or yelling and swearing won't help. Simply tell them you're going to contact consumer affairs for assistance and walk.

[Umai Naa!!]

It's not always the dealer's call on this. You need to take the issue up with Volkswagen Group Australia.

The $8200 would be the high pressure fuel pump, rail sensors, injectors, misc small single-use parts, like injector bolts, and labour.

The injectors themselves are about $1,000 each, one of the rail sensors is just under $1,000 and the other about $450. There's about 5 hours labour in swapping it all over, plus the initial diagnostic time.

I'd still fight it.

[Ryeman]

It's not always the dealer's call on this. You need to take the issue up with Volkswagen Group Australia.

The $8200 would be the high pressure fuel pump, rail sensors, injectors, misc small single-use parts, like injector bolts, and labour.

The injectors themselves are about $1,000 each, one of the rail sensors is just under $1,000 and the other about $450. There's about 5 hours labour in swapping it all over, plus the initial diagnostic time.

I'd still fight it.

Cars are getting cheaper- motoring is getting dearer!

[Umai Naa!!]

Got it in one.

[Ryeman]

The definition of white goods.....a product for recycling.