GTD HPFP failure at 65,000km

[kaanage]

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.

If you look at the reports from North America where the HPFP has failed in CR TDi's, the swarf from the shredded pump not only ends up in the areas listed above but also travels down the fuel recirculation circuit so all the fuel lines and the tank need to be removed and cleaned out as well.

It's a BIG issue which is why someone has come up with a post HPFP filter to contain the swarf in the case of failure which will limit the damage to just the HPFP (http://www.vwwatercooled.com/forums/...ml#post1136439) .

[Umai Naa!!]

I try not to pay too much attention to what happens overseas, mainly due to different engines, and warranty proceedures, but yeah if it applies here, then VGA will be in for another world of hurt if they don't get onto it.

[Ryeman]

Isn't this ultimately a Bosch problem that VW take up with them.......it seems to have been a 'known' issue, or was that only in the past?

[Macca6571]

Ok guys here is the response from the dealer after I very politely asked them for assistance.

"Just an update as to where we can go with your vehicle as we’ve had it in the workshop for 12 days and I’m sure you’d like it back.
I’ve discussed with my manager and my warranty department what options you have with Volkswagen regarding the high pressure pump.
They cover all their bases quite well in the owners manual as seen below, the workshop repair manual informs us to check for filings in the fuel system and what is required depending on the amount and location within the fuel system these files are.
With the amount seen in your system we need to replace the parts quoted.
If the hpfp had failed internally it wont create so much metal filings, it’s commonly the continual pump rotation with little lubricant that creates the filings.
If a new vehicle that’s still under warranty has a part failure like the lift pump in the tank which supplies the hpfp, the engine shuts down, the owner is instructed to call roadside assistance.
If they attempted to restart the car and cranked the engine over with a dry pump they would still have to pay for the repair as quoted even though the lift pump would be covered under warranty.
So after we get the fuel system clean of all metal filings then we can diagnose any problems and remedy them. I can approach VW for financial assistance in those repairs."

[Greg Roles]

I'd get some agreement on costs to "clean" the system up front. I'd also start looking around Australia for a CBBB engine from a wrecker, you can definitely get one for a lot less than $8k. As much as we all know there is a massive issue with the MK6 era onwards HPFP, and on many other cars from the same era ( BMW diesel woes anyone? ), I have to agree with others saying running the fuel low is not in any way a good idea. Yeah it may have a sump, it may not draw from the bottom, but one decent bump, one corner, you suck air, and the weakest link on the MK6's runs out of lube. I'd advise anyone reading this to fill up once you hit a quarter, and fill up at busy, brand name servo's - which is still no guarantee, but lessens the odds. Oh and two stroke / Moreys / some sort of lube EVERY tank.

On the MKV's it was the piezo injectors, on the MK6's it's all about fuel and the HPFP. Sorry to read your story, but yeah paying VW RRP for the parts is a killer. Get a diagnosis if not too dear to get to that point, then decide. Meantime there's a GTD wrecking at Narangba near me, not sure if it has an engine, just found it on Gumtree.

[neil]

so what happened ?????

[Ryeman]

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

Sounds like you we're running low but my impression is that the range of 45 km would be conservative.
I've been advised to keep the level in my tank low rather than being full for some weeks so that the fuel is 'fresh' when I drive.
I keep it full if only to reduce condensation in the tank......I'm confused now and believe it's just another reason to sell my diesel rather than the Pug.

[Ryeman]

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 fuel is supplied from the bottom of the tank all the time.

[Umai Naa!!]

Spot on.

The pump pick-up is in the lowest part of the tank. Otherwise you'd get fuel surge around corners.