Possible HP Fuel Pump issue with CASA/CATA engines - Club Touareg Forums
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post #1 of 19 Old 2 Weeks Ago Thread Starter
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Possible HP Fuel Pump issue with CASA/CATA engines

Whilst visiting my local Third Party VW Specialist yesterday, They informed that they have had two CASA V6 Tdi engines with catastrophic High Pressure Common Rail Pump failures in the past two weeks.

Both engines had done over 200,000 km and in both cases the HPFP had disintegrated resulting in metal fragments and filings being forced through the injectors, This resulted in total loss of not only the pump ( about AU$ 1,200 ) but also the injectors ( about AU$ 600 each ) resulting in a repair bill of over AU$5,000 plus labour.

The vehicles involved were apparently stock standard and had not be subjected to any apparent abuse. They don't have enough information as to the root cause but suggested that it may be related to fuel quality. They also stated that I may be interested in looking at Diesel Fuel treatments as a form of insurance. Understanding that they DON'T sell such products, and were only thinking out loud as to what may be useful.

At this stage the failure of two engines may be simply bad luck, which I sincerley hope is the case. I think it is something I will be following closely to see what more information I can find.

Kind Regards
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post #2 of 19 Old 1 Week Ago Thread Starter
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References from Other Sources & Forums.....

Catastrophic high pressure fuel pump failure - TDIClub Forums

3.0 HPFP Failure, 2009 Q7 220k - TDIClub Forums

https://www-odi.nhtsa.dot.gov/acms/c...1003-61863.pdf

HPFP Failure



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Australian diesel is only just within the fuel spec for the pumps - just. No tolerance. Yes a fuel additive to increase lubricity is advised if you intend to keep your treg. There is a lot of detail on the web on this - somewhere there was a comparison of the benefits of different additives.

A start is here: 2 Stroke Oil In Diesel ? - myTreg forums - Page 3

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Yes Stu HPFP failure is a real costly exercise.

I believe adding either synthetic 2 stroke oil or a diesel fuel lubricity additive like Flashlube or the like to your fuel will help.

Are there enough failures out there to justify the pump as a maintenance item at say 175 to 200 kms ?
Costly exercise but way cheaper if you were to have a failure.

As a note relating to the video Touareg TDI's pumps are not driven by the timing belt and are not timed.

regards
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Quote:
Originally Posted by dragline1570 View Post
Are there enough failures out there to justify the pump as a maintenance item at say 175 to 200 kms ?
Costly exercise but way cheaper if you were to have a failure.
I will be ordering a replacement HPFP this coming week, as I currently have 220,000 km on the clock, and replacing a pump is cheaper than replacing a pump + a full set of injectors. It might look like "overkill" however I am a firm believer in "Preventative Maintenance" rather than Restorative Repairs.

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This YouTube Video gives a good insight to the cause of HPFP failure in TDI engines. Even though it relates to a Jetta 4 cylinder engine the process is exactly the same.


Stuart....

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is there a extended HPFP warrantee on T3's in the US?
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There will be when the settlement is approved.

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Quote:
Originally Posted by hedditch View Post
Whilst visiting my local Third Party VW Specialist yesterday, They informed that they have had two CASA V6 Tdi engines with catastrophic High Pressure Common Rail Pump failures in the past two weeks.

Both engines had done over 200,000 km and in both cases the HPFP had disintegrated resulting in metal fragments and filings being forced through the injectors, This resulted in total loss of not only the pump ( about AU$ 1,200 ) but also the injectors ( about AU$ 600 each ) resulting in a repair bill of over AU$5,000 plus labour.

The vehicles involved were apparently stock standard and had not be subjected to any apparent abuse. They don't have enough information as to the root cause but suggested that it may be related to fuel quality. They also stated that I may be interested in looking at Diesel Fuel treatments as a form of insurance. Understanding that they DON'T sell such products, and were only thinking out loud as to what may be useful.

At this stage the failure of two engines may be simply bad luck, which I sincerley hope is the case. I think it is something I will be following closely to see what more information I can find.

Kind Regards
Stuart....
Has anyone come up with a upgraded version? I checked LOBA but they have nothing. I have been thinking about replacing mine as well just as preventative maint. I always use a lube (Titan Diesel additive) or about a pint of B100 at fuel ups.

Jason

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I will be ordering a replacement pump today, because I now have 230,000 km (130,000 mile) on the clock, and I have not been using any fuel additives. My thinking is a pump is cheap compared with a failure.

Stuart....

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