Injector or Fuel pump failure?

Hi, this is my first post here

I have a 2011 Mark 6 TDI 1.6 litre with 48k km on the clock. A couple of weeks ago I took it for a regular lubrication service at the local VW dealer. I also told them that lately the car was starting a bit rough and sometimes the rev counter would 'hunt' for the idle range when starting from cold. A couple of hours later they phoned phoned to inform me that they found metal bits in the fuel filter and this would require the replacement of the whole fuel system.. pump, injectors fuel lines at a cost of 5200 euros. They told me that the cause was the fuel quality, which is a problem since we don't have a lot of choice in Malta when it comes to fuel. We have fuel imported by Enemalta which technically complies with the EN 590 standard.

I have searched these forums and read about HPFP failures due to low fuel lubricity, but from what I'm able to understand, the biodiesel content in Euro EN 590 diesel should tackle that.

Anyways, to keep this short, I took the car to local VW specialist yesterday for a second opinion and we checked the fuel filter (since the dealer did not replace it). We did find small glittering metal bits in the filter but the specialist told me that the amount is not concerning him and appears to be normal wear and tear. The concern was some slimy sediment which he think was caused by contaminated diesel.

We then proceeded by replacing the fuel filter, checking for any fault codes (no fault codes found) and took the car for a spin. The car does make a sort of knocking sound (reminds me of old transit vans) when under pressure. I always thought this was normal since it made that sound since I can remember. The VW specialist told me that the problem was with the injectors, which needed to replaced at a cost of around 1500 euros parts and labour.

The question I have is whether it is safe to replace the injectors only. I do not want to ruin another set of injectors due to HPFP disintegration.

I was wondering if anyone had a similar experience. I have attached a photo of the fuel filter - note the sediment on the right hand side.

Any comments appreciated. Thanks in advance

Anyone? I don't bite

Usually when this happens you have to replace everything

bmwM5power said:

Usually when this happens you have to replace everything

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Yes, but some here have posted photos of little "flakes" in their fuel filter canisters also but are still running strong on their original HPFP. Particles in the fuel filter canister are not always indicative of a failing/failed HPFP.

To the OP: can you try something less expensive first like cleaning out the fuel system and injectors? If there are no codes shown by VAGCOM, then that's reassuring.

Thanks for your feedback, that's very good to hear. Yeah the VW specialist told me that he wasn't too concerned about the metal bits due to the 'small' amount. I will consider using the car for another 1k km with the new filter and then re-check it before making a decision. Unfortunately there's nothing I can do about the fuel quality, apart from going to Sicily, which is not realistic at all! haha

Thanks again!

Welcome Spike! Has anyone removed and mixed up your injectors??
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Do you have this Continental Pump:
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Or do you have the Bosch version:
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Thanks!!
Andrew

Hey Andrew, slightly OT but which of the two pumps have the highest failure rates, the Bosch or Continental? Is there a way to tell them apart without having to remove the pumps if the sticker is inaccessible?

amstel78 said:

Hey Andrew, slightly OT but which of the two pumps have the highest failure rates, the Bosch or Continental? Is there a way to tell them apart without having to remove the pumps if the sticker is inaccessible?

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Hello Amstel, The European 1.6 Continental pump is quite different than our Bosch CP4.1 pumps. It is a much more robust cast iron design, two cylinders in a boxer (oposed) fashion. The high pressure plungers are actuated by a wobble block around a single lobe eccentric shaft, similar in actuation to the CP3 design. (minus one plunger!!)
Virtually bulletproof, in comparison to our pumps!!!
Here are some better Picts:
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The tag is easy to spot, top side!!
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Thanks!!
Andrew

Thanks Andrew, those pictures clearly show the differences. Is there a way to retrofit the Continental pump to our 2.0L CRs?

Cheers,
James

Thanks Andrew, just saw your messages. Regarding the injectors, till now I'm pretty sure that no one has modified anything.

Fuel pump: I have noticed that the sticker on mine is slightly different from what you posted. I noticed mainly the manufacturing location and V210 as opposed to V220. Could it be due to an older pump? My car is the 2011 model. It was delivered to us in May of that year.

spiksander: short answer to all of your problems: 1) replace your Fuel filter, clean the fuel filter canister. 2) ask dealer and pay them the money to have your ECU software updated to the latest "9971" version. Older versions are known to cause the problems you describe. Been there, seen that. Software update will most likely solve all of them without the need for any hardware replacement.

Andrew: I also have the same 1.6 TDI pump. However, after replacing my fuel filter a few weeks ago, it seems that I have run the HPFP dry. I did the VCDS priming for several minutes, then started the car and it died after 1 second. I kept the car cranking several times until low oil pressure light came. Then I found that the pump had "air lock" - I disconnected the line going from HPFP (return line to fuel filter) and sucked out as much air as it was possible. After that, I started the car and immediately raised RPMs to 2000. It felt a bit rough but cleared up. No problems since that. How likely is that I have made some damage to the HPFP during that process?

Henrick said:

spiksander: short answer to all of your problems: 1) replace your Fuel filter, clean the fuel filter canister. 2) ask dealer and pay them the money to have your ECU software updated to the latest "9971" version. Older versions are known to cause the problems you describe. Been there, seen that. Software update will most likely solve all of them without the need for any hardware replacement.

Andrew: I also have the same 1.6 TDI pump. However, after replacing my fuel filter a few weeks ago, it seems that I have run the HPFP dry. I did the VCDS priming for several minutes, then started the car and it died after 1 second. I kept the car cranking several times until low oil pressure light came. Then I found that the pump had "air lock" - I disconnected the line going from HPFP (return line to fuel filter) and sucked out as much air as it was possible. After that, I started the car and immediately raised RPMs to 2000. It felt a bit rough but cleared up. No problems since that. How likely is that I have made some damage to the HPFP during that process?

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Spiksander, have confidence in your pump!!! They don't fail in the same manner as the North American pumps! In fact, it's not common at all.
Your pump was made in the Czech Republic on March 18, 2011.
That amount of contamination in the filter housing is not frightening.
Good advice from Amstel and Henrick above.
Freshen the filter, research that update and drive on!!
The thought about the injector swap was only a recoding concern. They each have a specific coding and need to be adapted to the ECM, if swapped or moved.
If you are concerned that your Maltese fuel is sub-par, consider a means of better filtration. Quite a few members around here have added better filtration, after the factory filter, on route to your high pressure pump.
Shoot us a picture please of the top of your fuel canister.
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Henrick - no worries. Your Continental HPFP is not at all fragile. Also consider that the eccentric shaft and wobble block would be 95% immersed in fuel, except a small amount of air trapped at the very top.
It's more likely air was trapped in the high pressure lines, not allowing pressure to build.
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Amstel - I did explore this pump years ago! Yes, it is possible, but not practical.
- the main accessory bracket is quite different. You need a 1.6 version from Europe.
- the output capacity is lower than our Bosch pumps as well. Big minus!
The even better mini CP3 (similar to the sprinter vans) is the best option. Bolt on and awesome reliability!All the best!
Andrew

HPFP damage!

Yesterday i change fuel filter on my Golf MK6,1.6tdi ,66kw ,I don't fill up canister with diesel ,and I start my car, first car start one second and off,I tray start again several time and car start again.Do I damage HPFP pump on my car?