I agree with anyone that says that the HPFP system on the TDI Volkswagens have a problem and needs redesigning.
Anything I say would be my opinion based on my direct experience with certain aftermarket repair shops, Volkswagen of Canada, Volkswagen of Canada dealers, Oil analysis lab and internet postings like this.
Other sources not mentioned could be the DOT and the NHTSA.
If I infered that the only source of the HPFP pump failures was due to the fuel sending rods rusting my apologizes.
My intent was to inform everyone that one source of premature HPFP failures was incorrect steel content used in the lift pumps, leading to fuel starvation.
Why they haven't had a recall on this problem would be speculative on everyone's part.
We don't operate a multimillion corporation where decisions regarding recalls are determined based on some small figure per unit.
When you multiply those $$'s x per unit the costs become enormous.
The HPFP had started to make noise and was replaced. The new one made the same noise and then they inspected the filtration system.
The dealer tried to get me to replace the whole fuel system on our dime due to miss fueling. We refused to even look at a bill and left.
We took it to a high performance shop, specializing in Volkswagens. He was well aware of the rust problem and recommended using Stanadyne additive.
(my opinion and presumption of everyone"s attitude)
Everyone is saying that the fuel in North America is substandard and is the cause of the problems.
I refused to believe this.
He said the dealer should have seen slight evidence in the filter on previous services and he had never seen it this bad before. (This repair shop had been recommended to me by a buddy who had a high performance TDI before the failures started.)
This lead me to believe that the dealers were not informed to look for rust in the fuel system at every service.
Volkswagen of Canada is stubborn and didn't want any part of paying to repair the vehicle and when the regional rep agreed it was done at the bare minimum.
(Again my opinion)
The minimal repair lead to a complete failure of the HPFP, a few months later. The wife was left on the side of the highway after little or no warning. It started to act cold and unresponsive. It stalled a couple of times and it refused to start. It was towed to the dealer.
This repair came with a totally different attitude.
They tested for miss-fueling and they replaced the complete fuel system.
They never accused us of anything and we were met with the utmost courtesy.
(Remember all of this is my opinion based on my experiences)
Cummins have engines that are running High injection pressures as great as the TDI. These same engines are reprogrammed by others and produce even higher pressures.
Check out Pittsburgh Power.
http://www.pittsburghpower.com/
Allot of diesel manufacturers are running high injector pressures and they are NOT having the same issues.
I personally have a 03 Dodge Cummins with a cp3 injection pump.
I have an Edge Juice with Attitude programmer.
Earlier model Cummins had Bosch injector pumps, they were prone to failure if the lift pump didn't supply consistent pressure.
My CP3 has had fluctuations in lift pump pressure and has yet to fail. I now run a Fass 150 lift pump for filtration.
When I saw the rust in the wifes filter and knew that the HPFP was starving I remembered the troubles the early injector pumps had on the Dodge Cummins.
I agree with anyone that the filtration, HPFP, fuel sending unit and any other parts that are failing prematurely should be corrected.
Good luck one and all
But I would suggest those with CAT filters, fuel return mod, etc. take them off before getting the fuel system repaired under warranty.
