Here is a summary of the recent HPFP failure on my mother in law's Tdi.
Both Pure Flow and Contain Flow (with 1Micron 70025 CimTek filter) 2micron kits were installed on the car, roughly the first week of September 2014.
After about 50-100 miles, the car died and would not start. The pump head was removed and an obstruction as found in the output check valve. After the obstruction was removed by flushing, the car was back up and running.
A few days and approx 200 miles later, the car was sluggish and throwing low pressure codes. The fuel metering valve was inspected and found to be pristine and 100% clean.
The fuel rail pressure solenoid control valve was removed and inspected to find a small amount of dirt on the very fine filter. Appears normal for a 80k mile car.
After cleaning this tiny filter, the car still was running sluggishly, having the same low pressure issues, just driving around the neighborhood a little. The rail solenoid filter was removed again and found to be in acceptable condition. It was decided to inspect the internals of the HPFP.
The cam follower and roller were found to be completely destroyed. The roller was worn beyond 50%, as well as the cam follower itself was actually allowed to touch the cam shaft. This indicates that more than 5mm was worn off the roller.
The camshaft was inspected as best as possible in its resting position, showing major wear, gouging and most likely no lobe lift. Once the camshaft can be removed, the full extent of wear will be seen.
After seeing the destruction of the moving elements inside the pump, it was necessary to search for metal in the system.
The Cascade (overflow) valve within the pump was removed and inspected. The filter was completely clogged as well as being oddly collapsed.
Both Pure Flow and Contain Flow (with 1Micron 70025 CimTek filter) 2micron kits were installed on the car, roughly the first week of September 2014.
After about 50-100 miles, the car died and would not start. The pump head was removed and an obstruction as found in the output check valve. After the obstruction was removed by flushing, the car was back up and running.
A few days and approx 200 miles later, the car was sluggish and throwing low pressure codes. The fuel metering valve was inspected and found to be pristine and 100% clean.
The fuel rail pressure solenoid control valve was removed and inspected to find a small amount of dirt on the very fine filter. Appears normal for a 80k mile car.
After cleaning this tiny filter, the car still was running sluggishly, having the same low pressure issues, just driving around the neighborhood a little. The rail solenoid filter was removed again and found to be in acceptable condition. It was decided to inspect the internals of the HPFP.
The cam follower and roller were found to be completely destroyed. The roller was worn beyond 50%, as well as the cam follower itself was actually allowed to touch the cam shaft. This indicates that more than 5mm was worn off the roller.
The camshaft was inspected as best as possible in its resting position, showing major wear, gouging and most likely no lobe lift. Once the camshaft can be removed, the full extent of wear will be seen.
After seeing the destruction of the moving elements inside the pump, it was necessary to search for metal in the system.
The Cascade (overflow) valve within the pump was removed and inspected. The filter was completely clogged as well as being oddly collapsed.