HPFP Failure 165K miles - Repair Experience

Capt.Aidan

Active member
Joined
Nov 21, 2021
Location
Greater Toronto Area
TDI
2015 Touareg 3.0 TDI Exec
Joining the HPFP Grenade Club. Lucky me!

Way over warranty, and understand that the recommendation is to replace everything in the fueling system.

Has anyone had any experience not doing the full replacement? What were you able to salvage?

Any advice is much appreciated.
 

pkhoury

That guy with the goats
Joined
Nov 30, 2010
Location
Medina, TX
TDI
2013 JSW, 2 x 2002 Golf, 1995 F450 7.3L
Not that this comment helps a lot, but when you do replace, please - go with a CP3 the next go around. I wouldn't go back to a CP4.1.

If you do the work yourself, I don't think the injectors are super crazy expensive to replace. I want to say maybe $100-250 new? Not as expensive as PD injectors, anyways. You *might* be able to flush out the fuel rail. Not sure about the injection lines. Perhaps @oilhammer can shed some light on that. I know dealers would charge an arm and a leg to replace all that stuff. It's tedious but not super hard to do.

I'm not sure if the fuel tank needs to be emptied, or if you need to flush out the fuel supply and return lines from the tank.
 

pkhoury

That guy with the goats
Joined
Nov 30, 2010
Location
Medina, TX
TDI
2013 JSW, 2 x 2002 Golf, 1995 F450 7.3L
I'll have to find one. A user named 2micron had a kit, but pulled out of the TDI game after dieselgate was announced. That's what I have on my JSW. Fantastic fuel pump, definitely more power (what you'd see in a modern Duramax or Cummins). I know several vendors have kits available.
 

Capt.Aidan

Active member
Joined
Nov 21, 2021
Location
Greater Toronto Area
TDI
2015 Touareg 3.0 TDI Exec
pkhoury, you do realize he is talking about the CNRB V6 engine, right?
Yea I was getting a little thrown off because I'm 90% sure the CBRB has a CP4.2.

I know the CP3 conversion can be done. But from what I've read, there is a fair amount of modification required to make it fit.
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
Can I asked how this was diagnosed? Do you have VCDS scans or logs or anything to share? Was it missfueled? What kind of mileage?
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
I do. But wouldn't a CP3 work in the V6 as well?
With enough skill and customizing, anything will work anywhere... have a quick look at the location of the HPFP on a CNRB before your next reply ;)
 

Capt.Aidan

Active member
Joined
Nov 21, 2021
Location
Greater Toronto Area
TDI
2015 Touareg 3.0 TDI Exec
Can I asked how this was diagnosed? Do you have VCDS scans or logs or anything to share? Was it missfueled? What kind of mileage?
Mileage in the thread title (265k km/165k miles).

Diagnosis: flashing glow plug light followed instantly by no power, and no start.
Metallic dust found in fuel filter and in the screen after the fuel pump.
Faults:
P0087 fuel rail pressure fault
P0263/P0278/P0269 injector faults

Always fueled at high velocity Shell or Esso stations. I did on a number of occasions run it to near empty (once every 15-20 fill ups). Tank was at half when the pump blew.
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
Did you keep up with fuel filter changes? You never saw any flakes or anything during filter changes?
 

Capt.Aidan

Active member
Joined
Nov 21, 2021
Location
Greater Toronto Area
TDI
2015 Touareg 3.0 TDI Exec
Did you keep up with fuel filter changes? You never saw any flakes or anything during filter changes?
Always. Was super diligent with maintenance. Full oil and filter change ever 10K kms (manual says 16k). Never had anything look suspect. Most recent service was 5K km before the pump blew.

Also, were you using any additives?
Never with any consistency. Every once in awhile I'd use the shell v power diesel which is supposed to have better lubricity and higher cetane.

From reading it seems our our north american spec ULSD has less lubricity than euro diesel. Which can speed up the wear on the CP4 pumps.
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
I asked about fuel filter changes... (you mentioned OCIs) how often did you change your diesel filters?
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
Sorry typo. Fuel and oil filters changed ever 10K km
Ok, that's crazy. Did you do it yourself? Always priming the system properly? Unless you got contaminated fuel, I can't see why your pump would blow up without any warning..... get your fuel tested and go after the station that sold you that junk.
 

Capt.Aidan

Active member
Joined
Nov 21, 2021
Location
Greater Toronto Area
TDI
2015 Touareg 3.0 TDI Exec
Ok, that's crazy. Did you do it yourself? Always priming the system properly? Unless you got contaminated fuel, I can't see why your pump would blow up without any warning..... get your fuel tested and go after the station that sold you that junk.
For the last 110k km since I've owned it.
Been maintained at the dealer until out of warranty, and then by my mechanic who is meticulous and very reliable.

Will look to see if we can get the fuel tested. It about 5 weeks since it failed so might be screwed at his point.
 

Capt.Aidan

Active member
Joined
Nov 21, 2021
Location
Greater Toronto Area
TDI
2015 Touareg 3.0 TDI Exec
Sounds like you're about to spend $10k to get back on the road..... not ideal for sure.
Yep, that's why I'm asking for experience in actually doing the repair. From other threads, the dealership recommends replacing the entire fueling system without investigation.

Looking for experience on potentially testing and cleaning injectors and fuel rails instead of replacing?
Does the fuel tank need to be replaced, etc?
Is there work arounds to safely salvage some components?
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
Get the Factory Service Manuals.... they list a "process" to follow when trying to determine just how much of the system needs to be replaced and\or just flushed out depending on where shrapnel is found, etc.
 

Capt.Aidan

Active member
Joined
Nov 21, 2021
Location
Greater Toronto Area
TDI
2015 Touareg 3.0 TDI Exec
Get the Factory Service Manuals.... they list a "process" to follow when trying to determine just how much of the system needs to be replaced and\or just flushed out depending on where shrapnel is found, etc.
Thats really good advice. Will look into it, and see if my mechanic can get access to that. Will report back.
Cheers!
 

PRY4SNO

Veteran Member
Joined
May 15, 2016
Location
Edmonton, AB
TDI
2013 Touareg Execline
Thats really good advice. Will look into it, and see if my mechanic can get access to that. Will report back.
Cheers!
Send me your email via PM and I'll send it to you after work tomorrow. It's only 13MB so should pass through most server file size limits.
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
Although very possible, that scenario is difficult for me to accept, especially since there were no prior warning signs. Unfortunately, since the user did not perform his own maintenance, we just have to assume\trust that the mechanic\shop was doing everything properly and correctly at these accelerated intervals. We also don't have any historical data\scans such as prior codes, injector deviations or calibration setpoints in order to attempt to see if there were any clues as far as this impending failure.

Up on this side of the border, we have decent fuel compared to you guys down there.... but there are still plenty of shady station owners who have leaky\contaminated tanks, etc.

If it was me, I would totally pony up for the fuel test.... I also wouldn't have waited, and probably taken some different approaches immediately after the failure, but there's no point in beating that horse any more....
 

oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
You sound like Volkswagen. "Our cars NEVER break, it MUST have been something YOU did!" LMAO...

Dude... they are not perfect. Sometimes they just fail. I've not seen many HPFP failures, but every one I have seen happened with zero warning on cars that were indeed maintained properly, never misfueled, and were the only ones subjected to the failure from that specific fuel station that day. And in some cases, these were not new-to-diesel owners. It happens. That's why they have TSBs about it, and warranty extensions, etc. They're not perfect.

Happens on other diesels, too. There are kits to put upgraded HPFPs on many of them. The shop local to me that works on diesel pickups all the time does about one a week on the 6.7L Fords.
 

TurboABA

Top Post Dawg
Joined
Jul 24, 2010
Location
Kitchener, ON
TDI
RIP-2010 Jetta 6spd 2014 Touareg Execline '14 A6 Technik S-line
Yes... I do NOT trust people (unless I have to).... because of my own experience with them.... anything from Pros to Experts to Dealers.
Have had things done by all of them, only to find evidence of incomplete or shady work.... it is very rare that anyone does anything properly and by the book in today's society... not necessarily because of them being total clowns or whatever, but it's just part of the way things are... all kinds of time\money\deadline pressure being a factor, and yes, sometimes, they are wearing oversized red shoes.

I clearly stated that ......
Although very possible, that scenario is difficult for me to accept
Regardless, here's something that might interest the OP if he needs to start putting together a shopping list, etc.
 
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