MKVI TDI dies on freeway. Diesel everywhere. Fuel rail cracked?

[doctorclark]

Potential new one for all of you.

(Background: 2011 TDI Jetta Sedan DSG purchased 12/20/2010. 12k miles on it. Also, I am a complete control freak over fueling, log all of my fuel ups, and like to do a B5 splash mix every once in awhile--all to say, basically, that there is no way any gasoline has ever touched my car. Also, I just did my 10k service two weeks ago).

Halfway back from Vegas yesterday (on the freeway), I lost all power over 1k rpm or so. Glow plug blinking light and then check engine light came on (both amber). Get to a gas station after driving on the shoulder for a bit (downhill coasting, luckily). Open the hood to find the engine compartment completely soaked with diesel, and a substantial puddle of fuel under the car.

Had the car towed to the nearest dealer (VW Roadside Assistance is okay, but took so long that three other tow trucks came and went before the VW-arranged one got there).

After the service tech ran some tests today on the fuel system, he said it was a cracked rail, and that was the only problem. Ran my story by the tech I normally work with, and he agreed that was the likely problem.

So there you go--not an HPFP issue (hopefully?), but perhaps related in some way to the NHTSA investigation over the slow leaks at the injectors' lines? Mine was not slow, it was a total fail.

Also, how does the rail crack? That thing is kind of important, right?

 

[Savageman69]

The rail is under crazy pressure so on flaw in it could spell disaster

 

[dweisel]

I'd like to see a "cracked rail" They are a pretty hefty piece of metal.Thick walled to stand the accumulated pressure. I guess anything is possible. Ask to see the part and take pics if possible.

 

[Snowman]

How much

The rail is under crazy pressure so on flaw in it could spell disaster

How much pressure are we talking?

 

[dweisel]

How much pressure are we talking?

I'd have to look up the exact number,but its a little over 26,000 psi.

 

[Westro]

Isn't this just what the NTSB has opened an investigation on?

http://forums.tdiclub.com/showthread.php?t=326307

 

[doctorclark]

Isn't this just what the NTSB has opened an investigation on?

http://forums.tdiclub.com/showthread.php?t=326307

The other thread for that investigation is http://forums.tdiclub.com/showthread.php?t=326287

But I think that investigation is for a slow leak closer to the injectors. If the actual rail is cracked in my case, this is a different (and much more significant/dangerous) defect.

One poster on different forum thread (11JettaTDI) had the slow leak, went to have it serviced a couple different times, and THEN had a catastrophic diesel-everywhere problem seemingly identical to mine.

In any case, I will ask the service tech if I can see and take pics of the replaced part. Should be tomorrow--but right now I'm 100+ miles from that dealer and my car, so we'll see.

 

[Mundgyver]

Can someone tell me what the barb fitting is for that I see in the picture I find that rather curious.

 

[Marlyece]

similar thing happened to my 2010 TDI. Someone from NHTSA contacted me. I had diesel spraying all over the place on the highway. I lost complete power and coasted off the exit. Fire Dept was there too. Make sure to report to them as they are investigating.mine was a cracked fuel line though, not the rail itself.

 

[JSWTDI09]

How much pressure are we talking?

I'd have to look up the exact number,but its a little over 26,000 psi.

Officially the max pressure is 1800 bar (which translates to 26,107 psi), so dweisel was very close.

Have Fun!

Don

 

[740GLE]

wonder if it's crappy welds.

 

[TDI_Timmy]

I would think it is forged or cast and then possibly tempered to add hardness and something going on with that process.

Sure hope I am using right terms.

 

[Fixmy59bug]

Can someone tell me what the barb fitting is for that I see in the picture I find that rather curious.

According to ETKA, it appears to be a fuel return line. I believe the pressure relief valve on the end opens a valve if the pressure gets too high. But since the pressure in the return line is not very high it does not need to be a flared/threaded fitting.

I think the more important question is why did Dweisel not listen to Willy Wonka about sampling the blueberry gum??

 

[Mundgyver]

Ahhhh, the return line . I have alot the learn on this new TDI of mine. Now I know where to hook in the fuel cooler.

 

[TwoTone]

Ahhhh, the return line . I have alot the learn on this new TDI of mine. Now I know where to hook in the fuel cooler.

Not sure if you were serious about the cooler, but just a warning, VW loves to deny warranty, I would add anything that could set yourself up for a fight.

While HPFP failures are few, adding anything to the fuel system could be asking for a 8-9k mistake.

 

[doctorclark]

Fixed?

Car is back, and so far (200 mi) so good. The problem was a leaking line #2, as reported by other members, and the reason for the NHTSA investigation (though my “leak” apparently turned into a “gush”). As dsw7_99 and mlemorie stated, and as El_Dobro suggested older model years had problems with, replacing the fuel line from the rail to the #2 injector was the only fix.

The service tech (who was great) said no amount of tightening would stop the leak, and that no other lines were leaking. He ordered a replacement line, installed it, and did full pressure testing of the fuel system—problem (hopefully) solved. The initial diagnosis of a “cracked rail” was because he first thought that a line from the rail to the injector (inclusive: “rail”) had a hairline crack. Turns out he couldn’t even find a crack—the leak seemed to be coming from where the line physically attaches to the engine/injector, and that the fitting for this was off.

Now I am wondering if this fuel leak and the HPFP failures could be related. Wouldn’t a leak in the fuel lines cause a dip in the fuel pressure sensor readings, and then cause the HPFP to crank out too high of pressure?


I'm debating adding my complaint to the 7 the NHTSA already has received: if VW can identify the affected vehicles by build location or date, wouldn't a recall of this little part be a good thing? Losing power on the freeway while spewing fuel everywhere is not something I would wish on other VW owners.

 

[BRIAN427COBRA]

Yes add to the complaints, if you don't VW will not be forced to investigate\fix the problem world wide.

 

[Mundgyver]

A fuel cooler would be for after the warranty runs out. On the Dodge Cummins some people install a fuel coolers in the return line to keep the fuel in the tank from heating up in the summer time as the VP-44 injection pump needs cold fuel to protect the electronics secion and you get better power.

 

[TDI_Timmy]

Yes, definitely add to the list. Why wouldn't you? Worried about retribution?

In all seriousness, it puts it one car closer to a fix and subsequent recall. Helps us all.

Just be thankful you were able to get off the freeway safely. Seemed like you had enough sense to not panic and slam on the brakes in 60+MPH traffic. That can't be said for everybody. So please report it.

I know if it happened to me I would be reporting it as soon as the car was on the flatbed.

 

[Griffin42]

I would definitely report this to NHTSA. Safety, is everybody's business as the motivational posters state. You might be helping others someday and by others I mean me, so please report this to the NHTSA. And thanks for the post.