daily double wrote:
Ford will NOT cover any water in the fuel on their diesels! I don't care if you have all the documentation in the world, Ford will not pay! They will admit there is water in all diesel fuel, but the bottom line is still the same. They even admitted to me that their warning system (water in fuel light) is not perfect. I just paid $10,216 .00 to find all this information!
The issue is the Bosch CP 4.X pumps... running 2000 bar and Bosch piezo injectors. The pump fails. IMHO, if you ever opened a Bosch CP4.1 or 4.2 pupm up that has failed, you'd see a design flaw with a cam driven piston with a tiny roller underneath it, the whole piston assembly is unretained... it can float at high speed, it will lose alignment and spin in the bore at high speed, losing contact with the cam, and this can be when the damage starts occurring.
IMHO, the design is defective, it's subject to heat from high pressure, lubricity issues from low lubricity fuel, and driving a steel piston in an aluminum bore.
I don't care if you agree with me or disgree with me, the failure rate is in excess of 5% within 5 years... I don't think that at 2000 bar pressure, it's a matter of if it will fail within 200k miles, it's a matter of when.
I do have a dog in this hunt, I own nothing but VW diesel common rails, two of them have the same Bosch CP4.2 pump in them, in v6 motors. The other one is the CP4.1 in an inline 4 cylinder.
Do yourself a favor, if you have a HPFP failure... please file a complaint form with NHTSA before you tow your truck in to the dealership to fix it.
NHTSA online complaint formOnce NHTSA has contacted you back, let them know which dealership is handling your warranty claim, and the name of the service manager. Let them know you have a Bosch CP4.2 High Pressure Fuel Pump that failed, and that you've looked on line, and that the product appears to have a defect in design, as observed in EA11003, which shares the same HPFP family of Bosch pumps.
That should get the gears turning at fomoco to get things covered by warranty by Ford, with a preemptive strike.
Anyone with a Bosch CP4.1 or CP4.2 family pump should file a complaint with NHTSA... know your fuel system parts and families under the hood of your tow vehicle.
