Ford's answers to the NHTSA 6.7 Investigation

ricatic wrote:
I had an interesting discussion with my neighbor yesterday. He is a service/warranty engineer at VW. We discussed the VW CP4 issues. He is quite aware of all the problems...he did say some interesting things about why VW has extended their warranty coverage on HPFP failures...let's just say it was not their idea!!!!

...he just smiled when I asked if Ford was next....

Regards

The version I heard was that VW will do just enough to stave off a full blown recall campaign being implemented by NHTSA, so they very much begrudgingly do the replacement, at great expense to them out of pocket. Which is why every single person, regardless of if their dealership fixes or fixed the problem fuel system and HPFP or not, should file a complaint with NHTSA to get Bosch off their arses to fix the problem permanently. Bosch was so busy blaming contaminated fuel, water, or gas in diesel, there is a complete lack of accountability over there, with typical German arrogance of it always being operator error.

What came out in the results in the correspondence between VW and Bosch, much of which was redacted, was that there was a severe quality control cleanliness issue in manufacture and assembly of the HPFP units made in 2 German facilities, and that the required polish and internal finish was quite high. They moved production to Slovakia, and seem to be getting a better finished product now, but, IMHO, the design is still defective and faulty, certainly when the issue of alignment problems between cam and roller and follower and failure is well documented early on in the correspondence.

The worst part about all of this is that VW, Ford, Audi, Porsche, and GMC/Chevy have all been taking the heat for what is a subontractor Bosch design problem, and no one, not a soul, can get a word out of Bosch on their crappy design, production and implementation of this HPFP and the craptasticness of the whole design of their pump.


Here it is November, the 2012 VW Passat with solenoid injectors and 1800 bar HPFP pressure with a longer stroke and a smaller plunger bore for that pressure level, one year later, and the failures are exceedingly rare at this point in time. I am aware of only 2 being reported so far on TDIclub, one in Atlana GA, the other near San Francisco, CA, again, hot weather states.

So far, it's the 2000 bar and piezo injectors that continue to die like flies, lots and lots of 2009 jetta TDI's again showing up in the fall with dead, grenaded Bosch CP4.1 HPFP'S again this year, due to either heat or lack of lubrication.


As an aside, I am almost 100% certain that in Audi/VW / Porsche product, if you own a laptop and VCDS software and cable, you can log requested vs actual fuel pressure data through the OBD2 port.