2009 Volkswagen Jetta Fuel System Diesel Engine Problems

WIFE WENT OUTSIDE TO START HER TDI AND AFTER SITTING AND MAKING NO PROGRESS IN WARMING AND SMELLING A LOT OF UN-BURNT DIESEL SHE DECIDED TO SHUT IT OFF. AFTER SHE CAME INSIDE AND TOLD ME IT WAS NOT WARMING UP AND IT SEEMED TO BE RUNNING OUT OF FUEL VERY QUICKLY I WENT OUTSIDE TO CHECK IT OUT. I COULD SEE THAT DIESEL HAD LEAKED ONTO THE GROUND, SO I OPENED THE HOOD AND FUEL WAS DRIPPING FROM THE ENGINE MOUNTED FUEL PUMP. I LEFT IT OVERNIGHT AT THIS POINT TO MAKE SURE NO FIRES WHERE STARTED. THE NEXT MORNING I TOOK IT APART TO FIND OUT WHAT THE SOURCE OF THE LEAK AND AFTER REMOVING THE PUMP, ASSOCIATED ELECTRICAL, AND RUBBER LINES I SAW THE END OF THE PUMP HAD POPPED OUT OF ITS CRIMPED ALUMINUM CASE. THIS WAS ALLOWING DIESEL TO LEAK PAST THE RUNNING ELECTRIC PUMP AND ONTO THE RUNNING ENGINE WHICH AT THE POINT OF TURNING IT OFF HAD COVERED THE ENTIRE SERPENTINE SIDE OF THE ENGINE COMPLETELY IN FUEL. IT WAS A BOSCH PART #1K0 906 098A WE HAVE CONTACTED VW ABOUT THIS AND THEY OFFERED NO ASSISTANCE IN EITHER OFFERING TO INVESTIGATE THE LEAK OR EXPEDITING THE BUYBACK PROCESS TO REMOVE THIS VEHICLE FROM THE ROADS AND MY DRIVEWAY KNOWING THAT IT LEAKED FUEL. VW DID ACKNOWLEDGE A PRIOR RECALL ON A RUBBER FUEL SUPPLY LINE HAD BEEN PERFORMED BEFORE THE CAR WAS PURCHASED. *TR

THE CAR WAS RUNNING FINE UP TO THE TIME IT QUIT. IT STALLED IN A PUDDLE AFTER 7 DAYS OF RAIN SO I ASSUMED IT HAD GOTTEN WATER IN THE SYSTEM SOMEHOW. I HAD IT TOWED TO MY LOCAL MECHANIC. HE IN TURN CALLED THE DEALER WHO SAID THEY WERE UNABLE TO SELL HIM THE PARTS FOR THE REPAIR AND THAT I NEEDED TO HAVE IT TOWED TO THEM. I HAVE SINCE BEEN TOLD THE REPAIR WORK WILL BE BETWEEN 8 AND 10 THOUSAND DOLLARS TO REPLACE THE DIESEL FUEL SYSTEM! I TOLD THEM TO HOLD OFF SO THAT I CAN WAY MY OPTIONS. I HAVE SINCE VERIFIED THAT INDEED THE HIGH PRESSURE FUEL PUMP HAD DISINTEGRATED AND DESTROYED THE FUEL SYSTEM. *TR

2009 VW JETTA TDI UNABLE TO START THE VEHICLE IT WOULD CRANK BUT WILL NOT START. THE VEHICLE WAS TOWED TO THE VW DEALER AND THEY SAID THAT THE FUEL PUMP IN THE FUEL TANK FAILED. THE PUMP IN THE TANK WAS REPLACED AND STILL WILL NOT START. THE DEALER THEN SAID THAT THE HPFP HIGH PRESSURE FUEL PUMP ON THE ENGINE WAS BAD. THEY CHANGED THE PUMP AND STILL WILL NOT START. THE DEALER DOES NOT KNOW WHAT IS WRONG WITH THE VEHICLE AT THIS TIME. THEY CALLED THEIR TECH LINE AWAITING AN ANSWER. I BELIEVE THIS IS A HIGH PRESSURE FUEL PUMP FAILURE ISSUE THAT IS A KNOWN ISSUE AND WELL TALKED ABOUT ON THE VW TDI FORUMS. IF THIS IS THE ISSUE THE PUMPS AND ANY REPAIRS SHOULD BE WARRANTIED FOR THE LIFE OF THE VEHICLE AS LONG AS YOU OWN THE VEHICLE SINCE IT WAS PURCHASED NEW FROM THE DEALER. *TR

I DROVE HOME FROM WORK ON 9/28/2013 GOT OFF THE FREEWAY, CAME TO A STOP AT END OF OFFRAMP AND THE FIRST WARNING LAMP CAME ON INDICATING A GLOW PLUG FAILURE. IT CONTINUED TO RUN AND I DROVE TO A NEARBY PARKING LOT AT APPROX. 50% POWER, PARKED, CYCLED THE IGNITION FROM ON TO OFF AND BACK ON AGAIN. THIS CLEARED THE FAULT TEMPORARILY, I DROVE TOWARD HOME AND WITHIN ANOTHER 2 MILES THE SAME GLOW PLUG FAULT RETURNED ALONG WITH THE CHECK ENGINE SYMBOL AND A WARNING INDICATING WORKSHOP WAS NEEDED. THE FOLLOWING DAY I BOUGHT A CODE READER, READ THE CODES AND FOUND SEVERAL LOGGED, SOME OF WHICH IM CERTAIN WERE RESIDUAL FAULTS FROM THE ACTUAL CAUSE OF THE FAILURE WHICH WAS INDICATED BY A RECURRING "LOW FUEL RAIL PRESSURE" FAULT. I HAVE CALLED THE DEALER WHICH INSTRUCTED ME TO LOOK AT THE FUEL FILTER AND AIDED BY AN ONLINE TECH INFO BLOG I INSPECTED THE HIGH PRESSURE FUEL PUMP ACTUATOR FOR METAL DEBRIS. THE FUEL FILTER INSPECTION SHOWED SMALL, TRACE AMOUNTS OF METAL DUST WHILE THE FUEL PUMP INSPECTION SHOWED LARGER AND MORE SUBSTANTIAL METAL SHAVINGS UNDER THE ACTUATOR. THE INSPECTION OF THE TWO COMPONENTS ARE INDICATIVE AND INLINE WITH SIMILAR FINDINGS THAT PROVE HIGH PRESSURE FUEL PUMP FAILURE, IT SHOULD BE NOTED THAT NO TRACE OF GASOLINE WAS FOUND IN THIS SYSTEM AND ONLY CLEAN DIESEL FUEL WAS PRESENT DURING INSPECTION. FUEL FILTER WAS JUST CHANGED IN AUG 20 2013 AT SAME TIME AS TIMING BELT WHERE HPFP DRIVE GEAR WAS RETORQUED. I NOW HAVE A CAR THAT IS NOT FUNCTIONAL AND I'M NOT HAPPY. I BOUGHT A DIESEL FOR LONGEVITY AND HIGH FUEL ECONOMY NOT THIS. *TR

CAR IS A JETTA TDI (DIESEL ENGINE). ENGINE WARNING LIGHT APPEARED WHILE DRIVING, APPROXIMATELY 50 YARDS LATER WHILE SLOWING DOWN THE ENGINE FAILED AND WOULD NOT RESTART. CAR WAS STOPPED AT INTERSECTION ON A BUSY 5 LANE ROAD AT 5:30 PM WITH CARS COMING FROM BEHIND AND AROUND AT SPEEDS OF 45+ MPH. SHERIFF CAME TO DIVERT TRAFFIC TO PREVENT A WRECK AND ALLOW TOW TRUCK TO TOW CAR SAFELY. DEALER STATES THAT HIGH PRESSURE FUEL PUMP FAILED, RUINING FUEL SYSTEM, QUOTES POTENTIAL REPAIR COST OF $8,500. FILLED FUEL TANK 5 MILES PRIOR TO INCIDENT WITH 11 GALLONS OF DIESEL FUEL (REPUTABLE FUEL DEALER, ALMOST ALWAYS USE THIS DEALER). THERE WAS NO WARNING PRIOR TO THE INCIDENT -- NO ROUGH ENGINE OR STALLING OR TROUBLE OF ANY KIND. CAR IS DRIVEN BY ONLY ONE DRIVER AND IS WELL MAINTAINED, HAS NEVER BEEN FUELED WITH ANYTHING BUT DIESEL FROM REPUTABLE DEALERS. CAR IS USUALLY DRIVEN ON THE FREEWAY (DEALER RECOMMENDED IT SPECIFICALLY FOR A LONG FREEWAY COMMUTE). LUCKY THAT IT DIDN'T STALL AT HIGH SPEED ON FREEWAY. *TR

THE EXHAUST FLAP IS STICKING IN THE OPEN POSITION, THUS CAUSING WARNING LIGHT ON DASH TO COME ON. *TR

WE WERE DRIVING OUR 2009 VOLKSWAGEN JETTA TDI DOWN THE HIGHWAY AT 65MPH ON FRIDAY MAY 24, 2013 WHEN SUDDENLY THE CAR BEGAN TO SHAKE AND SHUDDER VIOLENTLY. IT WAS VERY SCARY AND THEN IT SEEMED THAT THE POWER WAS COMING IN AND OUT. BECAUSE OF THE SUDDEN SHAKING AND LOSS OF POWER, I HAD TO VERY QUICKLY PULL TO THE SIDE OF THE ROAD, TO AVOID CAUSING AN ACCIDENT ON A HEAVILY CONGESTED HIGHWAY ON A HOLIDAY WEEKEND. THE VEHICLE IS ALWAYS SERVICED BY THE DEALERSHIP (INCLUDING ALL OIL CHANGES) AND IS UP TO DATE ON ALL PERTINENT MAINTENANCE. THE DEALERSHIP HAS DIAGNOSED THE VEHICLE WITH A FAILED HIGH PRESSURE FUEL PUMP (HPFP) AND HAS ACCUSED US OF SOMEHOW ALLOWING METAL INTO THE DIESEL FUEL (THEY EVEN HAD SOME METAL "SAMPLES" TO SHOW ME AT THEIR SERVICE COUNTER, HOW BIZARRE). I WENT BACK TO THE FUEL STATION WHERE WE LAST FILLED UP AND SPOKE TO THE MANAGER, WHO SAID THERE HAVE BEEN NO REPORTS OF ANY ISSUES RELATED TO CONTAMINANTS OF ANY KIND IN THEIR DIESEL FUEL. WE ARE STUCK WITH A $6,000 BILL FOR A DEALER-MAINTAINED CAR THAT HAS ~83,000 MILES ON IT AND IS JUST OVER 3 YEARS OLD, IN ADDITION TO THE FRIGHT OF A VIOLENT LOSS OF THE VEHICLE'S POWER, AT HIGHWAY SPEEDS. *TR