A5 2.7TDi High Pressure Fuel Pump

[John-A5]

My early 2008 A5 2.7TDi ( 90k miles )has broken down and wouldn't start-- after taking to an independent Audi specialist they advised that it as the High Pressure Fuel Pump that had failed. I bought a pump from a salvaged 36k miles car .. This has been fitted but the garage have advised the car is still cutting out and they think that there is engine lubrication and iron filings in the injectors and fuel lines .. And it will be an expensive fix.

any suggestions if this is right .. And can I get any sort of help from Audi ?

Thanks John

 

[Nithin]

Hello John,

How did you fix the problem? I am facing this now!

Regards,
Nithin

 

[desertstorm]

I doubt John will be replying that was his only post on July 14th 2013 and the last time he was on here was July 16th 2013.
The CP4 pump used on a lot of cars since 2008 seems to have issues where there is wear in the pump resulting in small metal particles entering the fuel system and causing issues.
http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/UCM475595/INCR-EA11003-61863.pdf
Unfortunately these particles can cause issues all over the fuel system finding there way into the injectors and other parts of the system.

 

[Nithin]

Thank you desertstorm. I am now facing this situation, where I have no warranty, and the service guys told me that the high pressure fuel pump could cost 2000 EUR and a full Fuel system replacement could cost 6000 EUR. Till before the service, I was able to switch off the car and drive away, but after the service where he said he did some tests and cleaned the metal shaving seen in the system, I am getting this alarm more often, and now I have the glow plug alarm flashing and a engine light ON. I really do not know what to do.

Regards,
Nithin

I doubt John will be replying that was his only post on July 14th 2013 and the last time he was on here was July 16th 2013.
The CP4 pump used on a lot of cars since 2008 seems to have issues where there is wear in the pump resulting in small metal particles entering the fuel system and causing issues.
http://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/UCM475595/INCR-EA11003-61863.pdf
Unfortunately these particles can cause issues all over the fuel system finding there way into the injectors and other parts of the system.

 

[desertstorm]

You can buy brand new pumps for 700 euros so why are they saying 2000 euros.
http://www.ebay.com/itm/Hochdruckpu...9130755AH-059130755AB-NEU-BOSCH-/111849111328
I would be inclined to replace the pump with a new item. You can try cleaning out the rest of the fuel system but the swarf from the pump tends to find it's way to the injectors. If you have to replace anything else in the system I would use second hand parts as injectors etc are very reliable and second hand are cheap.

 

[Rony1987]

I have the same problem with my audi a5, just bought used pump, fuel lines injectors, and new fuel filter! I will change all parts from fuel filer to pump! To avoid of metal parts in fuel system!

 

[desertstorm]

Hope this works out for you.

 

[Rony1987]

This is how looks the the fuel pump! A lot of metal parts in fuel system! Tested all injectors, they are broken!

Already changed pump, injectors and cleaned the fuel system! Still need to change fuel filter and clean the fueltank and adapt new injectors with vag! So hope that all the metal parts will be cleaned!

 

[desertstorm]

Wow that is pretty bad, Not surprised there is shrapnel every where in the fuel system.

 

[Rony1987]

Finaly! Done the repair! My advice is to buy new high pressure fuel pump, at least checked and tested injectors you can check also from your car but in my case they all was broken, change the rails from another car with fuel pressure regulator and fuel pressure sensor, also need to change fuel filter and taken of the tank to clean it from metal shrapnel! A lot of work to do! But it is only way to be sure that all be fixed properly because one shrapnel in fuel system can damage fuel pump injector or other sensor again!
So my story! At first i just cleened the fuel system and rails, changed filter, injectors and put used pump! The car started and i driven for about 15min and sudenly it stoped and didn't start! checked the errors and got "fuel pressure to low" after that i changed to another high pressure pump and got the same isue but this time car run only for 5 minutes! So at the end done all like in the book! bought new pump cleened again all fuel system changed the rails from another car, taken of the tank! Not sure what was the problem hp pump or rail sensors but now car runs fine!

 

[Rony1987]

Bosch high pressure pump new 670 eur
Injectors tested 6x160 eur
2 Rails with sensors and injector fuel return line 200 eur
Fuel filter 20 eur
Diesel for clening the system and tank 50 eur

And lot of hours in garage!

 

[desertstorm]

Glad you got their in the end. The CP4 pumps on these don't seem to cope as well as the older design pumps. Built to a price and not a specification I suspect.