HELP Metal in fuel system £3000 bill

Mike Astles · Aug 13, 2015

Good evening all!

I have just had what must be the worst day of my life!......

I bought an Audi A3 2.0L diesel in December. The car is a 60 plate and has 67k mileage. I switched to audi for some decent reliability and trust in a decent make.

Last night I headed out about 8pm and there was nothing out of the sorts. About 10 mins into my journey I put my foot down a bit to overtake a car (Not thrashing) and i noticed a lot of white smoke and then the engine cut out. I managed to steer it to the side of the road and stop. The car woudnt restart so I had to be recovered. No warning lights at all.

Finally managed to get it to a garage this morning and he first thought the fault was with the fuel pump under the rear seats. There was a low pressure warning on the system from the breakdown the night before. He got a price for the fuel pump and I was happy with that. Then a few hours later he called me back with some bad news. He said there is metal fragments in the tank, the fuel filter and he said this would have clogged up the injectors. I popped in to see and there was indeed lots of very small metal fragments within the fuel filter. Mostly on the top of it from what I could see. He also said he had looked in the tank and there was lots in there too.
The total cost which isnt all new parts and some repairs to my pump etc and its come to almost £3k!

I am absolutely gutted and I have googled to see if common problem etc but to be fair I am absolutely numb from the last 24 hours!

has anyone had any experience of this or has an opinion on the diagnosis?

I would really appreciate some help right now!

Thanks in advance

Mike

LEE69 · Aug 13, 2015

how did the metal get past the fuel filter?

NHN · Aug 13, 2015

Exactly, that's seems highly unlikely unless its come from the fuel lines return side which isn't filtered, but that's very unlikely, are you sure they're not spinning you.

Whereabouts are you located?

Mike Astles · Aug 13, 2015

LEE69 said:
how did the metal get past the fuel filter?

I asked the same question and from his explanation of the way the fuel system works he says its from the pump after the filter? This is why I really need some advice guys. He said from his experience its been mis- fuelled at some point in the past (before I had it) and was diluted rather than being drained... And this has caused the fragments to slowly break loose.

I am at a loss!

Thanks for reply!!!

NHN · Aug 13, 2015

Urmmmmmmm tandem pump, I've never heard of metal filings from these, if it even has one on that engine tbh.

Mike Astles · Aug 13, 2015

NHN said:
Exactly, that's seems highly unlikely unless its come from the fuel lines return side which isn't filtered, but that's very unlikely, are you sure they're not spinning you.

Whereabouts are you located?

I dunno guys. I have put a lot of work their way so I would like to hope not.

I am in Fleet, Hampshire.

Mike Astles · Aug 13, 2015

NHN said:
Urmmmmmmm tandem pump, I've never heard of metal filings from these, if it even has one on that engine tbh.

Whats your thoughts? Thanks for replying

Mike Astles · Aug 13, 2015

Here is a copy of the parts from the estimate if this is any help?

Robin Chandler · Aug 13, 2015

Tank fuel pump, fuel pump and pump repair! Not sure how many fuel pumps you have in a diesel!! Why are you being charged for 2 pumps and a repair?

LEE69 · Aug 13, 2015

Fuel 15 L X 1.40 then charging you vat on that, they got big glass windows in this place?

Tfsi gone · Aug 13, 2015

Think you maybe getting fleeced mate. Only way I could see metal deposits getting in would be via the fuel nozzle. Even then it would have to get through the fuel filter..
Was the fuel filter in tact?

Craig-P · Aug 13, 2015

Coming from a technician who has worked for VW and currently work for Seat now this is unfortunately a reported fault although a less common one then others and the price they are charging is about right tbh. It is normally caused by mis-fueling as petrol takes away the lubrication coating that the Diesel engine needs and therefore wears away the internal parts (Tandem pump) If we've ever got a car in with the same problem - Metal filings etc in fuel system you are told to replace the full system by the manufacturer so this includes, Both Pumps, All lines, Injectors, Fuel filter, Remove tank and clean out, Clean out fuel filter housing etc etc, So aswell as the cost of the parts you also have to think of the time involved in this job and therefore the cost of the labour alone which is where you get the £2-3K+ from so I'm afraid I wouldn't say there trying to pull a fast one!!

S3 AEX · Aug 13, 2015

Have a read of this mate, as above I don't think your being fleeced. It's not audi's reliability to blame here it's obviously wrong fuel at some point in the cars life. Have you any warranty?

https://www.theaa.com/breakdown-cover/wrong-fuel-advice.html

Tfsi gone · Aug 13, 2015

I understand the problems in Petroleum contaminating Diesel engines!
If after owning the car from December and only now its occurring though, that to me is strange...

Mike Astles · Aug 13, 2015

Thanks for all your replies guys!

Robin Chandler said:
Tank fuel pump, fuel pump and pump repair! Not sure how many fuel pumps you have in a diesel!! Why are you being charged for 2 pumps and a repair?

I have no idea how many the car has I really do rely on friends/forums for support in this! I am assuming there is two!

LEE69 said:
Fuel 15 L X 1.40 then charging you vat on that, they got big glass windows in this place?

Fair shout Lee, I will be getting that taken off! Cheeky sods its £1.07 30 seconds down the road!

Mike J said:
Think you maybe getting fleeced mate. Only way I could see metal deposits getting in would be via the fuel nozzle. Even then it would have to get through the fuel filter..
Was the fuel filter in tact?

He mentioned a circulation on the fuel system?! Hence why there is metal both sides of the filter. This is something I needed to check with you guys!

Craig-P said:
Coming from a technician who has worked for VW and currently work for Seat now this is unfortunately a reported fault although a less common one then others and the price they are charging is about right tbh. It is normally caused by mis-fueling as petrol takes away the lubrication coating that the Diesel engine needs and therefore wears away the internal parts (Tandem pump) If we've ever got a car in with the same problem - Metal filings etc in fuel system you are told to replace the full system by the manufacturer so this includes, Both Pumps, All lines, Injectors, Fuel filter, Remove tank and clean out, Clean out fuel filter housing etc etc, So aswell as the cost of the parts you also have to think of the time involved in this job and therefore the cost of the labour alone which is where you get the £2-3K+ from so I'm afraid I wouldn't say there trying to pull a fast one!!

Thank you Craig! Appreciate replying! I am having them fully cleaned and reconditioned so I am hoping this will be good enough!

S3 AEX said:
Have a read of this mate, as above I don't think your being fleeced. It's not audi's reliability to blame here it's obviously wrong fuel at some point in the cars life. Have you any warranty?

https://www.theaa.com/breakdown-cover/wrong-fuel-advice.html

No warranty I am afraid. I was too wary of these extended warranty's after a bad experience with another car! They always find a way to wriggle out. Car way bought from Imperial Car supermarket so I am going to write a letter to them! Nothing ventured nothing gained!

Mike J said:
I understand the problems in Petroleum contaminating Diesel engines!
If after owning the car from December and only now its occurring though, that to me is strange...

Would you have expect something earlier? I am 100% i have never filled it with anything else. I am the only one that uses the car too! This is whats really annoying me!

Thank you all for your time! Its really appreciated!

Mike

sonny. · Aug 14, 2015

A second opinion is never a bad thing. You're not far from me, i'd suggest taking it to Invincible MOT in Farnborough of Fleet MOT as I've had good experience with them. Good luck

Smirky · Aug 14, 2015

Mike Astles said:
Here is a copy of the parts from the estimate if this is any help?

Why are they charging you £400 to repair a brand new fuel pump ?

hollows wife · Aug 14, 2015

quickest and cheapest option would be another tank with pump in it and another engine ,then all thats left to do is need filter and clean fuel lines .

Craig-P · Aug 20, 2015

I would personally just get them to clean out what you can so, Tank, Lines, In-Tank pump, Fuel filter housing, Replace the Tandem pump and fuel filter put a full tank of fresh fuel in along with some fuel cleaning treatment (Redex or similar etc) And go from there..Failing that trade the car in and get something else

Mike Astles · Aug 21, 2015

Hi guys! Thanks all for replying. Well I'm 3k lighter now and went down to collect the car. When I went to start the car it took forever to start which it never did and they suggested I take it for a spin and see how it was. 30 seconds down the road and the Engine Management light came on and limp mode. Took it back to the garage and they plugged the compluter in and it was reading P0087 fault code. I think this is low fuel pressure warning

The guy said he has replaced everything on the fuel system except the rail. I can post a list of the parts if that will help? I have left it with them but I am really getting worried now!

Anyone have any thoughts?

Craig-P · Aug 29, 2015

Why didn't he replace the rail..?

Smirky · Aug 29, 2015

Does seem odd that u would replace everything fuel related bar the rail ,why risk it?

Mike Astles · Aug 29, 2015

Hi guys.

When I asked he said he was able to clean it. So I'm guessing he was happy it was clear?!

Got me wondering now!

Craig-P · Sep 13, 2015

Any update on this mate..?

Mike Astles · Sep 13, 2015

Craig-P said:
Any update on this mate..?

Had the car back a few weeks now running as normal as far as I can tell but not driven any other A3's. Garage said the rail was cleaned and bench tested fine. I do trust them so when I can't afford to replace the lot so be it! Does concern me still though.

In terms of the garage that sold me the car waiting on final response from them any day now. It just makes me wonder what I could have done when buying it that would have helped me in this situation! Scary to spend so much money and have no idea what's gone on before.

Thanks for checking up!

Craig-P · Sep 14, 2015

So when you took it back to them after picking it up first time round what did they then do..? I presume they still haven't replaced the rail then..?

Kayleighosx · Aug 18, 2021

Mike Astles said:
Good evening all!

I have just had what must be the worst day of my life!......

I bought an Audi A3 2.0L diesel in December. The car is a 60 plate and has 67k mileage. I switched to audi for some decent reliability and trust in a decent make.

Last night I headed out about 8pm and there was nothing out of the sorts. About 10 mins into my journey I put my foot down a bit to overtake a car (Not thrashing) and i noticed a lot of white smoke and then the engine cut out. I managed to steer it to the side of the road and stop. The car woudnt restart so I had to be recovered. No warning lights at all.

Finally managed to get it to a garage this morning and he first thought the fault was with the fuel pump under the rear seats. There was a low pressure warning on the system from the breakdown the night before. He got a price for the fuel pump and I was happy with that. Then a few hours later he called me back with some bad news. He said there is metal fragments in the tank, the fuel filter and he said this would have clogged up the injectors. I popped in to see and there was indeed lots of very small metal fragments within the fuel filter. Mostly on the top of it from what I could see. He also said he had looked in the tank and there was lots in there too.
The total cost which isnt all new parts and some repairs to my pump etc and its come to almost £3k!

I am absolutely gutted and I have googled to see if common problem etc but to be fair I am absolutely numb from the last 24 hours!

has anyone had any experience of this or has an opinion on the diagnosis?

I would really appreciate some help right now!

Thanks in advance

Mike

Hi Mike, just reading through forums as I’m at my wits end but what happened to you is the exact same that happened to me in my 2015 Audi A3 it’s been in the garage weeks now and been told the injectors probably have to be done and the whole system should be done then to prevent it happening again. I’m a lost cause looking for help as too what happened with you in the end.

**HELP** Metal in fuel system £3000 bill

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