Fuel Pump problems of the 2006 Volkswagen GTI

Owner of a 2006 vw Gti, threw engine code for known TSB regarding cam follower and cam shaft wear at the high pressure fuel pump. Mechanic inspected site and discovered that cam shaft wear/ damage was extreme and would require replacement of high pressure fuel pump, cam shaft, and cam follower all outside of warranty. This is a known issue and should have some extension on factory warranties from vw of America instead of expecting owners to pony up $1600-2400 in repair costs when it inevitably fails. For note of known issue, see vw TSB #2013147/8.

The contact owns a 2006 Volkswagen Gti. The contact noticed a reduction in power along with a shuddering of the vehicle and the check engine light illuminated intermittently. The dealer replaced the crank case breather hose and a fuel pressure sensor; however, the problem intensified and the vehicle was almost inoperable. The contact had the vehicle towed to the dealership and the vacuum hose was replaced. The dealer also performed the ignition coil recall repair on the vehicle. When he picked up the vehicle, the check engine light illuminated when he turned the vehicle on; however, the dealer suggested that he had a valve lash and fuel pump module repair. While driving long a distance, the vehicle check engine began to blink on and off. The failure was diagnosed by a second dealer who stated that there was a major failure with the camshaft system which needed to be replaced along with the high pressure fuel pump, and a cam follower. The vehicle was repaired and the check engine light was illuminated at the time of the complaint. He called the manufacturer and was told that they could not assist him. The current mileage was approximately 85,000. The failure mileage was approximately 84,000.

On April 4, 2009 I discovered that my fuel pump, cam follower and intake cam lobe have prematurely worn as described in a June 2007 vw TSB #15 07 04. The cam follower cap wore through, causing the fuel pump plunger tip to come into contact with the cam lobe, wearing all three parts to the point that they must be replaced, as per the TSB, even though the engine was maintained at the dealer during warranty period pursuant to vw specifications, and in excess of the intervals called for in the maintenance booklet that came with the car since the warranty period expired. Because my car never displayed a check engine light, the cam wear was never checked by the servicing dealer since they are instructed in the TSB not to proceed in the absence of a warning indicator, and by the time the issue was found, vw denied warranty claims due to mileage on the car (80,100 +/- at the time of discovery). It is my contention that the parts will continue to wear to the point that the fuel pump and/or cam shaft may fail during highway operation, possibly causing a collision or the release of fuel into the engine bay thereby causing a risk of fire. The vw maintenance booklet makes no mention of the necessity of replacing or even checking these parts for wear through 100,000 miles, and if the check engine light does not illuminate, the owner may have no warning of an impending failure of the parts. I have already replaced one cam follower, and have the original damaged part. An unscientific review of vw owner websites indicates this is a common failure, and in some instances has occurred in as few as 25,000 miles. I have contacted vw directly, and while they have not disputed the fact that the parts are defective, they refuse to offer any repair assistance.

There were no events leading up to this failure. Car hesitated. Took it to the dealership. This wa s supposedly a wide spread problem that the fuel pumps went bad in desert temperatures. New fuel pump took 4+ weeks to arrive - back ordered.