High Pressure Common Fail Diesels - happytorque
Well, over the past 12 months or so we have all read many posts about Common Rail Diesel engines being ticking time bombs. Mr Aprillia wouldnt touch one; and that scares me.
Im sitting here wonedring when my 03 plate HDI is going to trash its fuel system and leave me with a bill for £2500. One of the main reasons for opting for a diesel is the expected reliabilty and longevity. The suggestion now seems to be that we can expect neither. And we pay a significant premium for the privilege of this uncertainty. There are hundreds of thousands of us driving around in these HDI / TDI / PD /TDCI / Multijet thingies, so to try to calm my nerves i would like to ask all common rail backroomers a question or three......who amoungst us has actually has their engine / fuel system trash itself? what went wrong, at what mileage did it happen and how much did it cost to rectify? Then we can make a judgement on the magnitude of the problem.
cheers. Trev
High Pressure Common Fail Diesels - Quicksilver
About 58000 miles in an Honda Accord. High pressure pump failed. Lease car and under warranty so not my problem but cost about GBP1200 to put right!
High Pressure Common Fail Diesels - Blurred
Audi A4 V6 tdi injector system failed. 120k. Cost for a refurbishment circa £1300. Ouch.
High Pressure Common Fail Diesels - Bromptonaut
Xantia 110 Hdi 2000/X 90 k and owned from new. Valve fault on HP side of system at 80k; around £200 to correct.

LP "lift" pump in tank has also failed around 88k, but AFAIK installation is common to petrols.
High Pressure Common Fail Diesels - Screwloose
Trev

I've dealt with no less than five HP pump failures on 2 y.o. Mazda 6's in the last year. The dealers weaselled-out of paying warranty on every one. One poor chap was quoted £4,500 because the car was 500 miles past the 60K limit - even though he'd been reporting stalling problems since 51K. Delphi - the pumps' maker Denso's importer - are absolutely brilliant with these claims.

It can't just be me that's seeing all these failures? Any other Mazda 6 victims out there?


You're being a bit unkind lumping the TDi PD system in with common-fail. Given the numbers about and the mileage these do, the failure rate of their unit injectors seems quite acceptable. They don't require a full system replacement if one goes either. By far, the best high-tech diesel system.


Anecdotally; I'd have to say that the failure rate of HDi systems seems to be falling fast. Maybe all those dozens of system modifications are finally having an effect. I'd estimate your chances of having a catastrophic failure in less than 150K miles at around 5% - unless you mis-fuel it.....

They're still too complex and "on the edge" to ever want to own one that wasn't covered by a solid warranty though. And then there's the Euro 4 issues.....
High Pressure Common Fail Diesels - Menzies
My Ford Mondeo (2003) went wrong within warranty. Ford quoted over £2000 to put it right. They weasled out of paying under warranty by saying that it must have had contaminated fuel, something that I disputed with them and with Ford UK. It got me nowhere. An independent diesel repair workshop advised me to get rid of it, which I did.
I can only echo Screwloose by saying don't buy one unless you have a cast-iron warranty, and even then you may come unstuck.
High Pressure Common Fail Diesels - cheddar
You're being a bit unkind lumping the TDi PD system in
with common-fail. >>


Why, a totally illogical system, running the HP pumps off a belt driven camshaft, cambelt chanes at 40k intervals, so £1000 + scheduled bills over 120k miles that a chain cam CR does not have. Also rather less refined than CR, lastly VAG are seeing the light and going CR it seems.
High Pressure Common Fail Diesels - cheddar
So we have a Honda, five Mazdas, an Audi and a Ford, I also have a Ford that is just coming up to 112,000 miles and is fine.

Though haven't we done this subject to death recently?

The fact is that people with problems gravitate to a site such as this and if you Google the issue this site is top of the list so clearly it is not an issue featured prominenty within other such forums.
High Pressure Common Fail Diesels - George Porge
>> You're being a bit unkind lumping the TDi PD system
in
>> with common-fail. >>
Why, a totally illogical system, running the HP pumps off a
belt driven camshaft, cambelt chanes at 40k intervals, so £1000 +
scheduled bills over 120k miles that a chain cam CR does
not have. Also rather less refined than CR, lastly VAG are
seeing the light and going CR it seems.


No you're talking of 3 belt changes rather than 2 = £300 over 120K

There's plenty of belt driven common rail engines and if you've ever seen the devastation caused when a chain snaps, you'd prefer a belt anyday

Who says its less refined? Where's the proof? Just because its repeated over and over on here does'nt make it true.

I'd go with a PD engine over common rail anyday and techs that work on both systems on a dailly basis agree with me

Are the Mazda's and the Honda mentioned chain driven?
High Pressure Common Fail Diesels - cheddar
No you're talking of 3 belt changes rather than 2 =
£300 over 120K


Surely not, you mean VW would only charge £150 for a cambelt change? At least £300 I reckon and would need one at 40k, 80k and 120k miles.

There's plenty of belt driven common rail engines >>


Yes though the belt is not driving high pressure PD pumps and generally has scheduled changes 50% longer than the VAG engines.


>>and if you've
ever seen the devastation caused when a chain snaps, you'd prefer
a belt anyday

>>

That is like comparing throwing a rod with cam belt failure, a chain is designed to last the life of the engine and generally does, a belt is a service item.

Who says its less refined? Where's the proof? Just because its
repeated over and over on here does'nt make it true.


IME the 1.9 PD's are rather unrefined, the 2.0s are a little better though not up with the best by modern standards

Are the Mazda's and the Honda mentioned chain driven?

>>

That is irrelevant, the problems mentioned are not chain or belt related.
High Pressure Common Fail Diesels - madf
VAG TDI unrefined?

Yesp. I drove over 40k in 2 years in an A4TDI. Noisy/rough at low speeds. Grated on me.
Others I tried (A3/VW) were as bad.

PSA HDI and Toyota are MUCH smoother at low revs.
madf
High Pressure Common Fail Diesels - Frogeye
I had a Pug 406 110 Hdi which had the low pressure pump replaced around 45k miles. The sympton was no start and blowing a fuse. The garage replaced the pump and also the fan controller which had caught fire, so I am not sure which caused the fuse blowing. It seemed a coincidence that both failed at the same time. At 90k miles the high pressure pump started leaking, I was quoted £1k to fit so I got rid of the car.
After the positive comments on this site about VAG diesels, bought a Audi A4 2.0 Tdi multitronic. The gearbox is incredibly smooth and keeps the engine around its peak torque output. It also completely removes the diesel gruffness and all or nothing torque characteristics I experienced on a loan A3 manual with the same engine. I find the A4 is an extremely smooth, quiet refined car and the 2.0 Tdi engine gives more than enough power.
However I have noticed a few 2.0Tdi engines which sound very loud from the outside and many other quiet ones.
High Pressure Common Fail Diesels - Screwloose

Perhaps I'd better qualify my rather imprecise statement as relating specifically to the failure rate/disaster potential of the different systems; not matters of refinement, fuel economy or servicing costs.

VW have been threatening to do a CR system for quite a while. So..... let's see; that's a highly-complex, Euro 4 compliant, CR with the critical components doubtless sourced from Indonesia/Malaysia/Tunisia/Mexico/Brazil and all half-assembled by VW..... Mmmmm - yes please! Fixing that'll be a very nice little profit-earner.

[How much is a nice condo in Florida...?]
High Pressure Common Fail Diesels - Ross_D
I thought all the V6 VW diesels were common rail anyway, only the 4 cylinder lumps that were PD?
High Pressure Common Fail Diesels - happytorque
Thanks for the responses gents, but youre right, this subject has been discussed many many times on here. Im not too concerned about chain cam vs belt. Nor am i interested in which design is the smoothest. That has indeed been discussed before.
What i want to get a grip on is, 'who has actually experienced a CR fuel system failure, what car, what mileage, what cost'. Thats all im trying to establish.
Five Mazda 6's in a very short space of time is the kind of stuff we all need to mindfull of and thats the kind of valuable input i was hoping for.
The stuff about belt vs chain is all good stuff but not what im aiming for.
Is this a massive problem brewing for all the diesel drivers....or is it a few isolated cases being talked about rather alot and thats making us think the problem is far more widespread than it actually is?
More posts like the first four or five are the aim of this thread, so if youve had it happen to you i would very much appreciate your comments.
At the moment there doesnt seem to be all that many people who have experienced CR failure, so my next car may not after all have to be a Subaru Lagacy! And that is a positive message.
Cheers Trev
High Pressure Common Fail Diesels - George Porge
Cheddar 3-2=1, 1 x £300 = £300

I'll take a belt driven engine anyday, my B-I-Ls 22K mile corsa 3pot has had 2 chain and tensioner sets under warranty already at 27 months old. My fathers chain driven Sierra snapped its chain at 24K miles, chains last the life of the engine or vice versa

My PD 1.9 is fine, although I've never driven a French car ever ;O)

You mentioned chains and belts in the first place,not me.

PD engines cope with miss-fueling better than common rail, its a fact ask a tech.

VAG V6's use common rail only because there is'nt room for the cam driven PD injectors between the two banks of cylinders.

Ask any specialist which is the more reliable of the two VAG engines and they will tell you the PDs by far.

Its funny but there are two current threads on here plenty of people are singing the praises of the Fabia VRS that has a 1.9 PD engine under the bonnet

Buy the car you want I say, lifes too short


High Pressure Common Fail Diesels - TurboD
Just look at the Transit Owners Club site for problems, they are real.
Modern high pressure diesels are just not fit and forget, do your sums before buying ,not after.
Fine if on a lease- but if you are paying then - you need some mighty mpg to make them pay.
and the noise?, and smell?
High Pressure Common Fail Diesels - cheddar
Cheddar 3-2=1, 1 x £300 = £300


9/10

The right answer to the wrong sum, £300 per change x 3 changes (at 40k, 80k and 120k miles) = £900 (at least).

You mentioned chains and belts in the first place,not me.


Yes I did to say that PD is a totally illogical system, running the HP pumps off a belt driven camshaft.

I also said it is irrelevant that the Mazda's and the Honda mentioned are chain driven because that relevant point is that they are CR not PD rather than chain not belt.
High Pressure Common Fail Diesels - happytorque
oh boy....my thread has been hijacked
High Pressure Common Fail Diesels - PhilW
"when my 03 plate HDI is going to trash its fuel system and leave me with a bill for £2500. "
Wife's W reg Xantia HDi has now done 95k and is still very much on song. Engine not touched so far except for new cambelt at about 72k (even though interval is supposed to be 100k on the grounds that we were unlikely to keep it until it had done 150k so might as well have its one cambelt change done early and be safe rather than sorry - £150 at our favourite local independent- and that's a pretty good deal I reckon)
--
Phil
High Pressure Common Fail Diesels - DP
Based on experience of cars owned by friends and family, I wouldn't buy a CR diesel unless it had significant warranty cover remaining. I'm sure a lot of them run to high mileages without problem, and that they are getting better all the time, but there are too many horror stories and several from owners that I could be 99.9% sure did not misfuel or otherwise abuse the car. I'd expect to run the risk of £2k+ repair bills on an exotic sports car, not a diesel runabout. When the technology has matured, I'll look at it again.

I'm no VW fan, but in fairness the fuel systems on the VAG PD's in our family (5 in total ranging from 25k to 120k miles and 2 to 5 years old have never given a day's trouble apart from MAF sensors going pop on four of them. They have other reliability issues, particularly one of them (a 2002 Passat which has been chronically troublesome), but the fuel systems don't seem to go wrong. Not as refined as CR obviously, but the performance and economy are spectacular. 50-60 mpg from 130 bhp. Most modern common rails can't get within 10 mpg of that.

Cheers
DP
High Pressure Common Fail Diesels - Edward
02 Synergie HDI head gasket at 43k (engine out - £1000 paid by Warranty Direct).
Fuel sytem still OK, though (now 55k).
High Pressure Common Fail Diesels - Johnlad
They're still too complex and "on the edge" to ever want to own one that wasn't covered by a solid warranty though. And then there's the Euro 4 issues.....

Hi Screwfix
You are obviously having some problems yourself with complexities - I detect your problem is more with the electronics that the actual fuel delivery side. Think of it like this common rail is dragging the car diesel into line with petrol fuel injection ie controlled by electronics instead of fixed and inflexible inline pumps etc. The benefits are quite stupendus since the diesel is 40%plus more efficient that a petrol engine to start with and now with better control will achieve more economy and reliability as they grow.
High Pressure Common Fail Diesels - Johnlad
Hi
I'm not about to state all the other negatives are wrong just to put the common rail principle on an evenkeel. First common rail is a much more versatile system than any inline or rotary pump system because it can be controlled very finely and has been proven in the truck market for some years now.
I suspect that many car garages are still learning and guessing when things are not going well.
The system may impose some added diciplines but not to be feared. A little more attention to belt changes, cleanliness with fuel -as usual with a diesel- tightness of pipes and condition since pressure is often around 1500 psi and soon to be higher. The operating precision is with the electronic injectors so less to do with the pumps and calibration issues. In all they should not be more costly than the old systems but the only way forward with emmission control power output is with Common Rail so accept it.
High Pressure Common Fail Diesels - Screwloose
Johnlad

I should stick to the trucks, mate. A few years experience diagnosing CRs will radically change your viewpoint and improve your grasp of the complexities. The pressure in a CR is 1500+ bar - not psi: the pipes are one-shot use - no tightening required.
High Pressure Common Fail Diesels - Aprilia

Johnlad

You obviously don't let lack of knowledge inhibit you from posting, LOL!
High Pressure Common Fail Diesels - Johnlad
Hi Screwfix
You are right is is BAR sorry about the typo - The rest is still valid.
I have 30 years practical and qualified (I.Eng MIRTE).Still trying to grasp everything :-)
High Pressure Common Fail Diesels - Dynamic Dave
Hi Screwfix


Who's he then?
High Pressure Common Fail Diesels - Johnlad
Damb another typo
High Pressure Common Fail Diesels - Johnlad
Hi screwloose
I had a pug 406 HDI brought to me since the dealer had diagnosed a faulty HP pump - it turned out that the rattle/knock was the crank drive pulley about to collapse - no one is perfect but this would have been another so called "common fail" Guess my lack of knowledge must be improving.
High Pressure Common Fail Diesels - PeterRed
The low pressure fuel pump on my 406 HDI 110 failed at 35k about 3 years ago. I suppose you couldn't class that as a CR fault though. I'm not sure of the cost to fix because it failed the day before the lease expired. Having said that though, it was a lovely car to drive - far better than my Passat.
High Pressure Common Fail Diesels - bbroomlea{P}
Before I bought my A4 130 TDi with the PD engine, I had a Rover 75 with just over 225,000 when I traded it in. It suffered fuel pump failure near the engine (think it was the high pressure pump) and along with the ecu suspecing problems was going to cost over £2000 to fix. Shame really as the engine and especially the car was fine otherwise and used no oil and was as sweet as a nut.

This wasnt the first time there were fuelling problems and the guy who owned it beforehand had 2 pumps replaced in the tank at over £600 each and one in the engine bay. I am hoping the PD system will be more reliable and expect from research it will be.

The garage said that common rail units dont like being run too low on fuel and to keep the tank above 1/4 full at all times to avoid problems (this wasnt rover 75 specific!). My Dad owned my Audi before me and rarely filled up until the car bleeped at him to say it needed filling and 113,000 later it is fine.

I will run another common rail but not in the near future, the PD unit is far more economical and has more torque than any commonrail I have driven or been driven in.