AFN Engine: Fuel Injector Pump Failure After 200k km?

Hello,

My Passat 3B with the AFN engine now has 200,000 km on the clock. I took it to an independent garage the day before yesterday to have the timing belt replaced. This is the third time I've had it replaced (previously, it was replaced at 90,000 km and 120,000 km).

During the disassembly of the old belt, the workshop discovered axial and radial play in the fuel injection pump shaft. They showed me this: the gear could be easily tilted left and right.

They told me that it would be a significant risk to continue driving the car like this (due to the potential for engine damage). The ESP unit is now being sent to a repair company in Hamburg, where it will be repaired using a special testing rig.


Has anyone ever heard of this type of problem with an ESP system? Could it be caused by chip tuning? Is this really that concerning? And what would the cost of repairing an ESP system be?



I am grateful for any kind of response!

Hi.

verdiener wrote:

Has anyone ever heard of this type of problem with an ESP?

Yes.

Quote:

Could it be due to chip tuning?

No, I don't think so.

Quote:

Is this really that concerning?

Yes. If the timing belt moves up and down (which is possible due to the tilting), it will wear out faster and can break suddenly.

Quote:

And what is the cost of repairing an ESP (Electronic Stability Program)?

No idea. Get a KV test done and compare it to a AT pump.

Deleted upon request.

Hi Gustav,

diesel.gustav wrote:

If it were my car, I wouldn't follow the workshop's recommendation, but would continue driving.

"... well, some negotiation is normal - That's right. However, since he didn't mention a specific price, I assumed a more aggressive negotiation tactic, and in that case, I would definitely reconsider proceeding."

Could you provide my colleague with some data on the running performance so he can evaluate it himself?

Quote:

A rebuilt pump is probably cheaper in this case, because it is professionally refurbished, not just repaired by a hobbyist.

Exactly my point .

Deleted upon request.

So, the mechanic at the workshop said that it would be quite significant, and that he had never seen anything like it before. He actually showed it to me.

The gear on the ESP shaft could be tilted approximately 1-2 mm to the left and right.

They said that repairing it would definitely be cheaper than replacing the AT pump (around 1000 euros), but they couldn't guarantee the accuracy of that estimate.

verdiener wrote:

The gear on the ESP shaft could be tilted approximately 1-2mm to the left and right within a certain range.

Hi everyone,

Okay, I haven't been able to confirm those theories about belts slipping yet. Our Audi 80 TDI (now with 280,000 km) had a new timing belt installed by me 8,000 km ago, without changing anything on the pump. Axially, you can easily move the shaft by 1-2 mm on the 1Z (and probably not differently on the AFN either). In my Passat, I had new bearings installed (Henzo from dieselsend.de does this for €100 ), and even after that, I could still move the shaft axially by 1-2 mm. But a radial play of 1 to 2 mm seems a bit excessive to me. In our Audi, I would estimate a maximum of 0.5 mm. If you often check the timing belt, then leave it as it is. As long as the belt (even with the engine running) is centered and the sides are not damaged, nothing will happen.

Deleted upon request.

I received a message today from the fuel injection pump repair company:

The ESP housing is defective, which is why there is increased bearing clearance. The repair costs approximately 900 euros, while a replacement pump costs 950 euros. However, in the end, an AT pump is not significantly different from my refurbished one, and both have the same warranty period.

You can't really do anything about the fact that the prices of a near-monopolist are so high.


BUT:

What do you think about this? How can the housing break? And is it really possible, considering the high radial runout of the shaft?

verdiener wrote:

The housing of the ESP is defective, which is why there is increased bearing clearance.

Hi Verdiener,

That sounds like excuses... but wait until the pump experts chime in.

Deleted upon request.

@ diesel.gustav

Sorry, I don't have any more details yet. I just had a brief discussion with the workshop (who also couldn't say much, because everything goes through the repair company). I haven't gotten my car back yet either.

It will take 1-2 days.

I now have my Passat back.


###### Here is the diagnosis of the damage to the ESP


- Pump checked.
- Ohmic values are within tolerance.
- Housing damage: increased bearing clearance, the bolts from the rolling ring have moved into the housing .


The following spare parts are listed on the invoice:

- 1 set of spare parts 2 465 130 933
- 1x Injection pressure control valve 2 463 104 050
- 1x Radial shaft seal, part number 2 460 283 001.
- 1x Parts kit 2 467 010 003
- 4x Overflow valve 2 467 413 025
- 1x Cleaning supplies R
- 4x test oil per cylinder. EP TEST OIL.

I paid 745 euros net for the repair and setup.



It would be great if the experts could provide their feedback again now. Was the repair necessary? Was it justified? [/b]

Hi,

Are there any part numbers listed for the spare parts? "Spare part group" and "part set" are quite general descriptions.

I have added the ET numbers to the above post.