We are starting to see pump failures on the VAG 1.4 and 1.6 lt. Engines fitted with a Delphi DFP6.1E high-pressure pump. O.E. part number 04B 130 755H and Delphi part number 28477820. This problem causes the injectors to fail due to swarf contaminating the fuel system. Below are some pictures of the pilot valve in the injectors, you can see the particulate matter present on the valve pin. The pump and injectors will need inspecting and possibly replacing also the complete fuel system, tank, rail and pipes will need to be removed and clinically cleaned.
We recommend that should the pump display signs of swarf or metal filings:
- Remove the pump and injectors and send them to us for checking.
- Also, send us the injector pipes and rail for ultra-sonic cleaning.
- Remove and thoroughly clean all fuel supply and return pipes.
- Remove and thoroughly clean the fuel tank and fuel sender unit.
- Replace the in-tank fuel supply pump.
- Replace the fuel filter with an O.E. unit and clean the filter housing assembly.
- When replacing all the components flush everything out with clean diesel before connecting the injector pipes.
- Unfortunately, there are no short cuts and failing to do all of this at the same time, or only part of the process will result in injector/pump failure again.
