NewsW
US
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Joined: 02/06/2012
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The mod that need to happen is a supplemental fuel filter plumbed in between the common rail(s) and the HPFP.
A fairly complicated job, as FEA need to be done to ensure that there are no vibration harmonics etc. that would overstress / crack the assembly / lines.
Physical fit / form factor is also a problem --- depending on the size of the filter.
Another question --- if the filter begins to plug (from debris via failing HPFP), what do we do to ensure that the system is shut down (e.g. have to measure pressure differential before and after filter) and then pre-emptively warn / shut down engine at a certain point.
Major, major engineering fix, and costs will probably wipe out CP4.x vs. CP3.x savings.
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NewsW
US
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An interesting trend line:
http://blog.polk.com/blog/blog-posts-by-mark-pauze/hybrids-are-on-a-growth-track-again
Diesels are losing market share since 2008 but had a bump in 2011.
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ricatic
Home
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NewsW wrote:rick -- no info on that particular one, but know the first batch of failures were in VINs that were close together.
Notice they did not replace the high pressure lines... why not?
They were replaced
I sure would like to know what months those 2011's were built. Maybe Wiebull will see this and send me an email.
Regards
Ricatic
Debbie and Savannah the Wonderdachsund
2009 Big Horn 3055RL
2006 Chevrolet Silverado 3500 Dually LTX with the Gold Standard LBZ Engine and Allison Transmission
2011 F350 Lariat SRW CC SB 4WD 6.7 Diesel POS Gone Bye Bye
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NewsW
US
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An interim design mod will be to integrate a fairly high volume filter (not the piddly little one now) in the HPFP housing at the HP exit line, using the pressure differential to trigger a shut down and confine damage to pump.
That plus a return line filter.
Then metal particles are confined.
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NinerBikes
Somewhere camping
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NewsW wrote:An interim design mod will be to integrate a fairly high volume filter (not the piddly little one now) in the HPFP housing at the HP exit line, using the pressure differential to trigger a shut down and confine damage to pump.
That plus a return line filter.
Then metal particles are confined.
Bosch has to know all of this, their upper management or Board of Directors just don't give a sh*t. 4 years with this pump,on VW's and Audis, and they still have not addressed the engineering problems and material problems it presents. Their idea of making 3 changes to make the pump more "robust" on their idea of "substandard" fuel has failed. 2011's and 2012 VW's still grenade HPFP's.
I believe in the USA, you need to design product that is "fit for market". I don't see Bosch meeting that requirement, when they've known since 2002 what low lubricity fuel does to their pumps and they know the ASTM standards here for D975 and testing.
The flaw in their current design is using fuel for purposes other than fuel, for lubrication.
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BenK
SF BayArea
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Joined: 04/18/2002
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Bean counter....as long as they make their honuses....
Simulation begets this type of down the road issue...
These types of designers have no to little clue....
-Ben Picture of my rig
1996 GMC SLT Suburban 3/4 ton K3500/7.4L/4:1/+150Kmiles orig owner...
1980 Chevy Silverado C10/long bed/"BUILT" 5.7L/3:73/1 ton helper springs/+329Kmiles, bought it from dad...
1998 Mazda B2500 (1/2 ton) pickup, 2nd owner...
Praise Dyno Brake equiped and all have "nose bleed" braking!
Previous trucks/offroaders: 40's Jeep restored in mid 60's / 69 DuneBuggy (approx +1K lb: VW pan/200hpCorvair: eng, cam, dual carb'w velocity stacks'n 18" runners, 4spd transaxle) made myself from ground up / 1970 Toyota FJ40 / 1973 K5 Blazer (2dr Tahoe, 1 ton axles front/rear, +255K miles when sold it)...
Sold the boat (looking for another): Trophy with twin 150's...
51 cylinders in household, what's yours?...
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NewsW
US
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On a side note, I had another fuel related problem today.
No start / hard start (eventually started, but took a lot of cranks).
No code, not even a "pending code" and nothing amiss... only likely source is vapor lock.
Last year, I solved the problem by unplugging the fuel heater.
What happens when we transition from winter to summer fuel --- the winter stuff just vaporize too easily.
Another reason why the more I think of how many problems we are having... the more I think we are not dealing with variability in fuel characteristics too well.
Update: went and unplugged the fuel heater... it worked last time.
* This post was
edited 05/06/12 10:54am by NewsW *
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NewsW
US
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Update:
I am reviewing several state of the art Finite Modeling Analysis (FEA) tools, including one called Abaqus that is part of the Simula suite of tools.
http://www.3ds.com/products/simulia/portfolio/
Presumably, the pump was designed using a comparable set of tools or the same one.
Interesting the limitations of the FEA tools and how difficult it is to include Computational Fluid Dynamics (CFD) into it.
The gist is that operator skill and expertise is really critical to use the FEA tools, including fitting the mesh properly and then making certain judgments --- like where to put in a "flaw" so the parts bend right.
A question I have right off the bat is how a coating is modeled when it is so thin and the properties of the coating / underlying material may not be well characterized.
A very fine FEA mesh at the points of maximum expected stress need to be done, and the forces on it simulated.
A problem arise that the expected maximum stress locations may be quite different from the actual places --- when cavitation and hydraulic events are included, or the existence of particles.. contaminants... like water.
Don't know when I get my CFD simulation tool grand tour, to see what the limitations of that set of techniques are.
* This post was
edited 05/09/12 09:40am by NewsW *
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NinerBikes
Somewhere camping
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New observations on Bosch HPFP's made in Slovakia versus Germany. Full of Pictures. Material changes used in manufacturing... time to find out what Bosch is doing for Ford version CP 4.2 pumps, more so, where are the replacements currently being produced? What country?
pump comparison
http://forums.tdiclub.com/showpost.php?p=3799956&postcount=1706
* This post was
edited 05/10/12 11:13pm by NinerBikes *
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The Mad Norsky
Yankton, South Dakota
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Joined: 04/14/2003
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Interesting NinerBikes. Hope springs eternal. Maybe they will eventually get this right.
For you folks that have to attend summer school in link posting, there is something called the Advance Post Form. Click there, and on top of the dialogue box, in a box with a big blue circle in it, is the link button. Click that and paste your address in and PRESTO! You have a link that works. Like this one
A copy and paste of NinerBikes link. 
On a semi-related note, I did get a recall notice for my 2011 6.7L diesel. Despite hoping for good things, all I am going to get is a reprogram of the PCM and Nox Sensor Module and a possible replacement of the Nox sensor. 
Oh well.
* This post was
edited 05/10/12 10:57pm by The Mad Norsky *
The Mad Norsky, Doll, Logan, Korey & Rocky
2011 Ford F350 Power Stroke dually
RV'ing since 1991
I took the road less traveled .....Now I'm Lost!
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