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Autotech HPFP failed?

bbroecker37

Ready to race!
Location
Tampa Florida
Car(s)
2016 VW Golf GTI
Over the weekend my car died while I was driving it. At first the idle was terrible and it had no power. I pulled over into the median and it stalled. The car would crank over but never fire. crazy enough, no CEL turned on. I ended up having to push my car off the road. Thankfully someone was there to help me push it. I ended up getting the car towed to my house. I believe the Autotech HPFP internals failed. When I checked the dipstick it was showing high and smelled of gas. I checked the codes via OBD11. I found multiple misfires, fuel pressure sensor p119A00, and O2 sensor stuck lean P219500. I took the spark plugs out and none of them were wet but the tips looked grey. I also shined a light into the cylinders and they looked dry. Is there anything else I should look into?

The HPFP is the stock unit that came with the car with Autotech internals. I took it apart myself and installed the parts almost 2 years ago. This time I ordered a HPFP preassembled from Urotuning. Since they're local and I can get the part in one day.
 

bbroecker37

Ready to race!
Location
Tampa Florida
Car(s)
2016 VW Golf GTI
Hey guys, just wanted to update you. I determined the HPFP was not the issue. Before I went to install the new HPFP I did more research and the issue sounded more like a stuck injector. I took the spark plugs out again and looked into each cylinder with a light. Had someone open the driver's door to prime the low-pressure fuel pump. I could see in cylinder 3 that the injector was stuck open spraying fuel. Since this job requires taking the intake manifold off to replace the injectors. I took the opportunity to clean the carbon buildup.

I'm happy to report the car is working great after replacing all 4 injectors.
 

2slowvw

Moderator
Location
VA
Car(s)
2022 Tesla Model 3
Good news, thanks for posting the issue resolution as this may help someone in the future.
 

bbroecker37

Ready to race!
Location
Tampa Florida
Car(s)
2016 VW Golf GTI
Hey guys today I noticed something was off with my car. The exhaust sounds a lot quieter and also the car is down on power. Driving the car around normally feels fine but when I get on it the car feels slow. I’m starting to think the catalytic converter is plugged. I’m thinking when the car was running rich due to the stuck injector it dumped gas all over the cat.

I’m assuming there is nothing I can do but replace this? Or gut the cat? I am IE stage 2 with their down pipe.
 

scrllock

Autocross Champion
Location
MI
Disconnect the turbo v-band and stick a boroscope down the pipe. I assume since you're stage 2 you don't have a cat efficiency code.
 

bbroecker37

Ready to race!
Location
Tampa Florida
Car(s)
2016 VW Golf GTI
Disconnect the turbo v-band and stick a boroscope down the pipe. I assume since you're stage 2 you don't have a cat efficiency
Good idea, I bought a boroscope and it should be here tomorrow. I haven't seen any codes for cat efficiency. I did have a code for Sensor 1 bank 2 but I can't remember what it was since I cleared it and it hasn't reappeared. I think it was saying low-voltage.
 

bbroecker37

Ready to race!
Location
Tampa Florida
Car(s)
2016 VW Golf GTI
Well, I took the vband off and this is what I found... Time for a new downpipe 🙃

Image_2024-05-22 07_59_41_488.png
 

bbroecker37

Ready to race!
Location
Tampa Florida
Car(s)
2016 VW Golf GTI
So I removed the down pipe and it appears very little cat material was left. I removed it all but I still think there is some left in the muffler. I guess it made its way all the way back there. No way to check with the borescope. I can’t fish it back there because the OEM cat back is so long and has bends after the resonator. I’m thinking about cutting the pipe near the muffler and removing it from the car and try to shake out the debris. Then install a clamp to connect the two pieces. Just like they do with the club sport muffler.
 

bbroecker37

Ready to race!
Location
Tampa Florida
Car(s)
2016 VW Golf GTI
I'm happy to report that my car is back to normal. I cut the exhaust pipe near the muffler. Removed the muffler from the car and stuck a borescope in the pipe. I saw the rest of the cat all bunched up in the back. I wasn't able to get the debris to come out by shaking it or hitting the pipe with a rubber hammer. I ended up having to bend a clothes hanger and stick it in there and try to fish the metal debris out. This worked ok but was taking too long. I attached the hanger to my drill and it shred the metal debris into a bunch of metal flakes. I was able to dump them out of the muffler into a box. I then reattached the muffler back on the car and used a 65mm exhaust clamp to connect it back to the midpipe.

Before and after:
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