Complaint 2198320

Complaint Summary

ENGINE

Owner Narrative

This complaint concerns failure of the remedy for Safety Recall Z46 / NHTSA Campaign 22V406 involving the high pressure fuel pump (HPFP) on a 3.0L diesel pickup. The HPFP had previously been replaced under the recall by an authorized dealer. About 19 months later, while the vehicle was at a dealership for service, the replacement HPFP failed again during dealer testing. The dealer documented metal contamination throughout the fuel system caused by the HPFP failure. The dealer then replaced the contaminated fuel system components. After those repairs and during post-repair test driving, the vehicle developed new bottom-end engine noise. The dealer later documented connecting rod bearing damage / rod knock and recommended complete engine replacement. The vehicle had been brought in with no bottom-end engine noise, and the dealer’s intake inspection documented oil condition as OK. An independent oil analysis later showed the engine oil was normal and did not indicate long-term lubrication failure. This suggests the engine damage occurred acutely after the HPFP failure and resulting contamination event, not from routine wear. This condition creates a serious safety risk because HPFP failure can cause loss of fuel pressure, engine stall, or loss of motive power, and the subsequent engine damage raises the risk of sudden engine failure or seizure while driving. That could increase the risk of a crash, especially in traffic or at highway speeds. The failure was confirmed by the dealer and is documented in the repair order. The vehicle remains inoperable and is available for inspection upon request. I am requesting investigation into whether the recall remedy was adequate, since the recall replacement HPFP failed again and the resulting contamination appears to have led to catastrophic secondary engine damage.

Owner-submitted narrative on file with NHTSA. Complaint narratives are self-reported and have not been verified.