Had the new filler neck installed today. It has prongs that check for nozzle size and only open the hole if a big nozzle is going in.

Another interesting tidbit that may have an influence on the fuel pump failure rate:
The 40k mile service coming up includes fuel filter. Filter is changed every 20k. Since I have to pay for service now after 36k will be up, I did some reading. After the fuel filter is changed the electric pump needs to be run using the VCDS software to get all the air out of the system. If this is not done or not done right, air remains and the HPFP may be damaged, as it will run dry for a period of time. On older TDIs / previous models, turning the key would run the pump, but not on the newer one.

I would bet money that sloppy service of the fuel filter and leaving air in the system may play a role in these HPFP failures. What do you think?

G

http://www.myturbodiesel.com/1000q/a5/2009-2010-VW-TDI-fuel-filter.htm

The 2000-2003 TDI's have no electric pump, they must be primed manually. I have changed the fuel filter on the the new Jetta and it's not that hard, but you need the VAG.

My point is that if you don't run the pump right via the VAG, you leave air in the system. Could this contribute, as the procedure is now not as simple as it was on the older models?

This brings me to my next question: Should you do the filter change yourself, while you are still in warranty territory, or will it be easier to get support if you have the fuel system strictly dealer serviced?

G

In the event of a dispute, it would be difficult to prove that you did the fuel pump replacement per the correct procedure. For a service department looking for an out, that might be enough.

I agree I think VW and other manufacturers like adding another level of difficulty in servicing their products.

I think with the VAG I can print out the services performed.