Hi @cliffcoggin its a chain driven twin piston cp4.2 (Fig 1.) so dual cam that gives 4 compressions per rotation, can produce up to 2700 bar or zero 😒🤣
At 150,000 if it had worn I would expect to see a lot more failures of these on vehicles up round the 130K+ mile mark that were non catastrophic and it seems very rare.
They are fitted to earlier 3.0 BiTDI Audi's, Ford Power strokes (6.7 V8 Diesel) and Jeeps and RAM's some BMW high performance diesels. They seem to either grenade themselves-the roller underneath the pistons rotates 90° and then the rotating cam lobe gets a nice U carved into it (See Fig 2.) The shrapnel goes through to HP side, to the injectors so they're fubar, and back through the LP to the fuel tank, them through the LP pump to the filter, or fuel starvation/water or misfuelling=zero lubrication and a similar ending just a bit less aggressive.
Fig 1.
Orange is HP fuel out, and as you say, no reason why (and I believe from research it happens), that something cant stick shut and stop the HP fuel from exiting.
I've tried using a Birmingham screwdriver with a soft drift while cranking to shock the top (recommended method from a diesel specialist) to see if I get any pressure but nothing and I'm not prepared to hit any harder.
Fig 2.
I'm looking for someone to say "ah yeah I had one of these fail, it wasn't catastrophic it was the..."
I've found a guy in the States who had one fail on a Ford with very similar to my symptoms, was running but had some issues (mine was throwing P0087 at full throttle but could make 2700 Bar), came back to it and it wouldn't start...
He had a new HPFP that wouldn't make pressure right out the box! Eventually managed to get them to replace that one under warranty, got one with a test certificate and that sorted it.
I've got a final couple of things to double check and its surgery time...
I will update anon.