V231704_2041057

Technical Bulletin
Model(s)
Year
Touareg
2009-2012
Passat
2012
Eng. Code
Trans. Code
VIN Range From
VIN Range To
All
All
All
All
All
All
3.0L TDI
CATA
2.0L TDI
CKRA
Condition
23 17 04 April 13, 2017 2041057 Supersedes Technical Bulletin V231605 dated September 22, 2016 to update
fuel sampling requirement.
MIL ON, No Start, or Rough Running with DTCs P0087, P0088 or P0191 Stored in ECM Fault Memory (TDI
ONLY)
MIL ON, No Start, or Rough Running with one or more of the following DTCs Stored in ECM Fault Memory:
DTC
Description
P0087
Fuel Rail/System Pressure - Too Low
P0088
Fuel Rail/System Pressure - Too High
P0191
Fuel Rail Pressure Sensor "A" Circuit
Range/Performance
Technical Background
When diagnosing the condition above on a common rail diesel vehicle, if no root cause is found after checking all
other components and all GFF diagnostic procedures have been performed, it may be necessary to check for
metallic particles in the High Pressure Fuel Pump using the service section of this bulletin.
If such an inspection is necessary, the following guidelines must be observed when removing the N290 Fuel
Metering Valve.
Production Solution
No production change required.
Page 1 of 15
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
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otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Service
Section A – Initial Diagnosis of the High Pressure Fuel Pump (HPFP)
Note:
Removing the N290 Fuel Metering Valve to inspect for metallic particles should only be considered as a last step
after all GFF diagnostic procedures have been performed. This includes testing supply pressure to the high
pressure fuel pump (low pressure side), and checking for internal leakage from the injectors and the N276
Pressure Regulating Valve
Note:
Prior to removing the N290 Fuel
Metering Valve, the area surrounding the
valve (Figure 1) must be clean and dried
with compressed air to remove ALL
debris from the area. See Repair Manual
Group 20 Fuel Supply, General
Information, Clean Working Conditions in
Elsa.
If debris enters the fuel system,
components may be damaged.
Figure 1. Surrounding Area
Page 2 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
1. Remove the N290 Fuel Metering Valve
and inspect the valve and valve bore for
the presence of metallic particles (see
Figure 2).
Figure 2. N290 Fuel Metering Valve and Valve Bore
2. If metallic particles are found on the N290 Fuel Metering Valve or in the valve bore (see figure 2), replacement
of the high pressure fuel pump and major components of the fuel system are necessary. Proceed to Section B
– Fuel Sample Pre-Analysis
3. If no metallic particles are found on the N290 Fuel Metering Valve or in the valve bore, do not replace the high
pressure fuel pump. Continue with diagnosis, this bulletin does not apply.
Note:
To prevent fuel system damage, ensure
that the N290 Fuel Metering Valve is free
of any contaminates before reinstalling.
Prior to reinstallation of the N290 Fuel
Metering Valve, ensure that both O-rings
are not damaged. If they are damaged,
the high pressure fuel pump must be
replaced.
To prevent damaging the O-rings when
reinstalling the N290 Fuel Metering Valve,
lubricate the O-rings with diesel fuel (see
Figure 3).
Figure 3. N290 Fuel Metering Valve O-rings
Page 3 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
4. Install the N290 Fuel Metering Valve into the valve bore using light pressure.
5. Install and hand tighten both M5 fasteners, ensuring that the threads are clean and dry.
Pre-tighten to 2 Nm, then to 6.5 – 7 Nm.
Section B – Fuel Sample Pre-Analysis
Note:
A fuel sample must be taken and analyzed using the VAS 6774 tool before performing further repairs to the
vehicle.
Please review the instructional DVD included in the tool case titled ‘Fuel-Identification Kit VAS 6774’. Here you
will find a user manual, an FAQ, and a video that will describe the proper way to use, clean, and maintain this
tool. The instructions are also posted to ServiceNet by going to ServiceNet> Workshop Equipment> Tool
Information> Instruction Manuals & Videos> Manuals> VAS 6774 Fuel Identification Unit Operating Instructions.
Note:
It is important that the specific gravity of the fuel sample be tested first before proceeding with sensor
head testing. Fuels with a specific gravity of 6.5 or lower cannot be tested using the VAS 6774/7 under
any circumstances. For this reason please disregard the order of testing as seen in the video and follow
the order in the manual that came with the tool.
1. Obtain a 500 mL fuel sample from the vehicle.
2. Following the instructions included with the VAS 6774 kit, test the specific gravity of the fuel sample. A correct
specific gravity measurement is any reading between 9 and 13. (See Figure 5) If the specific gravity reading falls
outside of those numbers warranty coverage does not apply. If the specific gravity is between 9 and 13 proceed
to step 2a.
2a. If the specific gravity test results in a reading between 9 and 13 a sensor head test is required to check for
gasoline particles. If the specific gravity test results in a “Fail” warranty coverage does not apply.
Page 4 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Figure 5
Note:
Fuel samples which have a specific density between 0 and 6.5 indicate a fuel mixture which might be flammable
under certain conditions. If the specific gravity of the fuel sample is 6.5 or lower DO NOT use the VAS 6774/7 to
perform a sensor head test, warranty coverage does not apply.
2b A sensor head test must be performed next to check the fuel for gasoline residue. Follow the instructions
included with the tool to perform a sensor head test. If the sensor head test results in a “Pass” continue to step 3.
If the sensor head results in a “Fail” warranty coverage does not apply.
Page 5 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Figure 6
Note:
If the specific gravity is above 13 or below 9 the fuel has failed the test and warranty coverage does not apply.
3. If the sensor head test results in a “Pass” and the specific gravity test results in a reading between 9 and 13
you may proceed with section C – High Pressure Fuel Pump Replacement and Fuel System Repair.
Section C – High Pressure Fuel Pump Replacement and Fuel System Repair
1. Always use the latest information in Elsa for detailed removal and replacement instructions of the components
listed in this technical bulletin.
2. Remove in-tank fuel pump (Sending unit).
3. Drain and clean the fuel tank using suction pump VAS5226.
4. Fill the fuel tank with 1.3 gallons of fresh diesel fuel.
5. Drain and clean the tank completely using suction pump VAS5226.
6. Replace the in-tank fuel pump (Sending unit).
Page 6 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
7. Flush the fuel lines (both feed and return) from the fuel tank to the bulk head, using either mineral spirits or
brake clean with compressed air. Alternate from both ends of the lines while using a shop towel to catch any
debris that may still be in the line. Verify all metal is removed from both lines before proceeding.
8. Replace the following components as per Elsa: high pressure fuel pump, high pressure fuel lines, fuel rail (with
both sensors included), all fuel injectors, fuel return lines (overflow lines), fuel filter, fuel filter housing, auxiliary
fuel pump.
9. Once repairs are complete fuel the vehicle.
10. Ensure the fuel injector return lines are properly seated and sealed once installed.
Note:
The “injector quantity calibration” and the “injector voltage calibration” for the new injectors must be programmed
into the Engine Control Module -J623- after replacing injectors. Refer to “Guided Functions” in the vehicle
diagnostic tester.
11. Using the VAS tester, perform the guided function “Vent Fuel System”. (see Elsa for additional information
under “Fuel System, Filling and Bleeding”).
Note:
If the test plan is unavailable through Guided Functions, switch to Self Diagnosis>Engine Electronics>Basic
Settings>35 and perform the basic settings 3 times consecutively. For UDS vehicles, perform basic settings for
initial fueling.
12. Once the repairs are complete, test drive the vehicle.
13. Inspect for fuel seepage at the fuel injector return line connector. If seepage is found the condition MUST be
corrected.
Page 7 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Warranty
Reimbursement for Sections A & B Only Where Fuel Analysis Result = FAIL
Note:
Active VW Customer Mobility Program (VWCMP) loaner vehicles are eligible to receive $35 per day for
loaner expense reimbursement under this warranty extension. For dealers enrolled in the VWCMP, a nonVWCMP loaner vehicle can be provided at a reimbursement rate of $25 per day or a VW rental at $35 if a
VWCMP loaner is not available. These claims must be submitted in SAGA on a separate line using claim
type 1SP. Refer to document VWS-14-01 for applicable labor operation.
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Year
Touareg
2009-2012
Passat
2012
Eng. Code
Trans. Code
VIN Range From
VIN Range To
All
All
All
All
All
All
3.0L TDI
CATA
2.0L TDI
CKRA
SAGA Coding
Claim Type:
Use applicable Claim Type 1)
Service Number:
Damage
Code
2374
0010
Parts Manufacturer
HST
Damage Location
(Depends on Service
No.)
--
Use applicable when
indicated in Elsa (L/R)
Touareg, Passat
Causal Part: Select Labor Operation
01320000
Outside Material: Diesel Fuel
Part Number: FUEL
WWO 2)
Diagnostic Time 4)
GFF Time expenditure
01500000 = As required
YES
Page 8 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Road Test
01210002 = 00 TU
NO
01210004 = 00 TU
Technical Diagnosis
01320000 = As required
YES
Claim Comment: Input “As per Technical Bulletin 2041057” in comment section of Warranty Claim.
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
2)
Vendor code BPY or BPT must be recorded from the original High Pressure Fuel Pump.
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policies and Procedures Manual.
Note:
Vendor code BPY or BPT must be recorded from the original High Pressure Fuel Pump for claiming
purposes.
Reimbursement for Sections A & B & C Where Fuel Analysis Results = PASS
Note:
Active VW Customer Mobility Program (VWCMP) loaner vehicles are eligible to receive $35 per day for
loaner expense reimbursement under this warranty extension. For dealers enrolled in the VWCMP, a nonVWCMP loaner vehicle can be provided at a reimbursement rate of $25 per day or a VW rental at $35 if a
VWCMP loaner is not available. These claims must be submitted in SAGA on a separate line using claim
type 1SP. Refer to document VWS-14-01 for applicable labor operation.
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Year
Touareg
2009-2012
Passat
2012
Eng. Code
Trans. Code
VIN Range From
VIN Range To
All
All
All
All
All
All
3.0L TDI
CATA
2.0L TDI
CKRA
SAGA Coding
Claim Type:
Use applicable Claim Type 1)
Page 9 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Service Number:
2374
Damage
Code
0010
Parts Manufacturer
HST
Damage Location
(Depends on Service
No.)
--
Use applicable when
indicated in Elsa (L/R)
Touareg, Passat
BPY or BPT 2)
Labor Operation 3) : Fuel System Clean and
Replacement
23744299 = 850 TU (Touareg)
Labor Operation 3) : Fuel System Clean and
Replacement
23744299 = 750 TU (Passat)
Causal Part: High Pressure Fuel Pump
*** 130 755 **
Outside Material: Diesel Fuel
Part Number: FUEL
Diagnostic Time 4)
GFF Time expenditure
01500000 = As required
YES
Road Test
01210004 = 10 TU
YES
Technical Diagnosis
01320000 = As required
YES
Claim Comment: Input “As per Technical Bulletin 2041057” in comment section of Warranty Claim.
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
2)
Vendor code BPY or BPT must be recorded from the original High Pressure Fuel Pump.
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policies and Procedures Manual.
Page 10 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Required Parts and Tools
Passat
Note:
Part numbers are for reference only; please consult ETKA by VIN for most current information.
Part No:
03L 130 755AA
Part Description
Quantity
High pressure pump
1
03L 130 321Q
Line
1
03L 130 301AR
Line
1
03L 130 301AS
Line
1
03L 130 301AT
Line
1
03L 130 301BA
Line
1
03L 201 360AD
Fuel Line
1
03L 130 235AD
Return line
1
04L 130 216
Plate
2
WHT 004 739
Bolt
2
03L 130 277R
Injector
4
03L 130 089J
Rail
1
N 911 761 01
Bolt
3
N 107 145 01
Bolt
2
WHT 002 494
Bolt
1
N 910 488 04
Bolt
4
N 911 854 01
Bolt
3
Page 11 of 15
© 2017 Volkswagen Group of America, Inc.
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intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
038 109 454A
Nut
1
WHT 004 739
Bolt
2
7N0 127 400D
Filter
1
561 130 307
Fuel Line
1
561 130 295D
Fuel Line
1
561 130 307B
Fuel Line
1
3AA 919 050H
In-Tank fuel pump (Sending unit)
1
All torque to yield must be
replaced
All
2009 - 2010 Touareg
Note:
Part numbers are for reference only; please consult ETKA by VIN for most current information.
Part No:
059 130 755 BC
Part Description
High pressure pump
Quantity
See ETKA
or
059 130 755 BT
7L6 127 401H
Filter
1
059 130 216C
Plate
6
059 130 218 Q
Retention Valve
See ETKA
059 130 089 AM
Fuel Rail Left
1
059 130 090 AQ
Fuel Rail Right
1
059 130 855HX
Injector
6
059 130 241 CD
Pressure Lines
6
Seals
6
WHT 000 884
Page 12 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
059 130 310 AK
Fuel Line
1
059 130 309 AT
Fuel Line
1
059 130 300 EH
Fuel Line
1
059 130 758 J
Pressure Sensor
1
059 130 312 K
Fuel Line
1
7L6 919 715 H
Suction Jet Pump
1
1K0 906 089 C
Auxiliary fuel pump
1
7L6 130 295 AT
Auxiliary fuel pump supply line
1
059 130 300 DF
Fuel line with fuel temperature
sensor
1
In-Tank fuel pump (Sending unit)
1
All torque to yield bolts must be
replaced
All
7L6 919 088 F
2011 - 2012 Touareg
Note:
Part numbers are for reference only; please consult ETKA by VIN for most current information.
Part No:
059 130 755 BT
Part Description
High pressure pump
Quantity
See ETKA
7P6 127 401
Filter
1
059 130 216C
Plate
6
059 130 218 AD
Retention Valve
See ETKA
059 130 089 AM
Fuel Rail Left
1
059 130 090 BR
Fuel Rail Right
1
059 130 277 AM
Injector
6
Page 13 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
059 130 241 CD
Pressure Lines
6
Seals
6
059 130 310 AK
Fuel Line
1
059 130 309 AT
Fuel Line
1
059 130 758 J
Pressure Sensor
1
059 130 312 K
Fuel Line
1
059 130 297S
Fuel Line
1
7P6 919 715 A
Suction Jet Pump
1
Fuel line with fuel temperature
sensor
1
In-Tank fuel pump
1
WHT 000 884
059 130 300 EG
7P6 919 088 B
All torque to yield bolts must be
replaced
All
Tool Description
Tool No:
Midtronics Battery Tester/Charger
InCharge 940 (INC-940)
or
GRX3000VAS
VAS Fuel Identification Unit
VAS 6774
VAS Diagnostic Tool
VAS 6150/X & VAS 6160/X with
ODIS Service with: current online updates
Page 14 of 15
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Document Control Revision Table
Instance Number
Published Date
Version Number
Reason For Update
2042057/8
4/13/17
V231704
To update fuel sampling
requirement.
2042057/1
6/24/15
V231502
Original publication.
Page 15 of 15
© 2017 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.