V231506 2041057
Service Bulletin Details
Public Details for: V231506 2041057
Technical bulletin (fuel rail/system pressure, and fuel rail pressure sensor issues): 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
- 2013 - 2012 - 2011 - 2010 - 2009 -
Models from 2013
2013 VOLKSWAGEN TOUAREG |
Models from 2012
2012 VOLKSWAGEN PASSAT |
2012 VOLKSWAGEN TOUAREG |
Models from 2011
2011 VOLKSWAGEN TOUAREG |
Models from 2010
2010 VOLKSWAGEN TOUAREG |
Models from 2009
2009 VOLKSWAGEN TOUAREG |
Technical Bulletin Model(s) Year Touareg 2009-2012 Eng. Code Trans. Code VIN Range From VIN Range To All All All All All All 3.0L TDI CATA 2.0L TDI Passat 2012 CKRA Condition 23 15 06 August 25, 2015 2041057 Supersedes Technical Bulletin V231502 dated June 24, 2015 to update procedure text and part table numbers. 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 © 2015 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 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 © 2015 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, replacement of the high pressure fuel pump and major components of the fuel system are necessary. Proceed to Section B – Fuel Sampling and 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. Open a VTA case and contact the Volkswagen Technician’s Helpline for further assistance diagnosing the vehicle, this bulletin does not apply. Page 3 of 15 © 2015 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 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 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. 6. 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. Section B – Fuel Sampling and Analysis Note: A fuel sample must be taken and analyzed prior to repairing the vehicle. 1. The fuel sample kit, P/N LQ1LKIT must be ordered via the Compliance Label Ordering Portal in vwhub.com. The fuel sample kit will be sent to the dealership within 1 business day*. Page 4 of 15 © 2015 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 The Compliance Label Ordering Portal is available through the Service or Parts tab in VWHub.com Figure 4. Compliance Label Ordering Enter the VIN in the Quick VIN Order field. Figure 5. Enter VIN Figure 6. Select part number LQ1LKIT Page 5 of 15 © 2015 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 Tip: When ordering LQ1LKIT on the Compliance Label Ordering Portal, please include a secondary email address (ie. service manager) in the purchase order field for dealer e-mail notification. 2. Each fuel sample kit will contain the prepaid shipping label, detailed packaging instructions, and all necessary packaging to send the fuel sample via FedEx ground to a designated test facility. Note: HAZMAT certification is required for packaging the fuel sample but NOT for shipping *. The diesel fuel sample may be shipped to the laboratory utilizing ground shipment services provided the dealer is using the Limited Quantity Kit (PN# LQ1LKIT). 3. The fuel analysis results will be available to the dealership within 3 to 5 business days once the fuel sample has been shipped to the laboratory. The dealer will be notified via an email to acquire a pdf copy of the analysis result certificate via an embedded link to VW Google Search. The dealer enters the VIN and the report is presented under the heading "Component Locations, Wiring Diagrams, and Share Folders" in the lower right hand corner of the search results screen. 4. Once the test results are obtained by the dealership, they will be clearly marked “PASS” or “FAIL” in the comments section (see figures 7 and 8). 5. Refer to the Warranty Policies and Procedures Manual and the applicable Warranty Policy and Procedures Bulletin(s) for coverage eligibility details. Fuel Sample Analysis Results If the fuel sample Certificate of Analysis indicates “PASS”: Sections A & B & C will be reimbursed under warranty. If the fuel sample Certificate of Analysis indicates “FAIL”: Only sections A & B will be reimbursed under warranty. 6. When the fuel analysis process is complete, proceed to Section C – High Pressure Fuel Pump Replacement and Fuel System Repair. *Hawaii, Alaska, Puerto Rico Dealers: Please follow step one. Once a fuel sample is ordered, you will be contacted by a Volkswagen of America representative who will provide further instructions. A third party will be used to package and ship your fuel samples to the laboratory. Page 6 of 15 © 2015 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 Note: Each Certificate of Analysis will contain a “Pass” or “Fail” comment as shown. Figure 7. Example of a clean fuel sample analysis. Figure 8. Example of a contaminated fuel analysis. Page 7 of 15 © 2015 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 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). 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 vehices, 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 8 of 15 © 2015 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 Eng. Code Trans. Code VIN Range From VIN Range To All All All All All All 3.0L TDI CATA 2.0L TDI Passat 2012 CKRA SAGA Coding Claim Type: Use applicable Claim Type 1) Damage Service Number: HST Damage Location (Depends on Service No.) -- Use applicable when indicated in Elsa (L/R) Code 2374 0010 Parts Manufacturer 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 9 of 15 © 2015 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 Eng. Code Trans. Code VIN Range From VIN Range To All All All All All All 3.0L TDI CATA 2.0L TDI Passat 2012 CKRA SAGA Coding Claim Type: Use applicable Claim Type 1) Page 10 of 15 © 2015 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 Damage Service Number: HST Damage Location (Depends on Service No.) -- Use applicable when indicated in Elsa (L/R) Code 2374 0010 Parts Manufacturer 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 11 of 15 © 2015 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 12 of 15 © 2015 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 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 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 Quantity High pressure pump 1 Filter 1 059 130 216C Plate 6 059 130 218 Q Retention Valve 1 059 130 089 AM Fuel Rail Left 1 059 130 090 AQ Fuel Rail Right 1 059 130 855HX Injector 6 059 130 241 CD Pressure Lines 6 059 130 310 AK Fuel Line 1 OR 059 130 775BL 7L6 127 401H Page 13 of 15 © 2015 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 059 130 309 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 Quantity High pressure pump 1 Filter 1 Plate 6 059 130 218 AD Retention Valve 1 059 130 089 AM Fuel Rail Left 1 059 130 090 BR Fuel Rail Right 1 OR 059 130 755 BE 7P6 127 401H 059 130 216C Page 14 of 15 © 2015 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 059 130 277 AM Injector 6 059 130 241 CD Pressure Lines 6 059 130 310 AK Fuel Line 1 059 130 309 AT Fuel Line 1 059 130 300 EG 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 1 059 130 300 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 Diagnostic Tool VAS 6150/X & VAS 6160/X with ODIS Service with: current online updates 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. Page 15 of 15 © 2015 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.