211405

Technical Bulletin
Model
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Passat
2012-2014
2.0L TDI
ALL
ALL
ALL
(CKRA)
Condition
21 14 05 July 21, 2014 2036110 Supersedes technical bulletin V211402 dated March 28, 2014 to modify the 5
bulleted sentence in Step 2.
th
Engine Lacks Performance, Shaft of Turbine Fan of Turbo Charger Broken or Seized
Check Engine Light ON, Reduced Performance or Noise from Turbocharger. DTC P0299 may be stored in ECM.
DTC
Description
P0299
Turbo/Super Charger Underboost
Technical Background
In the case of a damaged turbocharger it is important to follow the steps contained in this document to avoid
repeat repairs.
Production Solution
Implemented into production.
Page 1 of 7
© 2014 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
Tip:
This bulletin must only be used, if the symptoms described here are identical with the damage on the customer
vehicle.
Check the damage as follows:
• Remove the engine cover according to the repair manual.
• Loosen the intake hose on the turbocharger according to the repair manual.
• Check whether the impeller housing shows signs of contact with the turbine fan.
• Check whether the shaft of the turbocharger turbine fan:
• Has excessive free play.
• Is damaged.
• Is broken or seized.
To confirm a broken shaft on the turbocharger the diesel particulate filter (DPF) must be detached on the
turbocharger. This is the only way to check the turbocharger for damage and engine oil ingress on the exhaust
side (figure 1).
If no damage is found this technical bulletin does not apply.
• If turbocharger is found to be damaged, the DPF must be reattached at the turbocharger before proceeding to
the following steps:
Figure 1 (broken turbocharger shaft, engine oil ingress on exhaust side)
Page 2 of 7
© 2014 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:
In addition, an endoscope can be fed through the threaded hole of the removed oxygen sensor to check:
The exhaust side of the turbocharger for damage and engine oil ingress.
The DPF for engine oil ingress.
Note:
If the turbine fan shaft is broken, the complete engine oil circuit must be flushed out before replacing the
turbocharger to avoid a repeat repair. To do this, proceed as follows:
Step 1
• Replace the oil filter according to the repair manual and thoroughly clean the inside of the oil filter housing.
• Drain the engine oil according to the repair manual.
• Unscrew the banjo bolt for the oil supply pipe on the cylinder block. Replace the banjo bolt with the hex head
bolt with part number WHT 005 747 (figure 2, in green) and tighten it according to the repair manual to block oil
supply to the damaged turbocharger.
Figure 2
Note:
Flush out the oil circuit while the faulty turbocharger/particulate filter is installed and the intake hose removed from
the turbocharger.
• Fill up the engine oil according to the manufacturer guidelines.
• Run the engine at idle speed for about 15-20 minutes.
• Replace the oil filter according to the repair manual and thoroughly clean the inside of the oil filter housing.
• Replace the oil filter housing cap (03L 115 433).
• Drain the engine oil according to the repair manual.
Page 3 of 7
© 2014 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
Step 2
• Replace the turbo charger with exhaust manifold according to the repair manual.
• Replace the oil supply pipe for the turbocharger according to the repair manual and attach it to the cylinder
block with a new banjo bolt and new seal rings according to the repair manual/parts information.
• Replace the oil return pipe from the turbocharger according to the repair manual/parts information.
• Replace the turbocharger support according to the repair manual/parts information and the banjo bolt for the
support (oil return) in the cylinder block according to the repair manual.
• Check the complete boost air system including intercooler for dirt or debris and clean it as necessary.
• Check the DPF for damage or oil ingress, if oil ingress is found it is necessary replace the DPF according to the
repair manual/parts information.
• Fill up the engine oil according to the manufacturer guidelines.
• Perform the guided fault finding and delete the ECM fault memory.
Page 4 of 7
© 2014 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
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
Passat
2012-2014
2.0L TDI
ALL
ALL
ALL
(CKRA)
SAGA Coding
Claim Type:
Use applicable Claim Type
Damage
Service Number:
HST
Damage Location
(Depends on Service No.)
--
Use applicable when
indicated in ElsaWeb
(L/R)
Code
2130
0010
Parts Manufacturer
Passat
3) :
17011799 = 60 TU
3)
21301983 = 290 TU
Labor Operation Drain and fill engine oil. Replace
drain plug for oil supply pipe, oil filter housing cap,
oil filter and thoroughly clean inside of oil filter
housing.
Labor Operation : Replace Turbocharger
1)
KKK
2)
3)
Labor Operation : Remove and Install Particulate
Filter
26741933 = 370 TU
3)
Labor Operation Use ONLY if Particulate Filter
replacement is necessary
26745583 = 30 TU
3)
21010199 = 10 TU
Labor Operation : Charge Battery
3)
27068950 = 10 TU
Causal Part: Turbo Charger
03L 253 056 **
Labor Operation : Check boost air system
Page 5 of 7
© 2014 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
Diagnostic Time
4)
GFF Time expenditure
01500000 = 30 TU max.
YES
Road Test
01210004 = 10 TU
YES
Technical Diagnosis
01320000 = 140 TU max.
YES
Includes: loosen and attach intake
hose and particulate Filter,
Inspect turbo charger
Claim Comment: Input “As per Technical Bulletin 2036110” in comment section of Warranty Claim.
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
2)
Code per warranty vendor code policy.
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policies and Procedures Manual.
Required Parts and Tools
Part No:
Part Description
Quantity
WHT 005 747
Hex. head bolt (for flushing)
1x
The following parts must be ordered separately according to the parts catalogue depending on
the requirements and the vehicle:
03L 253 056 QX
Turbo charger
1x
03L 145 771 AN
Engine oil supply pipe for turbo
charger
1x
03L 145 736 D
Engine oil return pipe for turbo
charger
1x
03L 145 535 D
Support (engine oil return) for
turbo charger
1x
WHT 005 635
Banjo bolt (support)
1x
03L 115 433
Oil filter lid
1x
Page 6 of 7
© 2014 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
03L 115 562
Oil filter with seal
2x
According to parts catalogue
Engine oil (Long Life)
8.6 l
According to parts catalogue
Bolts and seals
―
(as required)
561 253 053 A
Exhaust pipe with catalyst and
diesel particulate filter
1x
(if Necessary)
No special tools required.
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 7 of 7
© 2014 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.