Technical Bulletin
Model(s)

Year

Eng. Code

Trans. Code

VIN Range From

VIN Range To

All

2013-2016

All with TDI

All

All

All

Condition
23 15 04 August 19, 2015 2041118 Supersedes Technical Bulletin V231501 dated June 24, 2015 to include
additional service and fuel testing information.
Diesel Fuel System Diagnosis and Repair

One or more of the following fault codes may be stored in the 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
Note:
These vehicles are not covered by the Warranty Extension found within Policies and Procedure Bulletin VWP-1506.
The vehicle must have a Volkswagen-approved misfueling guard installed to be considered for regular or
powertrain warranty.

Production Solution
Information Only.

Page 1 of 20
© 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 2) 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 2. Surrounding Area
1. Remove the N290 Fuel Metering Valve and inspect the
valve and valve bore for the presence of metallic particles
(see Figure 3).

Figure 3. N290 Fuel Metering Valve and
Valve Bore
Page 2 of 20
© 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
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 in the fuel system is 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.

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 4).
Figure 4. N290 Fuel Metering Valve Orings

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 3), 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.
*Hawaii, Alaska, Puerto Rico: 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 3 of 20
© 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. The fuel sample kit, P/N LQ1LKIT must be ordered via the Compliance Label Ordering Portal in vwhub.com fuel
sample kit will be sent to the dealership within 1 business day*.

The Compliance Label Ordering Portal is
available through the Service or Parts tab in
VWHub.com

Figure 5. Compliance Label Ordering

Enter the VIN in the Quick VIN Order field.

Figure 6. Enter VIN

Figure 7. Select part number LQ1LKIT

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.
Page 4 of 20
© 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
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. To determine if this repair is covered under warranty, always refer to the Warranty Policies & Procedures
Manual.

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.

Note:
Each Certificate of Analysis will contain a “Pass” or
“Fail” comment as shown.

Figure 7. Example of a clean fuel sample
analysis.

Page 5 of 20
© 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

Figure 8. Example of a contaminated fuel
analysis.

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 the suction pump VAS5226.
4. Fill the fuel tank with (1.3 gallons) of fresh diesel fuel.
5. Drain and clean the tank completely using 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.
Note:
The rubber fuel line insulators from the original injector supply lines should be transferred to the new lines.
9. Once repairs are complete fuel the vehicle.
10. Ensure the fuel injector return lines are properly seated and sealed once it is installed.

Page 6 of 20
© 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:
The “injector quantity calibration” and the “injector voltage calibration” for the new injectors must be programmed
into the Engine Control Module -J623- after replacing one or more 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 7 of 20
© 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
Warranty covers the replacement of diesel fuel system components only if:
 The vehicle has a Volkswagen-approved misfueling guard installed and
 The correct, uncontaminated fuel is present in the vehicle.
Please use appropriate labor operations from ELSA and parts from ETKA based on vehicle type.
Reimbursement for Sections A & B Only Where Fuel Analysis Result = FAIL

To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Golf, Jetta, Jetta
SportWagen,
Beetle, Beetle
Convertible

Year(s)

Eng. Code(s)

Trans. Code(s)

VIN Range From

VIN Range To

All

All

All

2.0L TDI
2013-2016

(CJAA, CVCA,
CRUA)
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

Golf, Jetta, Jetta Wagon, Jetta
SportWagen, Beetle, Beetle
Convertible

Causal Part: Select Labor Operation

3ME 2)

01320000
Diagnostic Time 4)

GFF Time expenditure

01500000 = As required

Road Test

01210002 = 00 TU

YES
NO

01210004 = 00 TU
Technical Diagnosis

01320000 = As required

YES

Page 8 of 20
© 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
Claim Comment: Input “As per Technical Bulletin 2041118” 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.

Reimbursement for Sections A & B Only Where Fuel Analysis Result = FAIL

To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)

Year

Touareg

2013-2016

Eng. Code

Trans. Code

VIN Range From

VIN Range To

All

All

All

All

All

All

3.0L TDI
(CNRB)
2.0L TDI
Passat

2013-2016
(CKRA, CVCA)
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

WWO 2)

01320000
Diagnostic Time 4)

GFF Time expenditure

01500000 = As required

Road Test

01210002 = 00 TU

YES
NO

01210004 = 00 TU
Page 9 of 20
© 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
Technical Diagnosis

01320000 = As required

YES

Claim Comment: Input “As per Technical Bulletin 2041118” 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.

Reimbursement for Sections A & B & C Where Fuel Analysis Results = PASS

To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Golf, Jetta, Jetta
SportWagen,
Beetle, Beetle
Convertible

Year(s)

Eng. Code(s)

Trans. Code(s)

VIN Range From

VIN Range To

All

All

All

2.0L TDI
2013 - 2016

(CJAA, CVCA,
CRUA)
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
Parts Manufacturer

0010

Golf, Jetta, Jetta SportWagen,
Beetle, Beetle Convertible

Labor Operation 3) : Fuel System Clean and