NHTSA ID Number: 10122155
Manufacturer Communication Number: V231510 2041063
TSB/Document Date: 2017-11-08
Summary
Technical Bulletin (Fuel Rail/System Pressure 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 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 in this document must be observed when removing the N290 Fuel Metering Valve. This document discusses the "Fault Codes" necessary to diagnosis, and potential remedy of issue. The fault codes for checking warranty coverage for servicing the vehicle are also available.
Technical Bulletin
Model(s)
Year
Golf, Jetta, Jetta
SportWagen
2009-2012
Eng. Code
Trans. Code
VIN Range From
VIN Range To
All
All
All
2.0L TDI
(CBEA, CJAA)
Condition
23 15 10 December 10, 2015 2041063 Supersedes Technical Bulletin V231505 dated August 25, 2015 to include
Fuel Sample Pre-Analysis testing.
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 16
© 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
Note:
Inspect the fuel filler neck for a properly installed and
functioning misfueling guard (see figure 1). An
installed misfueling guard is required for warranty
coverage under the terms of the High Pressure Fuel
Pump Limited Warranty Extension. Refer to the
Warranty Policies and Procedures Manual and the
applicable Warranty Policy and Procedures
Bulletin(s) for coverage eligibility details.
Figure 1. Misfueling guard installed in the
filler neck.
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.
Page 2 of 16
© 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:
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
2. 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 in the fuel system is 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. 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 16
© 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 4).
Figure 4. 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.
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 proceed to section C - Fuel Sampling and Laboratory Analysis. If the specific gravity
is between 9 and 13 proceed to step 2a.
Page 4 of 16
© 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
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” continue onto section C - Fuel Sampling and
Laboratory Analysis.
Figure 5
Note:
Fuel samples which have a 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, proceed to section C – Fuel Sampling and Analysis.
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” continue to section C - Fuel Sampling and Laboratory Analysis.
Page 5 of 16
© 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 6
Note:
If the specific gravity is above 13 or below 9 the fuel has failed the test and must be sent out for laboratory testing.
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 D – High Pressure Fuel Pump Replacement and Fuel System Repair.
Section C – Fuel Sampling and Laboratory Analysis
Note:
This step must only be performed if either of the tests in Section B results in a “Fail”.
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*.
Page 6 of 16
© 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 7. Compliance Label Ordering
Enter the VIN in the Quick VIN Order field.
Figure 8. Enter VIN
Figure 9. 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.
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.
Page 7 of 16
© 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:
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 10 and11).
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 & D will be reimbursed under
warranty.
If the fuel sample Certificate of Analysis indicates “FAIL”: Only sections A & B & C will be reimbursed under
warranty.
6. When the fuel analysis process is complete, proceed to Section D – High Pressure Fuel Pump Replacement
and Fuel System Repair.
*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.
Note:
Each Certificate of Analysis will contain a “Pass”
or “Fail” comment as shown.
Figure 10. Example of a clean fuel sample analysis.
Page 8 of 16
© 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 11. Example of a contaminated fuel
analysis.
Section D – 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 9 of 16
© 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 10 of 16
© 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 & C 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(s)
Golf, Jetta, Jetta
SportWagen
2009-2012
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
All
All
All
2.0L TDI
(CBEA, CJAA)
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)
Golf, Jetta, Jetta Wagon, Jetta
SportWagen
Causal Part: Select Labor Operation
01320000
Outside Material: Diesel Fuel
Part Number: FUEL
3ME 2)
Diagnostic Time 4)
GFF Time expenditure
01500000 = As required
Road Test
01210002 = 00 TU
01210004 = 00 TU
YES
NO
Page 11 of 16
© 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 2041063” 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.
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 & D 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(s)
Golf, Jetta, Jetta
SportWagen
2009-2012
- Restores fuel economy
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- DESIGNED TO EXCEED EXPECTATIONS: Red Line complete SI-1 fuel...
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TSB/Document ID: V231510 2041063
Replacement Service Bulletin Number:
MFR Communication Date: 2015-12-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL
MFR Component System:
MFR Component Subsystem:
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