Technical Bulletin
Model(s)

Year

Eng. Code

Trans. Code

VIN Range From

VIN Range To

Touareg

2011-2015

3.0L

All

All

All

Hybrid

(CGFA)

Condition
01 15 11 May 5, 2015 2040202 Supersedes technical Bulletin V011510 dated May 4, 2015 to include road test
time units in warranty table.
MIL ON DTC P0492 and or DTC P0491 Stored in ECM Fault Memory
Customer states the MIL-On and the vehicle has one or both faults present with more than 15,000 miles.

DTC

Description

DTC P0491

Secondary Air System Insufficient Flow, Bank 1

DTC P0492

Secondary Air System Insufficient Flow, Bank 2

Technical Background
Under certain driving conditions, the secondary air ports in the cylinder head can accumulate carbon over time
causing restrictions.

Production Solution
Not applicable.

Page 1 of 5
© 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
Perform ODIS Testing:
1. Delete all DTCs. Bring the engine to operating temperature.
2. Go to Control Modules >> 01 Engine Control Module >> Control module OBD>> Basic Settings
>> Checking Secondary Air System.
3. Select MVB: MASS_SA_REL[0] and MASS_SA_REL[1].
4. Perform test (Press brake and gas pedal at the same time, start test on ODIS tester).
5. While Basic Setting test is running, check if the secondary air pump runs normally (no unusual
noises). In addition, check for a leak in the secondary air hose routing between the pump and
combi valves.
6. Immediately after the test is complete, read MASS_SA_REL[0] and MASS_SA_REL[1]. If the values are
between 0.1 and 0.7, and there were no issues with the pump and hoses, the system needs to be cleaned.
7. Create a VTA ticket and contact the Volkswagen Technician Helpline for further instructions.

Page 2 of 5
© 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
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

Touareg

2011-2015

3.0L

All

All

All

(CGFA)
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
2644

0010

Parts Manufacturer

Touareg

WWO

2)

3)

Labor Operation : Remove and Install Coolant Pipe 19 61 20 10 = 160 TU
3)

Labor Operation : Remove and Install Coolant
Flange

119 60 19 10 = 160 TU

3)

Labor Operation : Remove and Install Freeze Plugs 15 70 19 99 = 20 TU
(2)
3)

26 70 19 99 = 40 TU

Labor Operation : Pressure Washing

3)

26 44 30 99 = 75 TU

Causal Part: Select Labor Operation

26 44 30 99

Labor Operation : Lower and Install Catalyst
Converter

Diagnostic Time

4)

GFF Time expenditure

01500000 = 40 TU max.

YES

Road Test

01210002 = 10 TU

YES

01210004 = 10 TU
Page 3 of 5
© 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 = 00 TU max.

NO

Claim Comment: Input “As per Technical Bulletin 2040202” 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.

Page 4 of 5
© 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
Part Number

Part Description

Quantity

06E121119E

O-ring cross pipe

2

N 0119078

Freeze Plug

2

G 012A8G1G

Coolant

0.5

06E121119C

O-ring cross pipe to thermostat

1

06E 121 139H

Gasket

1

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

Tool Set

VAS6825

Adapter Set

VAS6825/1

Pressure Washer

Not Applicable

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 5 of 5
© 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.