Technical Bulletin
Model(s)

Year

Touareg

2009-2012

Passat

2012

Eng. Code

Trans. Code

VIN Range From

VIN Range To

All

All

All

All

All

All

3.0L TDI
CATA
2.0L TDI
CKRA

Condition
23 16 01 February 15, 2016 2041057 Supersedes Technical Bulletin V231508 dated December 9, 2015 to
include Passat In-Tank fuel pump part number and updates to Touareg part 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.

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© 2016 Volkswagen Group of America, Inc.
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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 17
© 2016 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 (see figure 2), replacement
of the high pressure fuel pump and major components of the fuel system are 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. Continue with diagnosis, 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 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.

Page 3 of 17
© 2016 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 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.
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.

Page 4 of 17
© 2016 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 5

Note:
Fuel samples which have a specific 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.

Page 5 of 17
© 2016 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
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.

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.

Page 6 of 17
© 2016 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 – 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.
The 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 7. Compliance Label Ordering

Enter the VIN in the Quick VIN Order field.

Figure 8. Enter VIN

Figure 9. Select part number LQ1LKIT

Page 7 of 17
© 2016 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 10 and 11).
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 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 8 of 17
© 2016 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 10. Example of a clean fuel sample analysis.

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 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).

Page 9 of 17
© 2016 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
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 10 of 17
© 2016 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

Touareg

2009-2012

Passat

2012

Eng. Code

Trans. Code

VIN Range From

VIN Range To

All

All

All

All

All

All

3.0L TDI
CATA
2.0L TDI
CKRA
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)

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 11 of 17
© 2016 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 & 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

Touareg

2009-2012

Passat

2012

Eng. Code

Trans. Code

VIN Range From

VIN Range To

All

All

All

All

All

All

3.0L TDI
CATA
2.0L TDI
CKRA
SAGA Coding

Claim Type:

Use applicable Claim Type 1)

Page 12 of 17
© 2016 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 Number:

2374

Damage
Code
0010

Parts Manufacturer

HST

Damage Location
(Depends on Service No.)