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 16 02 February 29, 2016 2041118 Supersedes Technical Bulletin V231509 dated December 10, 2015 to
update Touareg labor operations and part table.
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 22
© 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
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 22
© 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
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 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.

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.

Figure 4. N290 Fuel Metering Valve Orings

To prevent damaging the O-rings when
reinstalling the N290 Fuel Metering Valve,
lubricate the O-rings with diesel fuel (see
Figure 4).

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.

Page 3 of 22
© 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:
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.

Figure 5

Page 4 of 22
© 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:
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.

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 5 of 22
© 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”
*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.

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 7. Compliance Label Ordering

Enter the VIN in the Quick VIN Order field.

Figure 8. Enter VIN

Page 6 of 22
© 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 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.
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. 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 & 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.

Page 7 of 22
© 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.

Page 8 of 22
© 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 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.
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 vehicles, 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 9 of 22
© 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
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 & C 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)

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, 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
01210004 = 00 TU

Technical Diagnosis

01320000 = As required

YES
NO
YES

Page 10 of 22
© 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
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 & C 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

Passat

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
(CKRA, CVCA)
SAGA Coding

Claim Type:

Use applicable Claim Type 1)

Service Number:

Damage
Code

2374

0010

Parts Manufacturer

Touareg, Passat

Causal Part: Select Labor Operation

HST

Damage Location
(Depends on Service
No.)

--

Use applicable when
indicated in Elsa (L/R)
WWO 2)

01320000
Diagnostic Time 4)

GFF Time expenditure

01500000 = As required

Road Test

01210002 = 00 TU
01210004 = 00 TU

YES
NO

Page 11 of 22
© 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
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 & D 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)

Service Number:

2374
Parts Manufacturer

Damage
Code
0010