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NHTSA Recall 11V490000

American Government Special Collections Reference Desk

Agency:  National Highway Traffic Safety Administration
Vehicles:  Audi A3, Volkswagen Golf, Volkswagen Jetta

NHTSA Recall 11V490000

NHTSA Campaign ID number : 	11V490000
	
Vehicle Make / Model: 	    	Model Year(s):
     AUDI / A3 	    	2010-2012
     VOLKSWAGEN / GOLF 	    	2010-2012
     VOLKSWAGEN / JETTA 	    	2009-2012
     VOLKSWAGEN / JETTA SPORTWAGEN 	    	2009-2012
Manufacturer: VOLKSWAGEN OF AMERICA, INC 	Mfr's Report Date: SEP 30, 2011
NHTSA CAMPAIGN ID Number: 11V490000 	
N/A
NHTSA Action Number: N/A
Component: FUEL SYSTEM, DIESEL
Potential Number of Units Affected: 168,275
Summary:
VOLKSWAGEN IS RECALLING CERTAIN MODEL 2009-2012 JETTA AND JETTA SPORTWAGEN VEHICLES, MANUFACTURED FROM MAY 2008 THROUGH SEPTEMBER 2011, MODEL YEAR 2010-2012 VOLKSWAGEN GOLF VEHICLES, MANUFACTURED FROM MAY 2009 THROUGH SEPTEMBER 2011, AND MODEL YEAR 2010-2012 AUDI A3 VEHICLES, MANUFACTURED FROM SEPTEMBER 2009 THROUGH SEPTEMBER 2011, THAT ARE EQUIPPED WITH A 2.0L TDI COMMON RAIL DIESEL ENGINE/CLEAN DIESEL ENGINE. THE FUEL INJECTION PULSES COULD COINCIDE WITH THE NATURAL FREQUENCY OF THE INJECTOR LINE #2, IN SPECIFIC LOAD AND RPM CONDITIONS. THIS RESONANCE CREATES ADDITIONAL STRESS IN THE FUEL LINE.
Consequence:
DUE TO THE RESONANCE CONDITION, INJECTOR LINE NUMBER 2 COULD DEVELOP SMALL CRACKS WHICH COULD LEAD TO FUEL LEAKAGE. LEAKING FUEL IN THE PRESENCE OF AN IGNITION SOURCE, MAY LEAD TO A FIRE.
Remedy:
VOLKSWAGEN WILL INSTALL AN IMPROVED FUEL INJECTOR LINE FOR THE NUMBER 2 CYLINDER AND WILL INSTALL VIBRATION DAMPERS ON ALL OF THE INJECTOR LINES. VOLKSWAGEN AND AUDI WILL NOTIFY OWNERS TO HAVE THE VEHICLES REPAIRED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING NOVEMBER 2011. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.
Notes:
VOLKSWAGEN RECALL CAMPAIGN NUMBER IS 23J9/V5. OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV .


Associated Investigation

Diesel Fuel Injector Line Leakage
NHTSA ID: PE11023
Dated opened: August 2, 2011

By letter dated October 3, 2011, Volkswagen Group of America, Inc. (VW) notified the National Highway Traffic Safety Administration (NHTSA) that it will conduct a safety recall to address a defect in approximately 168,275 model year (MY) 2009-2012 Volkswagen Jetta, Jetta Sportwagen, Golf, and Audi A3 vehicles equipped with the 2.0L TDI Common Rail Clean Diesel engine (NHTSA Recall No. 11V-490). The recalled Jetta and Jetta Sportwagen vehicles were built from May 2008 through September 2011, the Golf vehicles were built from May 2009 through September 2011, and the Audi A3 vehicles were built from September 2009 through September 2011.

According to Volkswagen, in U.S. applications of the above cited TDI vehicles including engine codes CJAA and CBEA, the fuel injection pulses could coincide with the natural frequency of the injector line #2 in specific load and RPM conditions. This resonance creates additional stress on the fuel line which a small number of parts (based on the statistic spread of line strength) cannot withstand over its lifetime. As a contributing factor, VW indicated that a supplier used tube material with scratch marks from a grinding process during certain production periods. Lines manufactured in these periods were installed in vehicles produced in the following 10 months: December 2008, January-February 2009, October 2009, March-April 2010 and September-December 2010. Injector lines using this material exhibit a significantly higher failure rate. Dealers will replace injector line #2 in all vehicles built in these months. In addition, as a precautionary measure, all recalled vehicles will have vibration dampers installed on all four fuel injector lines.

Analysis of NHTSA complaints, VW complaints, VW field reports and warranty claims found allegations of injector line leakage in 443 subject vehicles. The leaking line was not identified in 62 of the vehicles. For the 381 that did provide information about which injector lines were leaking and/or replaced, 358 (94%) involved an injector line #2 leak/repair. Almost three-quarters of the injector line #2 leak/repair incident vehicles were built in the 10 months identified by VW, which accounted for approximately one-quarter of the recalled vehicles. The failure rate for injector line #2 in vehicles built in the 10 months affected by the supplier line scratching issue is 6.0 incidents per thousand vehicles (IPTV). The failure rate for injector line #2 in other production months of recalled vehicles is 0.8 IPTV. The leak/repair rates for the other injector lines are all well under 1 IPTV.

The action taken by Volkswagen is sufficient to resolve the issues raised by this investigation. The agency will continue to monitor this issue and reserves the right to take further action if warranted by the circumstances. Accordingly, this investigation is closed.


Documents

DateDocument Name & DetailsDocuments
30 September 2011Notification of Voluntary Recall
From: Christopher T. Sandvig, Volkswagen Group of America
To: Claude H. Harris, National Highway Traffic Safety Administration
NHTSA Recall 11V490000

PDF
- 303KB - 1 page
October 2011Frequently Asked Questions (FAQ) Voluntary Safety Recall 23J8
Audi of America, Inc.
NHTSA Recall 11V490000

PDF
- 64KB - 3 pages
October 2011Frequently Asked Questions (FAQ) Voluntary Safety Recall 23J9
Volkswagen
NHTSA Recall 11V490000

PDF
- 39KB - 3 pages
October 2011Safety Recall 23J8/K5
Audi of America, Inc./Volkswagen
NHTSA Recall 11V490000

PDF
- 101KB - 8 pages
3 October 2011Mandatory Stop-Sale Order and Upcoming Voluntary Safety Recall 23J9
Volkswagen
NHTSA Recall 11V490000

PDF
- 33KB - 2 pages
3 October 2011Mandatory Stop-Sale/Voluntary Safety Recall 23J8
Audi of America, Inc.
NHTSA Recall 11V490000

PDF
- 68KB - 2 pages
4 October 20112009-2012 Model Year Jetta, Jetta Sportwagen (U.S.)/Golf Wagon (CAN) 2010-2012 Model Year Golf Diesel Fuel Injection Lines
Volkswagen
NHTSA Recall 11V490000

PDF
- 239KB - 11 pages
4 October 20112010-2012 Model Year A3 Diesel Fuel Injection Lines
Audi
NHTSA Recall 11V490000

PDF
- 239KB - 11 pages
4 October 2011Upcoming Voluntary Safety Recall 23J8
Audi of America, Inc.
NHTSA Recall 11V490000

PDF
- 48KB - 2 pages
5 October 2011Diesel Fuel Injection Lines
From: Ric Willard, National Highway Traffic Safety Administration
To: Christopher T. Sandvig, Volkswagen Group of America, Inc.NHTSA Recall 11V490000

PDF
- 27KB - 3 pages
5 October 2011Notification of Voluntary Recall - Amendment
From: Christopher T. Sandvig, Volkswagen Group of America
To: Claude H. Harris, National Highway Traffic Safety Administration
NHTSA Recall 11V490000

PDF
- 195KB - 1 page
5 October 2011Upcoming Voluntary Safety Recall 23J9
Volkswagen
NHTSA Recall 11V490000

PDF
- 33KB - 2 pages
20 October 2011Notification of Voluntary Recall - Amendment to 11V-490
From: Christopher T. Sandvig, Volkswagen Group of America
To: Claude H. Harris, National Highway Traffic Safety Administration
NHTSA Recall 11V490000

PDF
- 23KB - 1 page
November 2011Voluntary Safety Recall 23J8
Audi of America, Inc.
NHTSA Recall 11V490000

PDF
- 90KB - 4 pages
9 November 20112010-2012 Model Year A3 Diesel Fuel Injection Lines
AudiNHTSA Recall 11V490000

PDF
- 505KB - 29 pages
10 November 2011Voluntary Recall Amendment - NHTSA Code 11V-490
From: Christopher T. Sandvig, Volkswagen Group of America
To: Claude H. Harris, National Highway Traffic Safety Administration
NHTSA Recall 11V490000

PDF
- 230KB - 1 page
1 December 2011Voluntary Recall Amendment- NHTSA Code 11V-490
From: Christopher T. Sandvig, Volkswagen Group of America
To: Claude H. Harris, National Highway Traffic Safety Administration
NHTSA Recall 11V490000

PDF
- 21KB - 1 page
31 January 2012Quarterly Recall Completion Report
Volkswagen Group of America
NHTSA Recall 11V490000

PDF
- 50KB - 3 pages
27 April 2012Quarterly Recall Completion Report
Volkswagen Group of America
NHTSA Recall 11V490000

PDF
- 48KB - 3 pages
31 October 2012Quarterly Recall Completion Report
Volkswagen Group of America
NHTSA Recall 11V490000

PDF
- 551KB - 3 pages
25 January 2013Quarterly Recall Completion Report
Volkswagen Group of America
NHTSA Recall 11V490000

PDF
- 85KB - 3 pages
26 April 2013Quarterly Recall Completion Report
Volkswagen Group of America
NHTSA Recall 11V490000

PDF
- 107KB - 3 pages


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