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Volkswagen Engineering Analysis EA11003: High-Pressure Fuel Pump Failure
2010 Volkswagen Jetta
High-Pressure Fuel Pump Failure
Fuel System, Diesel
Fuel System, Other:Delivery:Fuel Pump
- Summary
- The Office of Defects Investgation (ODI) opened EA11-003 on February 7, 2011, based on 160 complaints to ODI and Volkswagen involving high pressure fuel pump (HPFP) failures in model year (MY) 2009 through 2010 Volkswagen Jetta and Golf and Audi A3 TDI vehicles and questions regarding fuel sample results provided by Volkswagen as part of its response to PE10-034.During EA11-003, ODI analyzed design information, field experience and test data for MY 2009 through 2012 Volkswagen Jetta, Golf and Touareg and Audi A3 and Q7 vehicles equipped with TDI engines. Volkswagen has not identified any design or manufacturing defects in the subject TDI Clean Diesel pumps and has stated that the subject pumps were designed, tested and approved for use in the United States market, with substantial design margins for fuels that are out of specification.Volkswagen believes that misfueling with gasoline is the primary cause of HPFP drivetrain failures in the field.Only the Q7 vehicles were built with misfuel protection devices.In May 2013 Volkswagen initiated a service campaign to install misfuel protection devices in all MY 2009 through 2012 Jetta, Golf and A3 vehicles.Volkswagen implemented misfuel protection devices in all of the subject models beginning in MY 2013. ODI?s analysis of HPFP drivetrain failure incidents indicates that most failures do not result in engine stall while driving and, when pump drivetrain failure does result in stall while driving, it is usually preceded by numerous warning symptoms (e.g., glow plug warning lamp, chime, limp mode, and driveability symptoms).The failure data for the subject vehicles show relatively low stalling rates (less than one percent at three years in service) for each of the pump designs used in the subject vehicles.There have been no reports of crashes, injuries or fatalities related to the alleged defect. Based on these facts, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.For additional information, see the closing report in the document file for EA11-003.
- Documents (120)
- OPENING RESUME APPROVED
- VW 4/20/2011 LETTER TO ODI
- IR TO PEER - MERCEDES; TO INVESTIGATE COMPLAINTS OF HIGH PRESSURE FUEL PUMP FAILURE THAT RESULTED IN LOSS OF MOTIVE POWER OR ENGINE STALL. * 10/07/2011 * P
- IR TO PEER - VOLKSWAGEN; TO INVESTIGATE COMPLAINTS OF HIGH PRESSURE FUEL PUMP FAILURE IN CERTAIN MODEL YEAR 2009 THROUGH 2012 VOLKSWAGEN AND AUDI VEHICLES. * 10/07/2011 * P
- IR TO PEER - CHRYSLER; TO INVESTIGATE COMPLAINTS OF HIGH PRESSURE FUEL PUMP FAILURE. * 10/07/2011 * P
- IR TO PEER - GENERAL MOTORS; TO INVESTIGATE COMPLAINTS OF HIGH PRESSURE FUEL PUMP FAILURE. * 10/07/2011 * P
- IR TO PEER - FORD; TO INVESTIGATE COMPLAINTS OF HIGH PRESSURE FUEL PUMP FAILURE. * 10/07/2011 * P
- 54326 - VW 11-30-2012 LETTER TO ODI
- OCC 7-23-2012 LETTER TO BMW GRANTED CONFIDENTIAL TO BMW 12-22-2011 LETTER TO OCC REQUEST FOR CONFIDENTIAL
- BMW 12-22-2011 LETTER TO OCC REQUEST FOR CONFIDENTIAL
- GM 8-11-2011 REQUEST FOR CONFIDENTIAL
- OCC 6-18-2012 LETTER TO CHRYSLER GRANTED CONFIDENTIAL TREATMENT TO CHRYSLER 12-9-2011 REQUEST FOR CONFIDENTIAL
- CHRYSLER 12-9-2011 REQUEST FOR CONFIDENTIAL
- 53353 - VW 7-5-2012 LETTER TO ODI
- 53346 - VW 6-15-2012 LETTER TO ODI
- 53347 - VW 6-15-2012 ATTACHMENT WAVE 10-14
- 59445 - BOSCH 1-17-2011 INFORMATION TO ODI DISC 3, E-WAVE01TO01-042712-CBI
- 59449 - BOSCH 8-1-2008 INFORMATION TO ODI DISC 3, E-WAVE03TO03-051812-NONCONF
- 59428 - BOSCH 1-2-2008 INFORMATION TO ODI DISC 2, E-WAVE08TO08-NONCONF
- 59433 - BOSCH 3-12-2007 INFORMATION TO ODI DISC 2, E-WAVE02TO02-051112-TESTREPORTSEU-CBI
- 59435 - BOSCH 3-27-2009 INFORMATION TO ODI DISC 2, E-WAVE15TO15-062912-CBI
- 59437 - BOSCH 5-31-2012 INFORMATION TO ODI DISC 2, E-WAVE05TO05-053112-CBI
- 59439 - BOSCH 8-24-2012 INFORMATION TO ODI DISC 2, E-WAVE31TO31-082412-CBI-BOSCH
- 59441 - BOSCH 9-24-2008 INFORMATION TO ODI DISC 2, E-WAVE02TO02-051112-CONFIDENTIAL-CBI
- IR TO PEER - BMW; TO INVESTIGATE COMPLAINTS OF HIGH PRESSURE FUEL PUMP FAILURE. * 10/07/2011 * P
- VW 4-20-2011, EXHIBIT TO REQUEST 4, REQUEST NUMBER FOUR DATA
- 59414 - BOSCH 9-26-2008 INFORMATION TO ODI DISC 1, E-WAVE06TO06-053112-CBI
- 59415 - BOSCH 9-26-2008 INFORMATION TO ODI DISC 3, E-WAVE02TO02-051112-NONCONF
- 59417 - BOSCH 10-5-2010 INFORMATION TO ODI DISC 1, E-WAVE18TO18-062912-CBI
- 59418 - BOSCH 10-15-2009 INFORMATION TO ODI DISC 1, E-WAVE20-CBI-EA11003EN-00575[7]
- 59419 - BOSCH 10-18-2010 INFORMATION TO ODI DISC 1, E-WAVE10TO10-061512-NONCONF
- 59420 - BOSCH 10-24-2008 INFORMATION TO ODI DISC 1, E-WAVE23TO23-081012-CBI
- 59421 - BOSCH 10-29-2010 INFORMATION TO ODI DISC 1, E-WAVE06TO06-053112-NONCONF
- 59424 - BOSCH 11-12-2010 INFORMATION TO ODI DISC 1, E-WAVE26TO26-081012-NONCONF
- 59425 - BOSCH 11-18-2010 INFORMATION TO ODI DISC 1, E-WAVE29TO29-081712-NONCONF
- 59426 - BOSCH 11-24-2010 INFORMATION TO ODI DISC 1, E-WAVE27TO27-081712-NONCONF
- 59465 - BOSCH 1-27-2012 INFORMATION TO ODI DISC 5, E-WAVE31TO31-081712-CBI
- 59467 - BOSCH 3-26-2009 INFORMATION TO ODI DISC 5, E-WAVE04TO04-051812-CBI
- 59469 - BOSCH 5-18-2012 INFORMATION TO ODI DISC 5, E-WAVE03TO03-051812-CBI
- CHRYSLER 12-9-2011 LETTER TO ODI
- GM 12-9-2011 LETTER TO ODI
- MERCEDES 12-9-2011 LETTER TO ODI
- CHRYSLER 12-9-2011, ENCLOSURE 4 - FIELD DATA
- CHRYSLER 12-9-2011, ENCLOSURE 7 - FIELD DATA, 20623126, LETTER
- CHRYSLER 12-9-2011, ENCLOSURE 14 -DIAGNOSTIC TROUBLE CODES,PICKUP DIESEL FUEL SYSTEM DIAGNOSTIC TROUBLE CODE LIST
- CHRYSLER 12-9-2011, ENCLOSURE 17 - INFINEUM FUEL SURVEYS
- GM 12-9-2011, ATT_1, Q3, 10, 13, 14, 15, 17 & 19
- GM 12-9-2011, ATT_1, Q_18
- FORD 1-20-2012 APPENDIX B, E, F1, F2, F3, F4, I, J, K1, K2, M1 & O
- FORD 1-20-2012 APPENDIX G, NON-CONFIDENTIAL ENGINEERING REVIEW
- FORD 1-20-2012 APPENDIX L
- FORD 1-20-2012 APPENDIX P
- FORD 1-20-2012 APPENDIX D PART 1 OF 2
- ODI 3-6-2012 DOCUMENT TRANSLATION PLAN TO VW
- BMW 12-22-2011 LETTER TO ODI
- MFR RESPONSE EXTENSION - REQUESTING UPDATES TO INFORMATION REQUEST FOR QUESTIONS 1 THROUGH 5. * 03/10/2011 * P
- BMW 12-22-2011 ATTACHMENT FIELD REPORT, DEALER FIELD REPORTS, CONSUMER-COMPLAINTS Q7 & Q4
- 59334 - BOSCH 1-4-2008 INFORMATION TO ODI DISC 1, E-WAVE09TO09-053112-NONCONF
- 59335 - BOSCH 1-11-2008 INFORMATION TO ODI DISC 1, E-WAVE02TO02-051112-TESTREPORTSUSA-CBI
- 59340 - BOSCH 1-29-2008 INFORMATION TO ODI DISC 1, E-WAVE16TO16-062912-CBI
- 59343 - BOSCH 2-19-2008 INFORMATION TO ODI DISC 1, E-WAVE17TO17-062912-CBI
- 59345 - BOSCH 2-22-2008 INFORMATION TO ODI DISC 1, E-WAVE22TO22-072712-NONCONF
- 59346 - BOSCH 2-26-2008 INFORMATION TO ODI DISC 1, E-WAVE16TO16-062912-NONCONF
- 59347 - BOSCH 3-7-2011 INFORMATION TO ODI DISC 1, E-WAVE11TO11-061512-NONCONF
- 59349 - BOSCH 3-26-2008 INFORMATION TO ODI DISC 1, E-WAVE12TO12-061512-CBI
- 59350 - BOSCH 3-29-2009 INFORMATION TO ODI DISC 1, E-WAVE15TO15-062912-NONCONF
- 59351 - BOSCH 3-31-2009 INFORMATION TO ODI DISC 1, E-WAVE17TO17-062912-NONCONF
- CLOSING RESUME APPROVED
- ENGINEERING ANALYSIS CLOSING REPORT DATED 3/27/15. * 03/31/2015 * p
- MEMOS TO FILE DATED 8/14/13. * 04/01/2015 * p
- 61870 - MEMO VW 12-12-2012, METTING WITH ODI
- 61871 - MEMO VW 12-20-2012, METTING WITH ODI
- 59375 - BOSCH 5-31-2012 INFORMATION TO ODI DISC 1, E-WAVE07TO07-053112-CBI
- 59378 - BOSCH 6-15-2009 INFORMATION TO ODI DISC 1, E-WAVE20TO20-071312-NONCONF
- 59379 - BOSCH 6-15-2012 INFORMATION TO ODI DISC 1, E-WAVE10TO10-061512-CBI
- 59380 - BOSCH 6-19-2009 INFORMATION TO ODI DISC 1, E-WAVE20-CBI-EA11003EN-00495[5]
- 59381 - BOSCH 6-22-2009 INFORMATION TO ODI DISC 1, E-WAVE20-CBI-EA11003EN-00493[3]
- 59382 - BOSCH 6-22-2009 INFORMATION TO ODI DISC 1, E-WAVE20TO20-062912-CBI
- 59386 - BOSCH 7-13-2009 INFORMATION TO ODI DISC 1, E-WAVE20-CBI-EA11003EN-00574[5]
- 59389 - BOSCH 7-24-2008 INFORMATION TO ODI DISC 1, E-WAVE21TO21-071312-NONCONF
- 59390 - BOSCH 7-24-2009 INFORMATION TO ODI DISC 1, E-WAVE25TO25-081012-NONCONF
- 59393 - BOSCH 8-1-2008 INFORMATION TO ODI DISC 1, E-WAVE13TO13-061512-CBI
- 59394 - BOSCH 8-10-2012 INFORMATION TO ODI DISC 1, E-WAVE23TO23-081012-NONCONF
- 59395 - BOSCH 8-10-2012 INFORMATION TO ODI DISC 1, E-WAVE25TO25-081012-CBI
- 59396 - BOSCH 8-11-2011 INFORMATION TO ODI DISC 1, E-WAVE28TO28-081712-CBI
- 59398 - BOSCH 8-17-2012 INFORMATION TO ODI DISC 1, E-WAVE28TO28-O81712-NONCONF
- 59399 - BOSCH 8-17-2012 INFORMATION TO ODI DISC 1, E-WAVE29TO29-081712-CBI
- 59401 - BOSCH 8-24-2012 INFORMATION TO ODI DISC 1, E-WAVE32TO32-082412-CBI
- 59402 - BOSCH 8-24-2012 INFORMATION TO ODI DISC 1, E-WAVE32TO32-082412-CBI-BOSCH
- 59405 - BOSCH 8-31-2010 INFORMATION TO ODI DISC 1, E-WAVE08TO08-053112-CBI
- 59406 - BOSCH 9-9-2009 INFORMATION TO ODI DISC 1, E-WAVE19TO19-071312-NONCONF
- 59407 - BOSCH 9-14-2010 INFORMATION TO ODI DISC 1, E-WAVE13TO13-061512-NONCONF
- 59408 - BOSCH 9-15-2010 INFORMATION TO ODI DISC 1, E-WAVE21TO21-062912-CBI
- 59409 - BOSCH 9-21-2010 INFORMATION TO ODI DISC 1, E-WAVE04TO04-051812-NONCONF
- 59412 - BOSCH 9-23-2010 INFORMATION TO ODI DISC 1, E-WAVE14TO14-061512-CBI
- 59413 - BOSCH 9-24-2009 INFORMATION TO ODI DISC 1, , E-WAVE19TO19-062912-CBI
- Volkswagen 5-9-2012 REQUEST FOR AN EXTENSION
- FORD 1-20-2012 LETTER TO ODI
- CHRYSLER 12-9-2011, ENCLOSURE 10 - DEALER-FIELD COMMUNICATION
- MERCEDES 12-9-2011 ATTACHMENT 5, 6, 7, 8, 9, 10, 11, 12, 13 & 14
- FORD 1-20-2012 APPENDIX G, NON-CONF FIELD COMMUNICATIONS
- FORD 1-20-2012 APPENDIX D PART 2 OF 2
- OCC 12-29-2011 LETTER TO GM GRANTED CONFIDENTIAL TREATMENT TO GM 8-11-2011 REQUEST FOR CONFIDENTIAL
- 59385 - BOSCH 7-11-2006 INFORMATION TO ODI DISC 1, G-PAKET011-MISSBRAUCHSVERSUCHE
- 59404 - BOSCH 8-25-2011 INFORMATION TO ODI DISC 1, E-WAVE28TO28-082412-CBI-BOSCH
- 59384 - BOSCH 6-24-2011 INFORMATION TO ODI DISC 1, E-WAVE31TO31-081712-NONCONF
- 59427 - BOSCH 12-21-2005 INFORMATION TO ODI DISC 1, E-WAVE02TO02-052112-UNREDACTEDVINS-CBI
- 59451 - BOSCH 8-24-2012 INFORMATION TO ODI DISC 3, E-WAVE29TO29-082412-CBI-BOSCH
- 59344 - BOSCH 2-19-2010 INFORMATION TO ODI DISC 1, E-WAVE14TO14-061512-NONCONF
- 59383 - BOSCH 6-23-2009 INFORMATION TO ODI DISC 1, E-WAVE20-CBI-EA11003EN-00494[8]
- 59352 - BOSCH 4-7-2008 INFORMATION TO ODI DISC 1, E-WAVE30TO30-081712-CBI
- 59388 - BOSCH 7-13-2012 INFORMATION TO ODI DISC 1, E-WAVE18TO18-071312-NONCONF
- 59400 - BOSCH 8-17-2012 INFORMATION TO ODI DISC 1, E-WAVE30TO30-081712-NONCONF
- 59348 - BOSCH 3-15-2010 INFORMATION TO ODI DISC 1, E-WAVE07TO07-053112-NONCONF
- 59487 - BOSCH 10-10-2010 INFORMATION TO ODI DISC 5, E-WAVE24TO24-081012-CBI
- 59423 - BOSCH 11-12-2010 INFORMATION TO ODI DISC 1, E-WAVE24TO24-081012-NONCONF
- 59422 - BOSCH 11-4-2010 INFORMATION TO ODI DISC 1, E-WAVE27TO27-082412-CBI-BOSCH
- 59410 - BOSCH 9-23-2009 INFORMATION TO ODI DISC 1, E-WAVE12TO12-061512-NONCONF
- 59454 - BOSCH 11-13-2011 INFORMATION TO ODI DISC 3, E-WAVE27TO27-081712-CBI
- 59446 - BOSCH 4-12-2007 INFORMATION TO ODI DISC 3, E-WAVE30TO30-082412-CBI-BOSCH
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