2009-2012 Audi A3 Diesel Fuel Injector Line Leakage Recall

NHTSA's Findings So Far

The National Highway Traffic Safety Administration (NHTSA) initiated investigation PE11023 concerning diesel fuel injector line leakage in certain Volkswagen and Audi models. Volkswagen Group of America, Inc. (VW) notified NHTSA of a safety recall (NHTSA Recall No. 11V-490) to address a defect in approximately 168,275 vehicles. This includes 2009-2012 Audi A3 models equipped with the 2.0L TDI Common Rail Clean Diesel engine, specifically engine codes CJAA and CBEA.

This 2011 Audi A3 investigation found that fuel injection pulses could coincide with the natural frequency of injector line #2 under specific load and RPM conditions. This resonance created additional stress on the fuel line. A contributing factor was identified as a supplier using tube material with scratch marks from a grinding process during certain production periods. Lines manufactured during these periods exhibited a significantly higher failure rate.

Scope of the Issue

The recall (NHTSA Recall No. 11V-490) covers 2009-2012 Audi A3 vehicles built from September 2009 through September 2011. The affected vehicles also include 2009-2012 Volkswagen Jetta, Jetta Sportwagen, and Golf models.

Analysis of complaints and warranty claims revealed 443 instances of injector line leakage. Among the 381 vehicles where the leaking line was identified, 358 (94%) involved an injector line #2 leak or repair. Almost three-quarters of these injector line #2 incidents occurred in vehicles built during the 10 months identified by VW as having the supplier line scratching issue. These months were December 2008, January-February 2009, October 2009, March-April 2010, and September-December 2010.

The failure rate for injector line #2 in vehicles built during these specific 10 months was 6.0 incidents per thousand vehicles (IPTV), significantly higher than the 0.8 IPTV for other production months. Leak rates for other injector lines were well under 1 IPTV.

Manufacturer's Remedy

To address the defect, dealers will replace injector line #2 in all vehicles built during the identified problematic months. Additionally, as a precautionary measure, all recalled vehicles will have vibration dampers installed on all four fuel injector lines. This action aims to prevent future occurrences of the diesel fuel injector line leakage.

Status of the Investigation

The action taken by Volkswagen is considered sufficient to resolve the issues raised by this 2011 Audi A3 investigation. Accordingly, NHTSA has closed investigation PE11023. The agency will continue to monitor this issue and reserves the right to take further action if circumstances warrant. Owners of affected 2009-2012 Audi A3 vehicles should contact their dealer to schedule the recall repair.

Source: NHTSA Investigation PE11023