2038887

Technical Bulletin
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
Golf
2000-2006
All
All
All
All
Jetta Wagen
2000-2006
All
All
All
All
Condition
57 14 05 November 10, 2014 2038887
Corrosion on the Fold of the Front Inner Door
Corrosion on the fold of the front inner door in the extra
seal area.
Note:
To determine if this procedure is covered under Warranty,
always refer to the Warranty Policies and Procedures
Manual.
Documentation required per Warranty Policies and
Procedures Manual.
For vehicles outside of the Limited Warranty Against
Corrosion Perforation this Technical Bulletin is for
information only.
Figure 1
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© 2014 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 Background
Corrosion under the door fold in the area of the extra seal and the Poly Vinyl Chloride (PVC) foil.
Production Solution
No production change required.
Service
Figure 2 (Paint Group 01/02) – Door Repair
• Remove corrosion and clean the area thoroughly with a Volatile Organic Compound (VOC) compliant cleaner.
• Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer (locally sourced).
• Seal the metal edge in the fold area with a thin layer of fine seam sealer.
• To ensure an even contact surface for the extra seal, apply the polyurethane sealer - AKD 476 KD 505 - with a
soft plastic coating blade.
• Restore paint structure according to the paint repair manual.
• Bond a new door seal - Part No. 1J0 837 671 or Part No. 1J0 837 672 - (without PVC foil). Make sure the door
seal is securely bonded by warming up the contact area on the door with a hot air blower (30 - 50°C).
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© 2014 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 3 (Paint Group 03) – Door Replacement
• Replacement of the door under warranty is only permitted with through-corrosion (perforation)
• The replacement door comes with a PVC foil for the door seal.
Note:
If through corrosion (perforation) is not present, door replacement will only be accepted if it qualifies per the
Reimbursement Policy section of the Warranty Policies and Procedure Manual. This section provides important
guidelines when considering component repair vs. replacement options (the “80% rule”).
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© 2014 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
Note:
• Dealers may complete the repair as described without prior authorization (through a WISE Warranty Repair
Acceptance request).
• Documentation required: Clear pictures, completed estimate and body shop invoice must be saved and kept on
file at the Dealership for audit purposes.
• This bulletin applies for 1 door repair or replacement. If both doors exhibit the corrosion they should be
evaluated individually and claimed on separates lines. Total Body Painting Prep Time for both doors should be
claimed on the first line only.
• Labor time units (TU), Material units (MU), and Material unit rate are correct at the time of publication. The time
units and/or material units may differ if the repair catalogue is updated. The information in the repair catalogue
applies, except for the open time items (labor operations ending in 99) which are calculated at actual time
multiplied by the body shop labor rate. The material allowance (Paint material price per unit) is subject to
change. Refer to WISE > Resource Center > Forms>Paint/Corrosion for the most current forms.
• This section is applicable for vehicles within the terms of Volkswagen’s Limited Warranty Against Corrosion
Perforation. For vehicles outside the terms of the Limited Warranty Against Corrosion Perforation this section
is for information only.
• This bulletin may be provided to outside shops to ensure the proper repair is completed.
Note:
Claim Processing Options
Option 1: Utilize the attached form examples and interactive forms on WISE to assist with calculating the
reimbursement amounts. This will expedite the claim review process and reduce the time to pay the claim.
Note that miscalculations are subject to claim adjustment.
For the complete set of pre-populated Paint/Corrosion Claim Form templates associated with this Technical
Bulletin, refer to WISE > Resource Center > Forms > Paint/Corrosion.
Option 2: Email repair estimates to [email protected]. The paint and corrosion team will calculate the warranty
allowance and complete the required form(s) on behalf of the dealer.
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© 2014 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
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
1)
Procedures Manual
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
Golf
2000-2006
All
All
All
All
Jetta Wagen
2000-2006
All
All
All
All
SAGA Coding
Claim Type:
160
1)
Damage
Service Number:
HST
Damage Location (Depends on
Service No.)
--
061 or 063
Code
5751
0003
Parts Manufacturer
Golf (1J1), Jetta Wagen (1J6)
061 or 063
2)
Golf 9B1 (Brazil)
061 or 063
2)
Repair
Please use the following part number in “Outside Materials”
LACKMATF: Paint and Materials
4)
2 Door Models – MU @ $12 per unit
4 Door Model – MU @ $12 per unit
Epoxy Primer (Locally Sourced)
Claim Dollar Amount (MAX: $40)
Please use the following Labor Operation in “Outside Labor”
• Select the appropriate Labor Operation
below:
• L0010000: External Painting-straight color
• L0020000: External Painting-metallic/2-layer
L0030000: External Painting-pearl color
4)
2 Door Model
Claim Dollar Amount
4 Door Model
Claim Dollar Amount
• Use this for all body repair in this bulletin:
• A0041000: Body Shop repair no paint
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© 2014 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
Replace
Please use the following part number in “Outside Materials”
LACKMATF: Paint and Materials
4)
2 Door Models –MU @ $12 per unit
4 Door Model –MU @ $12 per unit
Please use the following Labor Operation in “Outside Labor”
• Select the appropriate Labor Operation
below:
4)
2 Door Model
• L0010000: External Painting-straight color
Claim Dollar Amount
• L0020000: External Painting-metallic/2-layer
4 Door Model
• L0030000: External Painting-pearl color
Claim Dollar Amount
• Use this for all body repair in this bulletin:
• A0041000: Body Shop repair no paint
Causal Part:
L00#0000
Diagnostic Time
GFF Time expenditure
01500000 = 00 TU max.
Road Test
01210002 = 00 TU
4)
NO
NO
01210004 = 00 TU
Technical Diagnosis
01320000 = 00 TU max.
NO
Claim Comment: Input “As per Technical Bulletin 2038887” in comment section of Warranty Claim.
1)
For vehicles outside of the Limited Warranty Against Corrosion Perforation this Technical Bulletin is for
information only.
2)
Corrosion claim vendor code will be the damage location.
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policies and Procedures Manual.
5)
See attachment “srt_reference_table.pdf” for labor time reference.
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© 2014 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
Required Parts and Tools
Repair
Part No:
AKD 476 KD 505
1J0 837 671 A / 672 A
Part Description
Quantity
Polyurethane Sealer
1
Door Seal (self-adhesive) Left or
Right
1
OR
Replace
1J3 831 056H / 055H
Golf (2-Door) Front Door Left or
Right
1
1J4 831 056H / 055H
Golf(4-Door) / Jetta Wagen Front
Door Left or Right
1
1J0 837 671 A / 672 A
Door Seal (self-adhesive) Left or
Right
1
No special tools required.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
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© 2014 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.
Paint/Corrosion Claim Form
Dealer No.
400000
Repair
Order No.
910000
VIN (17-Digits)
9BWDE61J444000000
Color No. (4-digit ElsaPro Paint No.)
LB5N
100.00
Dealer Labor Rate
If repeat repair, provide explanation in box below:
Paint material price per unit
Service No.
Damage
Code
Dmg
Loc
Part manufacturer
(Vendor Code)
5751
0003
061
061
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
Paint One New Front Door (2 Door Model) (S1)
57516150
190
22
Paint One New Front Door Trim Strip (S1)
66216150
20
1
51017153
110
Verify ALL Labor Operation Time Units
and Material Units
If both doors are affected, the prep time
should be entered on the first line of the
SAGA claim and only once on the first
Paint/Corrosion Claim Form
Note: Authorization and claim reimbursement are contingent on the usage of original
parts for the repair
Body Painting Prep Time
The vehicle history must be checked for any previous damage. Digital photographs must be included with the repair order per VWoA instructions. If there is a
sublet invoice for painting, the invoice amount must be split between outside (sublet) labor and outside (sublet) material.
Part Number
Part Description
Part Qty
Part Price
per Unit
Total Part
Price
Description of Repair
Paint Subtotal
Repair/Replace Labor
Operation(s)
320
23
Time
Units
Remove and Install One Front Door
57511900
30
Front Door Replace (2 Door Model)
57515550
160
Body Cavity Seal Coat
51017501
30
All other parts should be claimed
separately in the SAGA claim
Full interactive forms can be found in the
foilowing location:
WISE > Resource Center > Forms > Paint/
Corrosion > TB# in the sub heading > Locate
form specific to the vehicle and the repair.
Outside Material
LACKMATF
Part Amount Subtotal
$
-
Total Paint Material Amount
$
276.00
Total Parts Amount
$
276.00
VW Representative
Authorization No.
Body Labor Subtotal
Total TU/MU
Authorization Date
TB 2038504
Authorization
valid until:
VW Representative Name (printed)
VW Representative Signature
220
540
23
L00X0000 $
320.00
A0041000 $
220.00
Total Outside Material: $
276.00
Total: $
816.00
Paint/Corrosion Claim Form
400000
Dealer No.
Repair
Order No.
910000
VIN (17-Digits)
9BWDE61J444000000
Color No. (4-digit ElsaPro Paint No.)
LB5N
Dealer Labor Rate
If repeat repair, provide explanation in box below:
100.00
Paint material price per unit
Service No.
Damage
Code
Dmg
Loc
Part manufacturer
(Vendor Code)
5751
0003
061
061
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
Paint One New Front Door (2 Door Model) (S1)
57517953
160
9
Paint One New Front Door Trim Strip (S1)
66217999
20
1
51017173
160
Verify ALL Labor Operation Time Units and
Material Units
If both doors are affected, the prep time
should be enteredd on the first line of the
SAGA claim and only once on the first
Paint/Corrosion Claim Form
Note: Authorization and claim reimbursement are contingent on the usage of original
parts for the repair
Body Painting Prep Time
The vehicle history must be checked for any previous damage. Digital photographs must be included with the repair order per VWoA instructions. If there is a
sublet invoice for painting, the invoice amount must be split between outside (sublet) labor and outside (sublet) material.
Part Number
Part Description
Part Qty
Epoxy Primer
Part Price
per Unit
1 $
Total Part
Price
40.00
Description of Repair
Paint Subtotal
Repair/Replace Labor
Operation(s)
340
10
Time
Units
Remove and Install One Front Door
57511900
30
Dismantle and Assemble One Front
57513750
160
57514199
50
Door
Remove Rust from One Door Fold
Example Part Qty and Part Price per Unit only
and Seal Off
All other parts should be claimed separately
in the SAGA claim
Full interactive forms can be found in the
foilowing location:
WISE > Resource Center > Forms > Paint/
Corrosion > TB# in the sub heading > Locate
form specific to the vehicle and the repair.
Outside Material
LACKMATF
Part Amount Subtotal
$
40.00
Body Labor Subtotal
240
Total Paint Material Amount
$
120.00
Total TU/MU
580
Total Parts Amount
$
160.00
VW Representative
Authorization No.
Authorization Date
TB 2038504
Authorization
valid until:
VW Representative Name (printed)
VW Representative Signature
L00X0000 $
10
340.00
A0041000 $
240.00
Total Outside Material: $
160.00
Total: $
740.00
SRT Reference Table for TPI# 2038887
Repair door (2 door Model - Golf)
Body Labor
Labor Operation : Remove and install
one front door
Labor Operation : Dismantle and
assemble one front door
Labor Operation : Remove rust from
one door fold and seal off
57 51 19 00 = 30 TU
57 51 37 50 = 130 TU
57 51 41 99 = 50 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
Labor Operation: Paint one front door
Labor Operation: Paint one new front
door trim strip
51 01 71 73 = 110 TU
57 51 79 53 = 130 TU
66 21 61 50 = 20 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front door
Labor Operation: Paint one new front
door trim strip
13 MU
1 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Repair door (4 door Model - Golf)
Body Labor
Labor Operation : Remove and install
one front door
Labor Operation : Dismantle and
assemble one front door
Labor Operation : Remove rust from
one door fold and seal off
57 51 19 00 = 30 TU
57 51 37 60 = 160 TU
57 51 41 99 = 50 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
Labor Operation: Paint one front door
Labor Operation: Paint one new front
door trim strip
51 01 71 73 = 110 TU
57 51 79 53 = 130 TU
66 21 61 50 = 20
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front door
Labor Operation: Paint one new front
door trim strip
10 MU
1 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Repair door (Jetta Wagen)
Body Labor
Labor Operation : Remove and
install one front door
Labor Operation : Dismantle and
assemble one front door
Labor Operation : Remove rust
from one door fold and seal off
57 51 19 00 = 30 TU
57 51 37 50 = 160 TU
57 51 41 99 = 50 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
51 01 71 73 = 160 TU
Labor Operation: Paint one front
door
57 51 79 53 = 160 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front
door
9 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Replace door (2 door Model - Golf)
Body Labor
Labor Operation : Remove and
install one front door
Labor Operation : Replace one front
door
Labor Operation : Wax Body
57 51 19 00 = 30 TU
57 51 55 50 = 160 TU
51 01 75 01 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
Labor Operation: Paint one front
door
Labor Operation: Paint one new
front door trim strip
51 01 71 53 = 110 TU
57 51 61 50 = 190 TU
66 21 61 50 = 20 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front
door
Labor Operation: Paint one new
front door trim strip
22 MU
1 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Replace door (4 door Model - Golf)
Body Labor
Labor Operation : Remove and
install one front door
Labor Operation : Replace one front
door
Labor Operation : Wax Body
57 51 19 00 = 30 TU
57 51 55 60 = 160 TU
51 01 75 01 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
Labor Operation: Paint one front
door
Labor Operation: Paint one new
front door trim strip
51 01 71 53 = 110 TU
57 51 61 60 = 160 TU
66 21 61 50 = 20 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front
door
Labor Operation: Paint one new
front door trim strip
18 MU
1 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Replace door (Jetta Wagen)
Body Labor
Labor Operation : Remove and
install one front door
Labor Operation : Replace one front
door
Labor Operation : Wax Body
57 51 19 00 = 30 TU
57 51 55 50 = 160 TU
51 01 75 01 = 30 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
51 01 71 53 = 160 TU
Labor Operation: Paint one front
door
57 51 61 50 = 130 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front
door
10 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF