2039211

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Phaeton
2004 –2006
All
All
All
All
Condition
58 14 04 December 18, 2014 2039211
Corrosion on Rear Doors (Multiple Locations)
Outer door areas (Figure 1-4):
Figure 1 – Upper window channel strip
Figure 2 – Central protective strip
Figure 1.1
Figure 2.1
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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 – Lower protective strip
Figure 4 – Surface/edge corrosion
Figure 3.1
Figure 4.1
Inner door area (Figure 5).
Holes and edges in the flange area
Figure 5
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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
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.
Technical Background
Alignments in production can lead to hairline cracks in the top coat and paint damage (edges on holes) on the
already painted door. Humidity then penetrates paint and causes blistering and/or white corrosion.
Production Solution
Corrections in the production process after discovering deviations.
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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
Service
Procedure:
A. Repair rear door Only perform this operation if the total repair cost is 80% or less of the total replacement cost.
or
B. Replace rear door
Steps 1 and 2 should be completed regardless of repair or replacement of the door.
1. Central protective strip
2. Lower protective strip
Note
• In most cases the protective strips are damaged when they are removed. Order, and as necessary,
paint the required parts before the repair.
• Inspect the outer and inner doors in the visible area for further paint bubbles. As necessary repair
according to Volkswagen guidelines.
• Inspect the fine seam sealing in the inner edge area of the doors for cracks, and as necessary, repair
according to Volkswagen guidelines.
A. Repair the rear door as follows:
• Disassemble the door according to the repair manual. See Repair Group 58 in Elsa
If the affected area is only lightly corroded (no through-corrosion), proceed as follows:
• Inspect the inner edge area of the doors for cracks, particularly the fine seam sealing.
• Completely remove the corrosion in the damaged area.
• Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer to both sides of the door
(locally sourced).
• Seal the edges/metal sheathings with adhesive (part number: AKD 476 KD505) before painting.
•
Repaint door according to Volkswagen guidelines
B. Replace the rear door as follows:
• Replace the door according to the repair manual. See Repair Group 58 in Elsa.
• Paint new door according to Volkswagen guidelines.
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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
Steps 1 and 2 should be completed regardless of repair or replacement of the door.
1. Central protective strip
• Before installing the side protective strip, attach from outside, and only on the front and rear holes/elongated
hole (Figure 6 and 7, red arrows), a trim protective foil (part number: AKL 448 030 05) or similar as additional
anti-chafing protection.
Figure 6
Figure 7: (example)
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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
• Before installing the side protective strip, adhere (press) the foil around the hole lightly (e.g. with a ball pen,
illustration 8).
Note
Make sure that the painted edges do not get damaged when attaching the foil.
Figure 8: (example)
2. Lower protective strip
• Before installing the lower protective strip, attach on every front and rear hole (Figure 9, red arrows) from
outside, trim protective foil (part number: AKL 448 030 05) as additional anti-chafing protection.
Figure 9
• Before fitting the protective strip adhere (press) the foil around the hole lightly.
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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
• Attach new and loose plastic adjustment screws (Figure 10, red circle) with locking compound (part number: D
185 410 A2).
Figure 10: (example)
• Adjust the protective strip (according to the repair manual) within the hardening time of the locking compound
(part number: D 185 410 A2).
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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 multiple 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
Phaeton
2004-2006
All
All
All
All
SAGA Coding
1)
Claim Type:
160
Damage
Service Number:
HST
Damage Location
(Depends on Service No.)
--
160 or 162
Code
5851
0003
Parts Manufacturer
2)
Phaeton (3D8)
160 or 162
Repair
Please use the following part number in “Outside Materials”
4)
LACKMATF: Paint and Materials
MU @ $12 per unit
Epoxy Primer (Locally Sourced)
Claim Dollar Amount (MAX: $40)
Please use the following Labor Operation in “Outside Labor”
4)
Select the appropriate Labor Operation below:
- L0010000: External Painting-straight color
Claim Dollar Amount
- L0020000: External Painting-metallic/2-layer
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
Claim Dollar Amount
- A0041000: Body Shop repair no paint
Replace
Please use the following part number in “Outside Materials”
LACKMATF: Paint and Materials
4)
MU @ $12 per unit
Please use the following Labor Operation in “Outside Labor”
4)
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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
Select the appropriate Labor Operation below:
- L0010000: External Painting-straight color
Claim Dollar Amount
- L0020000: External Painting-metallic/2-layer
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
Claim Dollar Amount
- A0041000: Body Shop repair no paint
Causal Part:
L00#0000
Diagnostic Time
4)
GFF Time expenditure
01500000 = 00 TU max.
NO
Road Test
01210002 = 00 TU
NO
01210004 = 00 TU
Technical Diagnosis
01320000 = 00 TU
NO
Claim Comment: Input “As per Technical Bulletin 2039211” in comment section of Warranty Claim.
1)
For Vehicles outside the Limited Warranty Against Corrosion Perforation this bulletin is 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_ref_table.pdf” for labor time reference.
Page 10 of 11 plus attachments
© 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 and Replace
Part number
Designation
AKD 476 KD505
Polyurethane adhesive sealant – Quantity: 0.25
AKL 448 030 05
Protective Foil
D 185 410 A2
Liquid locking fluid (Compound) – Quantity: 0.25
One of the following
3D7 853 073 B GRU
Rear Left Side Protective Strip
3D7 853 074 B GRU
Rear Right Side Protective Strip
3D7 854 949 A V7S
Rear Left Lower Protective Strip (Cover for door)
3D7 854 950 A V7S
Rear Right Lower Protective Strip (Cover for door)
Replace (One of the following)
3D7 833 051 F
Rear Left Door
3D7 833 052 F
Rear Right Door
For Special Tools see Repair Manual.
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
400000
Dealer No.
Repair
Order No.
910000
VIN (17-Digits)
WVWZZZ3DZA6000000
Color No. (4-digit ElsaWeb 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)
5851
0003
061
061
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint One Rear Door (S3)
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
58517903
130
51017133
190
8
Verify ALL Labor Operation Times and
Material Units
If Both doors are affected the prep time
should be claimed on the first line in Saga
and only the first Paint/Corrosion 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)
320
8
Time
Units
Disassemble and reassemble rear door
58513750
370
Remove corrosion from rear
58516300
70
51017500
30
door/modify rear door
Wax Body
Example Quantity and Price Only
Example Time Units
All other parts should be claimed
seperately in the SAGA Claim
Full pre-populated forms can be found in the
following location:
WISE > Resource Center > Forms > Paint/
Corrosion > TB# - Form specific to the vehicle
and the repair.
Outside Material
LACKMATF
Part Amount Subtotal
$
40.00
Total Paint Material Amount
$
96.00
Total Parts Amount
$
136.00
VW Representative
Authorization No.
Body Labor Subtotal
Total TU/MU
Authorization Date
TB 2039211
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
470
790
8
L00X0000 $
320.00
A0041000 $
470.00
Total Outside Material: $
136.00
Total: $
926.00
Paint/Corrosion Claim Form
Dealer No.
400000
Repair
Order No.
910000
VIN (17-Digits)
WVWZZZ3DZA6000000
Color No. (4-digit ElsaWeb 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)
5851
0003
061
061
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint One Rear Door (S3)
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
58516150
90
51017153
160
8
Verify ALL Labor Operation Times and
Material Units
If Both doors are affected the prep time
should be claimed on the first line in Saga
and only the first Paint/Corrosion 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)
250
8
Time
Units
Remove and Install One Rear Door
58511900
50
Replace on rear door
58515550
330
Wax Body
51017500
30
All other parts should be claimed
seperately in the SAGA Claim
Full pre-populated forms can be found in the
following location:
WISE > Resource Center > Forms > Paint/
Corrosion > TB# - Form specific to the vehicle
and the repair.
Outside Material
LACKMATF
Part Amount Subtotal
$
-
Total Paint Material Amount
$
96.00
Total Parts Amount
$
96.00
VW Representative
Authorization No.
Body Labor Subtotal
Total TU/MU
Authorization Date
TB 2039211
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
410
660
8
L00X0000 $
250.00
A0041000 $
410.00
Total Outside Material: $
96.00
Total: $
756.00
SRT Reference Table for TPI# 2039211
Repair rear door (Phaeton)
Body Labor
Labor Operation: Disassemble
and reassemble rear door
Labor Operation: Remove corrosion
in damaged area.
Modify affected areas as needed:
1. Upper window channel strip
2. Central side protective strip
3. Lower protective strip
4. Surface/edge corrosion
Labor Operation: Wax Body
58 51 37 50 = 330 TU
58 51 63 00 = * TU
Claim time units times labor
rate in SAGA under Outside
Labor Operation:
A0041000
51 01 75 00 = 30 TU
Refinish Labor
Labor Operation: Prepare painting
51 01 71 33 = 190 TU
Labor Operation: Paint one rear door
(S3)
Or
58 51 79 03 = 110 TU
Labor Operation: Paint one rear door
(S3/piano finish)
58 51 79 13 = 160 TU
Or
Claim time units times labor
rate in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one rear door
or
Labor Operation: Paint one rear door.
(S3/piano finish)
7 MU
or
10 MU
Claim material unit times
$12.00 in SAGA under
Outside Materials:
LACKMATF
* Front door replacement should be considered if the total repair cost will exceed 80% of the total replacement cost.
Refer to 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”).
Replace rear door (Phaeton)
Body Labor
Labor Operation : Remove and
install one rear door
Labor Operation : Replace one rear
58 51 55 50 = 330 TU
Labor Operation : Wax Body
51 01 75 00 = 30 TU
door
58 51 19 00 = 50 TU
Claim time units times
labor rate in SAGA under
Outside Labor Operation:
A0041000
Refinish Labor
Labor Operation: Prepare painting
51 01 71 53 = 160 TU
Labor Operation: Paint one rear door
(S3)
Or
58 51 61 50 = 90 TU
Labor Operation: Paint one rear door
(S3/piano finish)
58 51 61 60 = 130 TU
Or
Claim time units times
labor rate in SAGA under
Outside Labor Operation:
L00#0000*
Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one rear door
or
Labor Operation: Paint one rear door.
(S3/piano finish)
7 MU
or
11 MU
Claim material unit times
$12.00 in SAGA under
Outside Materials:
LACKMATF