V601702 2045403

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Golf, Golf GTI
2015
All
All
AU_FM082335
AU_FM500000
Golf, Golf GTI
2016
All
All
AU_GM000001
AU_GM500000
Golf, Golf GTI
2017
All
All
AU_HM000001
AU_HM012965
Condition
60 17 02 May 31, 2017 2045403 Supersedes Technical Bulletin 60-17-01 (V601701) dated February 6, 2017 to
update procedure labor operation time units, reduce kit quantity and remove note about repair kit claiming.
Water leak from the Sunroof (Panoramic Roof) on Golf and GTI models
Note:
This bulletin must be read in its entirety before beginning repair.
This bulletin is applicable ONLY for Golf and GTI model vehicles equipped with a sunroof. Golf
Sportwagen and Alltrack are not affected.
Tip:
The term Panoramic Sunroof refers to a sunroof that is larger than a standard sunroof and is typically the width of
the vehicle from roof pillar to roof pillar. It does not specify the difference between a single pane and a dual pane
panoramic roof.
Page 1 of 17
© 2017 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
Verify the customer complaint. Water leaks occur near the A-Pillars in the corners of the sunroof water channel.
Figure 1 (Water leaking through corner of water channel, headliner lowered for clarity.)
Note:
Some of the plastic rivets/buttons may be missing from the steel reinforcement plate as illustrated by the
white outline in Figure 1. This will not affect the structure of the water channel. DO NOT attempt to repair
or seal the openings caused by the missing rivets.
Remove the wind deflector, inner sunroof seal and thoroughly clean the water channel with isopropyl alcohol, a
microfiber cloth and compressed air prior to inspecting for cracks.
Inspect the sunroof water channel for stress cracks (see figure 2). There are a total of 12 areas to inspect for
cracks which are outlined in Figure 3 below. (More than 1 crack may be found).
Figure 2 (Examples of stress cracks in water channel)
Page 2 of 17
© 2017 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 (Inspections zones for stress cracks / application zones and sequence for foil application)
Tip:
Left side shown in figure 3 above. Please note foil patches are applied to the right side in the same application
zones and sequence.
Technical Background
A difference in the expansion rate between the plastic water channel and steel reinforcement plates may cause
stress cracks to occur at the edges of the reinforcement plates.
Production Solution
Updated parts in production as of VIN AU_HM012965.
Page 3 of 17
© 2017 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
Install Sunroof Water Channel Repair Kit
Note:
In most cases there will be stress cracks in multiple locations of the water channel. Care must be taken to
ensure all cracks are identified, sealed and that all 12 foil patches are installed correctly. Failure to seal all
cracks and install all 12 foil patches will result in a repeat failure.
1. Move the front seats forward and tilt the seat backs forward to allow room to work on the roof by standing
through the sunroof opening from the rear of the vehicle (See Figure 4).
Note:
Care must be taken not to damage center console by kneeling or leaning against it during repair process.
Figure 4
Page 4 of 17
© 2017 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
2. Remove the inner sunroof seal from around the front of the sunroof opening and lay it back over the sunroof
glass (See figures 5 and 6).
Tip:
Masking tape can be used to hold the seal in place on top of the sunroof glass for the duration of the repair.
Figure 5 (Inner Sunroof Seal)
Figure 6 (Inner sunroof seal draped over sunroof glass)
3. Remove the wind deflector according to the repair manual in ELSA.
Page 5 of 17
© 2017 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
4. Thoroughly clean the water channel with isopropyl alcohol, a microfiber cloth and compressed air. Use a bone
tool or the squeegee supplied with the repair kit to clean the area underneath the sunroof trim panel by pushing
the cloth underneath the trim (See Figure 7).
Note:
Any dirt or debris will prevent the repair from being performed properly.
Figure 7
5. Wait at least 10 minutes after cleaning the water channel before proceeding to allow alcohol to evaporate.
6. Use masking tape to lift and compress the outer sunroof seal to provide additional access to the water channel
underneath the sunroof trim panel (See Figures 8 and 9).
Figures 8 and 9
Page 6 of 17
© 2017 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
7. For all cracks, put a 1 mm bead of sealant (Teroson MS-930, part number D 172090A2) over any existing
cracks, 1 at a time. Start the sealant bead as far under the sunroof trim as possible and pull the bead to the end
of the crack.
Note:
The nozzle supplied with the sealant is already cut to a 1 mm opening.
Only work on 1 crack at a time due to the short cure time of the sealant.
Figures 10 and 11 (Sealant application)
8. Using the squeegee supplied with the repair kit, spread the sealant pushing it underneath the trim panel from
the inside edge of the roof opening to completely cover the crack.
Page 7 of 17
© 2017 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
9. Remove all excess sealant from the water channel. There must not be any excess sealant that may prevent the
foils from being applied completely flat to the water channel. The crack should be filled with sealant with no
excess sealant around the crack (See figures 12 and 13).
Tip:
Cleaning solution (part number D 00940104) can be used to remove any sealant smears in the surrounding
areas.
Figures 12 and 13 (Spread sealant working from sunroof opening to underneath the trim panel. Sealant should
fill crack and there should be no excess sealant on the water channel.)
10. Repeat process for all cracks in frame.
11. Wait 30 minutes for sealant to cure before applying the foils to the water channel.
Page 8 of 17
© 2017 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
12. Apply the foil tapes one at a time according to the sequence shown in Figure 14.
Note:
Foil tapes must be applied in all 12 positions regardless if there is a crack or not.
Tip:
For foil positions 4 and 6, it is more important to apply the foil as far underneath the trim panel as possible then
attempting to align the foil with the seal channel. Foil positions 4 and 5 should not overlap each other. DO NOT
cover the water drain hole or the witness line around the water drain with the foil in positions 4 or 5 (See Figure
15).
Figure 14 Foil application sequence (Both sides of water channel).
Page 9 of 17
© 2017 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 15 Drain hole and witness line.
13. Peel half of the backing tape off the foil and fold it over to use to hold the foil during application. Align the foil
with the edge of the water channel and apply the foil, working it forward using the included squeegee to ensure
there are no air bubbles, wrinkles and that there are no gaps under the foil. Peel backing tape off as you work
forward. Use the squeegee to work the tape down as smooth as possible.
Figure 16 Peel half of backing tape off foil and fold in half to use to hold the foil as it is applied.
Tip:
There may be a burr on the water channel in this location that appears to be an air bubble. This is normal and an
acceptable condition after applying the foil (Figure 17).
Page 10 of 17
© 2017 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
Tip:
The foil positions are designed to cover witness lines in the water channel. It is normal to see a line in the foil after
it is applied.
Figure 17 Burr under foil position 1.
14. In position 6, peel half of the backing tape off the section of foil to be placed underneath the trim panel and
fold it over to use to hold the foil during application. Ensure the tape is as far underneath the trim panel as
possible before beginning to adhere it to the water channel. Apply the foil working it toward the rear using the
included squeegee to ensure there are no air bubbles or wrinkles and that there are no gaps under the foil. Peel
backing tape off as you work. Use the squeegee to work the tape down smooth and as far underneath the trim
panel as possible (Figure 18).
Figure 18 Foil positions 2 and 6 fully applied.
Page 11 of 17
© 2017 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
15. In position 5, peel half of the backing tape off starting at the pointed edge in the radius and fold it over to use
to hold the foil during application. Carefully align the radius of the foil to the radius of the seal channel and ensure
the drain hole and witness mark around the drain will not be covered. Apply the foil working it forward using the
included squeegee to ensure there are no air bubbles or wrinkles and that there are no gaps under the foil. Peel
backing tape off as you work. Use the squeegee to work the tape down smooth and as far underneath the trim
panel as possible (Figure 19).
Figure 19 Foil position 5 fully applied.
Figure 20 Foil position 5 incorrectly applied covering witness line around drain.
Page 12 of 17
© 2017 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
Tip:
Foil position 4 is the most difficult position to install. The foil must not overlap the foil in position 5, it must not
cover the witness line around the drain, and it is difficult to place under the trim due to the limited work space.
This position is very easily folded over due to this.
16. In position 4, peel half of the backing tape off the section of foil to be placed underneath the trim panel and
fold it over to use to hold the foil during application. Use a pivoting motion to swing the foil underneath the
trim. Ensure the tape is as far underneath the trim panel as possible before beginning to adhere it to the water
channel. Apply the foil working it from underneath the trim toward the sunroof opening. Use the included
squeegee to ensure there are no air bubbles or wrinkles and that there are no gaps under the foil. Peel backing
tape off as you work. Use the squeegee to work the tape down smooth and as far underneath the trim panel as
possible (Figures 21 and 22).
1.
3.
2.
4.
Figure 21 Use a pivoting motion to work foil underneath trim panel in position 4.
Page 13 of 17
© 2017 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 22 Foil position 4 fully applied.
Tip:
It is more important that the foil in position 4 be applied as far underneath the trim panel as possible versus
attempting to align it to the edge of the seal channel.
17. After all six foils have been applied to one side of the water channel, repeat steps 12-16 on the opposite
corner of the water channel.
18. Once all 12 foils have been applied to the water channel, inspect the foils to ensure they are completely flat to
the water channel and that there are no air bubbles or gaps underneath the foil. Use the squeegee to help push
out any defects (Figures 23 and 24).
Figures 23 and 24 Air bubble under foil, air gap underneath foil.
Page 14 of 17
© 2017 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
Tip:
Use a flashlight at different angles to help identify any air bubbles. If any foil needs to be removed and reinstalled,
discard the foil and use a new piece (Figures 25 and 26).
Figure 25 and 26 use a flashlight to help identify any air bubbles in the foils and use the squeegee to work out
any defects.
Tip:
The foil must be fully applied underneath the trim panel. If the foil is folded over, it should be removed and a new
piece applied (see figure 27). Use the squeegee to work the foil down on to the water channel as far underneath
the trim panel as possible.
Figure 27 Foil folded and not adhered underneath trim panel
19. Reinstall the wind deflector and sunroof seal.
20. Close the sunroof and water test the vehicle to ensure there are no additional leaks. During the water test,
pour water through each of the 4 sunroof drains to ensure the drains are flowing properly.
Page 15 of 17
© 2017 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
To determine if this procedure is covered under Warranty, always refer to the Warranty Policies and
Procedures Manual 1)
Model(s)
Year(s)
Eng. Code(s)
Trans.
Code(s)
VIN Range From
VIN Range To
Golf, Golf GTI
2015
All
All
AU_FM082335
AU_FM500000
Golf, Golf GTI
2016
All
All
AU_GM000001
AU_GM500000
Golf, Golf GTI
2017
All
All
AU_HM000001
AU_HM012965
SAGA Coding
Claim Type:
Use applicable Claim Type 1)
Service Number:
6052
Parts Manufacturer
Damage
Code
0050
HST
Damage Location
(Depends on Service No.)
--
Use applicable when
indicated in Elsa (L/R)
Golf, Golf GTI
Labor Operation 3) : Install Sunroof Water Channel
Repair Kit
60524199 = 170 TU
Labor Operation 3) : Water Test
60520399 = 20TU
Causal Part:
5GM898041*
3YK 2)
Diagnostic Time 4)
GFF Time expenditure
01500000 = 00 TU max.
Road Test
01210002 = 00 TU
01210004 = 00 TU
Technical Diagnosis
01320000 = 20 TU max.
NO
NO
YES
Claim Comment: Input “As per Technical Bulletin 2045403” in comment section of Warranty Claim.
Page 16 of 17
© 2017 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
1)
Vehicle may be outside any Warranty in which case this Technical Bulletin is informational only
2)
Code per warranty vendor code policy.
3)
Labor Time Units (TUs) are subject to change with ELSA updates.
4)
Documentation required per Warranty Policies and Procedures Manual.
Required Parts and Tools
Part No:
Part Description
Quantity
5GM 898 041*
Repair Kit
1
D 172 090 A2
Sealant
1
Part numbers are accurate at time of publication. Always refer to ETKA for the latest part information.
(*) use latest part number suffix when applicable.
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.
Document Control Revision Table
Instance Number
Published Date
Version Number
Reason For Update
2045403/5
5/31/17
V601702
To update procedure labor
operation time units,
reduce kit quantity and
remove note about repair
kit claiming.
2045403/4
2/6/17
V601701
Updated title, procedure
and model clarification.
2045403/1
9/28/16
V601606
Original Publication.
Page 17 of 17
© 2017 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.