V551604-2038992

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Jetta
1999 – 2010
All
All
All
All
Condition
55 16 04 June 8, 2016 2038992 Supersedes Technical Bulletin V551602 dated February 8, 2016 to update
Claim Processing comment.
Corrosion on the Rear Lid around License Plate Lights
Figure 1: Corrosion on and around the license plate light
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
Electrolytic corrosion around the license plate lights (opening/contact surface, inside and outside) because of
water ingress via the seal of the license plate lights.
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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
Production Solution
Not applicable.
Service
Procedure:
1a. Repair (Remove corrosion and restore paint structure).
Only perform this operation if the total repair cost is 80% or less of the total replacement cost.
Or
1b. Replace the rear lid.
Note:
Steps 2-3 should be completed whether the rear lid is repaired or replaced.
2. Seal off contact surface and screw holes of license plate lights with butyl sealing cord (part number:
AKL 450 005 05).
3. Replacement of license plate lights.
1a. Repair (Remove corrosion and restore paint structure)
 Remove the license plate lights from the rear lid according to the repair manual. See Repair Group 94 in Elsa.
 Remove all trim panels from the rear lid to prepare for corrosion removal according to the repair manual. See
Repair Group 70 in Elsa.
 Remove the corrosion on the rear lid contact surface around the license plate light (inside and outside) with a
pneumatic brush grinder.
Note:
If through-corrosion (perforation) is not present, rear lid 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”).
 Prepare the rear lid for painting according to manufactures guidelines - it is not necessary to remove the glass.
 Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer (locally sourced).
 Repaint the rear lid according to manufactures guidelines.
Page 2 of 8 Plus attachment
© 2016 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
1b. Replace the rear lid
 Replace the rear lid according to the repair manual. See Repair Group 55 in Elsa.
2. Additionally seal the contact surface of the license plate lights with butyl sealing cord (part number:
AKL 450 005 05).
 Apply butyl sealing cord (0.2 cm x 20 cm) on the contact surface and attachment area of the license plate
lights (Figure 2 and 3 in green).
Figure 2) License plate light, butyl sealing cord areas
Figure 3) License plate light, contact surface and hole sealed with butyl sealing cord
Page 3 of 8 Plus attachment
© 2016 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
3. Replacement of the license plate lights
 Install the new license plate lights in the rear lid according to the repair manual. See Repair Group 94 in Elsa.
 Remove any excess butyl sealing cord.
 Install all trim panels for the rear lid according to the repair manual. See Repair Group 70 in Elsa.
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.
 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
Utilize the attached form examples and pre-populated 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. You can email completed excel forms (in the excel
format) to [email protected]. The Paint and Corrosion Team will review your completed form(s) and adjust for
overlap on behalf of the dealer.
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.
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© 2016 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
Procedures Manual 1)
Model(s)
Year(s)
Eng. Code(s)
Trans. Code(s)
VIN Range From
VIN Range To
Jetta
1999-2010
All
All
All
All
SAGA Coding
1601)
Claim Type:
Service Number:
5559
Damage
Code
0003
Parts Manufacturer
HST
Damage Location (Depends on
Service No.)
--
030
Jetta (1K2, 9M2)
030 2)
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
- L0020000: External Painting-metallic/2-layer
Claim Dollar Amount
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
- A0041000: Body Shop repair no paint
Claim Dollar Amount
Replace
Please use the following part number in “Outside Materials” 4)
LACKMATF: Paint and Materials
MU @ $12 per unit
Please use the following Labor Operation in “Outside Labor” 4)
Page 5 of 8 Plus attachment
© 2016 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
- L0020000: External Painting-metallic/2-layer
Claim Dollar Amount
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
- A0041000: Body Shop repair no paint
Causal Part:
Claim Dollar Amount
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 2038992” 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 6 of 8 Plus attachment
© 2016 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
1999-2005 Jetta (A4)
Replace
Part number
Part Description
Quantity
Rear Trunk
1
1JM 827 025 *
Repair and Replace
AKL 450 005 05
1J5 943 021 D
Butyl sealing cord
0.1
License Plate Lights
2
2005.5-2010 Jetta (A5)
Part number
Part Description
Quantity
Rear Trunk
1
1K5 827 025 AP
Repair and Replace
AKL 450 005 05
Butyl sealing cord
0.1
3B5 998 026 A
License Plate Light
2
 *Order part number based on vehicle V.I.N.
Always refer to ETKA for proper part application.
No Special Tools Required.
Page 7 of 8 Plus attachment
© 2016 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
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
2038992/3
6/8/16
V551604
Update Claim Processing
statement.
2038992/2
2/8/16
V551602
To include additional model and
model year applicability.
2038992/1
12/4/14
V551404
Original publication.
Page 8 of 8 Plus attachment
© 2016 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)
3VWBA71K18M167634
Color No. (4-digit ElsaPro Paint No.)
LR9A
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)
5559
0003
030
030
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint trunk lid
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
55907953
130
51017173
160
9
Verify ALL Labor Operation Time Units
and Material Units
If both fenders 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
EPOXY
Part Qty
Epoxy Primer
Part Price
per Unit
1 $
Total Part
Price
40.00
Example Part Qty and Part Price per Unit only
All other parts should be claimed separately in
the SAGA claim
Description of Repair
Outside Material
55901900
70
Remove and install 2 rear lights
94312010
30
Replace rear lock mechanism
55571950
10
Remove and Install rear lid trim
70871900
20
Remove and install rear emblem
66511900
20
Remove and install rear lettering
66502000
20
Remove corrosion on rear lid
55906300
100
Wax body
51017500
30
Example Time Units
Part Amount Subtotal
$
40.00
Body Labor Subtotal
300
$
108.00
Total TU/MU
590
Total Parts Amount
$
148.00
Authorization Date
TB 2038992
Authorization
valid until:
Warranty
VW Representative Name (printed)
9
Time
Units
Total Paint Material Amount
VW Representative
Authorization No.
Repair/Replace Labor
Operation(s)
290
Remove and Install trunk lid
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.
LACKMATF
Paint Subtotal
VW Representative Signature
9
L00#0000 $
290.00
A0041000 $
300.00
Parts and Materials: $
148.00
Total: $
738.00
Paint/Corrosion Claim Form
Dealer No.
400000
Repair
Order No.
910000
VIN (17-Digits)
3VWBA71K18M167634
Color No. (4-digit ElsaPro Paint No.)
LR9A
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)
5559
0003
030
030
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint trunk lid
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
55906150
130
51017153
160
9
Verify ALL Labor Operation Time Units
and Material Units
If both fenders 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)
290
9
Time
Units
Remove and Install trunk lid
55901900
70
Replace trunk lid
55905550
110
Wax body
51017500
30
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
$
108.00
Total Parts Amount
$
108.00
VW Representative
Authorization No.
Body Labor Subtotal
Total TU/MU
Authorization Date
TB 2038992
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
210
500
9
L00#0000 $
290.00
A0041000 $
210.00
Parts and Materials: $
108.00
Total: $
608.00
SRT Reference Table for TPI# 2038992
Repair (A5 Jetta) – Models(1K2)
Body Labor
Labor Operation : Remove and install
trunk lid
55 90 19 00 = 70 TU
Labor Operation : Remove and
install 2 rear lights
94 31 20 10 = 30 TU
Labor Operation : Remove and
install rear lock mechanism
55 57 19 50 = 10 TU
Labor Operation : Remove and
install rear lid trim
70 87 19 00 = 20 TU
Labor Operation : Remove and
install rear emblem
66 51 19 00 = 20 TU
Labor Operation : Remove and
install rear letterings
66 50 20 00 = 20 TU
Labor Operation : Remove
corrosion on rear lid
55 90 63 00 = * TU
Labor Operation : Wax body
51 01 75 00 = 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 73 = 160 TU
Labor Operation: Paint boot lid
55 90 79 53 = 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 boot lid
9 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
* Rear lid 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 (A5 Jetta) – Models(1K2)
Body Labor
Labor Operation : Remove and install
trunk lid
55 90 19 00 = 70 TU
Labor Operation : Replace trunk lid
55 90 55 50 = 110 TU
Labor Operation : Wax body
51 01 75 00 = 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 trunk lid
55 90 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 boot lid
9 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Repair (A4 Jetta) – Models(9M2)
Body Labor
Labor Operation : Remove and install
trunk lid
55 90 19 00 = 110 TU
Labor Operation : Remove and
install 2 rear lights
94 31 20 00 = 30 TU
Labor Operation : Remove and
install rear lock mechanism
55 57 19 50 = 10 TU
Labor Operation : Remove and
install rear lid trim
70 87 19 00 = 40 TU
Labor Operation : Remove and
install rear emblem
66 50 19 00 = 20 TU
Labor Operation : Remove and
install rear letterings
66 50 20 00 = 20 TU
Labor Operation : Remove
corrosion on rear lid
55 90 63 00 = * TU
Labor Operation : Wax body
51 01 75 00 = 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 73 = 160 TU
Labor Operation: Paint boot lid
55 90 79 53 = 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 boot lid
6 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
* Rear lid 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 (A4 Jetta) – Models(9M2)
Body Labor
Labor Operation : Remove and install
trunk lid
55 90 19 00 = 110 TU
Labor Operation : Replace trunk lid
55 90 55 50 = 90 TU
Labor Operation : Wax body
51 01 75 00 = 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 trunk lid
55 90 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 boot lid
9 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF