V551611_2038993
Service Bulletin Details
Public Details for: V551611_2038993
Original version accidently archived 8/9/19. Recreate exact content in new format and republish, as warranty policy still relevant to applicable later model years.
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Technical Service Bulletin 55-16-11 - Corrosion on Rear Lid at Rear Window Area Transaction No: 2038993/7 Release date: 8/14/2019 Condition Applicable Vehicles Model(s) Year Eng. Code Trans. Code VIN Range From VIN Range To Passat Wagon 1998 - 2010 All All All All Revision Table Instance Number Published Date Version Number Reason For Update 2038993/7 8/14/19 55-16-11 Incorrect archiving 8/9/19. 2038993/1 12/16/14 V551407 Original publication. Figure 1 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. Page 1 of 6 plus attachments © 2019 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 Service Bulletin 55-16-11 - Corrosion on Rear Lid at Rear Window Area Transaction No: 2038993/7 Release date: 8/14/2019 Technical Background When the rear window heater is switched ON, power is transmitted to the outer sealing lip of the rear window. In some places the window sealer makes contact with the bus bar of the rear window heater. Production Solution Not applicable. Service 1a. Repair rear lid and replace rear window Only perform this operation if the total repair cost is 80% or less of the total replacement cost. Or 1b. replace rear lid and replace rear window Note: If the rear lid is rusted through, do not repair, replace with a new part. Install a new rear glass in every case, since the complete removal of the sealer from the bus bar cannot be guaranteed. Use sealer part number DH 009 100 03 or DA 004 600 A2 - for sealing the window. To avoid repeat cases make sure that no sealer gets on the bus bar of the rear window. Cover the bus bar with masking tape during installation and remove the tape after sealing. 1a. Repair the rear lid, replace rear window: Remove the rear window according to the repair manual. See repair group 64 in Elsa Remove the corrosion on the outer rear lid with the 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”). Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer (locally sourced). Re-paint the rear lid according to Volkswagen guidelines. Install the new rear window glass according to the repair manual. See repair group 64 in Elsa. 1b. Rear lid and rear window replacement: Remove all necessary parts / trim pieces of the original rear lid. See Repair Group 70 and Repair Group 55 in Elsa. Paint the new rear lid according to the Volkswagen guidelines. Remove the original rear lid. See Repair Group 55 in Elsa. Page 2 of 6 plus attachments © 2019 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 Service Bulletin 55-16-11 - Corrosion on Rear Lid at Rear Window Area Transaction No: 2038993/7 Release date: 8/14/2019 Install the new rear lid. See Repair Group 55 in Elsa. Install the new rear window glass according to the repair manual. See repair group 64 in Elsa. Install all remaining parts / trim pieces previously removed. See Repair Group 70 and Repair Group 55 in Elsa. Adjust the rear lid fit according to the repair manual. See Repair Group 55 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. Page 3 of 6 plus attachments © 2019 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 Service Bulletin Transaction No: 2038993/7 Release date: 8/14/2019 55-16-11 - Corrosion on Rear Lid at Rear Window Area 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 Passat Wagon 1998 – 2010 All All All All SAGA Coding 1601) Claim Type: Damage Service Number: HST Damage Location (Depends on Service No.) -- 030 Code 5559 0003 Parts Manufacturer Passat Wagon (3B5,3B6,3C5) 0302) 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: - A0041000: Body Shop repair no paint Claim Dollar Amount - A0061000: Glass Replacement Replace Please use the following part number in “Outside Materials” 4) Select the appropriate Labor Operation below: Claim Dollar Amount - L0010000: External Painting-straight color Page 4 of 6 plus attachments © 2019 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 Service Bulletin 55-16-11 - Corrosion on Rear Lid at Rear Window Area Transaction No: 2038993/7 Release date: 8/14/2019 - L0020000: External Painting-metallic/2-layer - L0030000: External Painting-pearl color Use this for all body repair in this bulletin: - A0041000: Body Shop repair no paint Claim Dollar Amount - A0061000: Glass Replacement Causal Part: L00#0000 Diagnostic Time 4) GFF Time expenditure 01500000 = 00 TU max. Road Test 01210002 = 00 TU NO NO 01210004 = 00 TU Technical Diagnosis 01320000 = 00 TU max. NO Claim Comment: Input “As per Technical Bulletin 2038993” 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_reference_table.pdf” for labor time reference. Page 5 of 6 plus attachments © 2019 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 Service Bulletin 55-16-11 - Corrosion on Rear Lid at Rear Window Area Transaction No: 2038993/7 Release date: 8/14/2019 Required Parts and Tools Lift Gate Repair and Rear Windshield Replacement (Only one of the Rear Window Parts Below) See ETKA for proper application. Part number Part Description Quantity 3B9 845 051 E Rear Window Glass Heating (B5) 1 3C9 845 051 P Rear Window Glass Heating (B6) 1 D 004 660 M2 2K Glass Glue Application Set 1 Lift Gate Repair and Rear Windshield Replacement (Use parts above plus one of the following) See ETKA for proper application. 3B9 827 025 AR Lift Gate (rear trunk lid) (B5) 1 3C9 827 025 D/M/K Lift Gate (rear trunk lid) (B6) 1 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. Page 6 of 6 plus attachments © 2019 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) If repeat repair, provide explanation in box below: WVWPD63BX4E000000 Color No. (4-digit ElsaPro Paint No.) LA7W Dealer Labor Rate 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 lift gate Paint Labor Operation(s) No No Time Units Mat'l Units 55597963 160 51017173 160 9 Verify ALL Labor Operation Time Units and Material Units 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 64865510 190 Remove and install lift gate 55591910 90 Remove and install rear lock mechanism 55571960 10 Remove and install rear logo 66511900 20 Remove and install rear letterings 66501900 20 Remove corrosion on rear lid 55596300 60 Wax body 51017500 30 Example Time Units Part Amount Subtotal $ 40.00 Body Labor Subtotal 420 $ 108.00 Total TU/MU 740 Total Parts Amount $ 148.00 Authorization Date TB 2038993 L00#0000 $ A0041000 & A006100 Authorization valid until: Warranty VW Representative Name (printed) 9 Time Units Total Paint Material Amount VW Representative Authorization No. Repair/Replace Labor Operation(s) 320 Replace the rear window 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 9 320.00 $ 420.00 Parts and Materials: $ 148.00 Total: $ 888.00 Paint/Corrosion Claim Form Dealer No. 400000 Repair Order No. 910000 VIN (17-Digits) WVWPD63BX4E000000 Color No. (4-digit ElsaPro Paint No.) LA7W 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 lift gate Paint Labor Operation(s) No No Time Units Mat'l Units 55596160 130 51017153 160 10 Verify ALL Labor Operation Time Units and Material Units 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 10 Time Units Remove and install lift gate 55591910 90 Replace lift gate 55595560 250 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 $ 120.00 Total Parts Amount $ 120.00 VW Representative Authorization No. Body Labor Subtotal Total TU/MU Authorization Date TB 2038993 Authorization valid until: Warranty VW Representative Name (printed) VW Representative Signature 370 660 10 L00#0000 $ 290.00 A0041000 & A006100 $ 370.00 Parts and Materials: $ 120.00 Total: $ 780.00 SRT Reference Table for TPI# 2038993 Repair (Passat Wagon) – Model (3B6) 2001-2006 Body Labor Labor Operation : Replace the rear window 64 86 55 10 = 190 TU Labor Operation : Remove and install lift gate 55 59 19 10= 90 TU Labor Operation : Remove and install rear lock mechanism 55 57 19 60 = 10 TU Labor Operation : Remove and install rear logo 66511900 = 20 TU Labor Operation : Remove and install rear lettering 66 50 19 00 = 20 TU Labor Operation : Remove corrosion on lift gate 55596300= * 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: A0061000 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 lift gate 55 59 79 63 = 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 boot lid 9 MU Multiply claim material units x $12.00. Enter in SAGA under Outside Materials: LACKMATF * Lift gate 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 (Passat Wagon) – Model(3B6) 2001-2006 Body Labor Labor Operation : Remove and install lift gate 55 59 19 10 = 90 TU Labor Operation : Replace lift gate 55 59 55 60 = 250 TU Labor Operation : Wax body 51 01 75 00 = 30 TU Refinish Labor Labor Operation: Prepare painting 51 01 71 53 = 160 TU Labor Operation: Paint lift gate 55596160 = 130 TU Multiply claim time units x warranty labor rate. Enter in SAGA under Outside Labor Operation: A0041000 Glass replacement: Subtract total glass replacement cost from total above. Enter in SAGA under Outside Labor Operation: A0061000 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 lift gate 10 MU Multiply claim material units x $12.00. Enter in SAGA under Outside Materials: LACKMATF SRT Reference Table for TPI# 2038993 Repair (B5 Passat Wagen) – Model(3B5) 1998-2001 Body Labor Labor Operation : Replace the rear window 64 86 55 10 = 190 TU Labor Operation : Remove and install lift gate 55 59 19 10= 90 TU Labor Operation : Remove and install rear lock mechanism 55 57 19 60 = 10 TU Labor Operation : Remove and install rear logo 66 51 19 00 = 20 TU Labor Operation : Remove and install rear lettering 66 50 19 00 = 20 TU Labor Operation : Remove corrosion on lift gate 55 59 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: A0061000 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 lift gate 55 59 79 63 = 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 boot lid 9 MU Multiply claim material units x $12.00. Enter in SAGA under Outside Materials: LACKMATF * Lift gate 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 (B5 Passat Wagen) – Model(3B5) 1998-2001 Body Labor Labor Operation : Remove and install lift gate 55 59 19 10 = 90 TU Labor Operation : Replace lift gate 55 59 55 60 = 250 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 Glass replacement: Subtract total glass replacement cost from total above. Enter in SAGA under Outside Labor Operation: A0061000 Refinish Labor Labor Operation: Prepare painting 51 01 71 53 = 160 TU Labor Operation: Paint lift gate 55 59 61 60 = 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 lift gate 10 MU Multiply claim material units x $12.00. Enter in SAGA under Outside Materials: LACKMATF Repair (B6 Passat Wagen) – Model(3C5) 2006-2010 Body Labor Labor Operation : Replace the rear window 64 86 55 10 = 190 TU Labor Operation : Remove and install lift gate 55 59 19 00= 130 TU Labor Operation : Remove and install rear lock mechanism 55 57 19 60 = 10 TU Labor Operation : Remove and install rear logo 66 51 19 00 = 20 TU Labor Operation : Remove and install rear lettering 66 50 19 00 = 20 TU Labor Operation : Remove corrosion on lift gate 55 59 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: A0061000 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 lift gate 55 59 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 * Lift gate 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 (B6 Passat Wagen) – Model(3C5) 2006-2010 Body Labor Labor Operation : Remove and install lift gate 55 59 19 00 = 130 TU Labor Operation : Replace lift gate 55 59 55 50 = 220 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 Glass replacement: Subtract total glass replacement cost from total above. Enter in SAGA under Outside Labor Operation: A0061000 Refinish Labor Labor Operation: Prepare painting 51 01 71 53 = 160 TU Labor Operation: Paint lift gate 55 59 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 lift gate 13 MU Multiply claim material units x $12.00. Enter in SAGA under Outside Materials: LACKMATF