TB501401

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Passat Sedan
2001-2010
All
All
All
All
Passat Wagon
2001-2010
All
All
All
All
Condition
50 14 01 November 24, 2014 2038981
Front Fender - Corrosion on Wheel Arch
Customer states:
Corrosion on the wheel arch area of the front fender (Figure 1).
Figure 1 (corrosion on left wheel arch)
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
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Technical Background
The wheel liner touches the arch area of the fender and rubs off the paint in the contact area.
The corrosion is caused by dirt accumulations and movements of the wheel liner.
Production Solution
No production change required.
Service
1. Repair the fender: If the edge area is only slightly corroded (no through-corrosion/perforation), proceed
as follows:
• Remove the front bumper according to the repair manual. See Repair Manual Group 63 in Elsa.
• Remove the side indicator (in fender, if equipped) according to the repair manual. See Repair Manual Group
94 in Elsa.
• Remove the front wheel liner according to the repair manual. See Repair Manual Group 66 in Elsa.
• Remove the corrosion with the pneumatic brush grinder VAS 6446.
• Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer (locally sourced).
• On the inner fender apply (in the complete contact/edge area) adhesive/sealer (part number: D 511 500 A2) as
further edge protection (Figure 2, green line).
Figure 2
• Restore the paint structure according to the paint repair manual.
• Install the wheel liner according to the repair manual. See Repair Manual Group 66 in Elsa.
Page 2 of 6 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
Note:
When installing the wheel liner, make sure it doesn’t touch the edge of the fender. As necessary, align the liner.
• Install the side indicator (in fender, if equipped) according to the repair manual. See Repair Manual Group 94 in
Elsa.
• Install the front bumper cover according to the repair manual. See Repair Manual Group 63 in Elsa.
2. Replace the fender
• Replace the fender according to the repair manual. See Repair Manual Group 50 in Elsa.
• Apply polyurethane adhesive (part number: AKD 476 KD5 05) on the inner fender (in the complete contact and
edge area) as further edge protection (Figure 2, green line).
Note:
When installing the wheel liner make sure it doesn’t touch the edge of the wing. As necessary, align the liner.
If through-corrosion (perforation) is not present, fender 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”).
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 front fender repair or replacement. If both sides exhibit the corrosion they should be
evaluated individually and claimed on separates lines. Total Body Painting Prep Time for both front fenders
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.
Page 3 of 6 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
Note:
Claim Processing Options
Option 1: 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.
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.
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
Passat Sedan
2001-2010
All
All
All
All
Passat Wagon
2001-2010
All
All
All
All
SAGA Coding
1)
Claim Type:
160
HST
Damage Location
(Depends on Service
No.)
--
040 or 041
Damage
Service Number:
Code
5055
0003
Parts Manufacturer
2)
Passat Sedan and Passat Wagon
(3B*)
040 or 041
Passat Sedan and Passat Wagon
(3C*)
040 or 041
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)
Page 4 of 6 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
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)
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
GFF Time expenditure
01500000 = 00 TU max.
Road Test
01210002 = 00 TU
4)
NO
NO
01210004 = 00 TU
Technical Diagnosis
01320000 = 00 TU
NO
Claim Comment: Input “As per Technical Bulletin 2038981” 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.
Page 5 of 6 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
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.
Required Parts and Tools
Part Number
Designation
Quantity
Repair
D 511 500 A2
adhesive/sealer
0.5
Replace
AKD 476 KD5 05
polyurethane adhesive
0.5
One of the following
3B0 821 105 E
Fender (Left) – B5 Passat and
Wagon
-
3B0 821 106 E
Fender (Right) – B5 Passat and
Wagon
-
3C0 821 021
Fender (Left) – B6 Passat and
Wagon
-
3C0 821 022
Fender (Right) – B6 Passat and
Wagon
-
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.
Page 6 of 6 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.
Paint/Corrosion Claim Form
Dealer No.
400000
Repair
Order No.
910000
VIN (17-Digits)
WVWJK93CX8P089569
Color No. (4-digit ElsaPro Paint No.)
LB9A
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)
5055
0003
040
040
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint one Front Fender
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
50556150
70
51017153
160
5
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)
230
5
Time
Units
Remove and install front bumper cover
63291900
90
Remove and install front fender
50551950
70
Seal off Fender (PU adhesive)
50555199
30
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
$
60.00
Total Parts Amount
$
60.00
VW Representative
Authorization No.
Body Labor Subtotal
Authorization Date
TB 2038981
Authorization
valid until:
VW Representative Name (printed)
220
Total TU/MU
VW Representative Signature
450
5
L00X0000
$
230.00
A0041000
$
220.00
Parts and Materials:
$
60.00
Total:
$
510.00
Paint/Corrosion Claim Form
400000
Dealer No.
Repair
Order No.
910000
VIN (17-Digits)
If repeat repair, provide explanation in box below:
WVWND63BX3E460509
Color No. (4-digit ElsaPro Paint No.)
LC9X
Dealer Labor Rate
100.00
Paint material price per unit
Service No.
Damage
Code
Dmg
Loc
Part manufacturer
(Vendor Code)
5055
0003
040
040
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint one Front Fender
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
50557903
90
51017133
190
4
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
Epoxy Primer
Part Price
per Unit
1 $
Total Part
Price
40.00
Example Part Qty and Part Price per Unit only
Description of Repair
Paint Subtotal
Repair/Replace Labor
Operation(s)
280
5
Time
Units
Remove and install front bumper cover
63291900
90
Remove and install signal on fender
94521999
10
Remove rust from one door fold
50554199
30
Seal off Fender (PU adhesive)
50555199
30
Wax Body
51017500
30
and seal off
All other parts should be claimed separately 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
Body Labor Subtotal
190
Total Paint Material Amount
$
60.00
Total TU/MU
470
Total Parts Amount
$
100.00
VW Representative
Authorization No.
Authorization Date
TB 2038981
Authorization
valid until:
VW Representative Name (printed)
VW Representative Signature
L00X0000 $
5
280.00
A0041000 $
190.00
Parts and Materials: $
100.00
Total: $
570.00
SRT Reference Table for TPI# 2038981
Repair Fender (B5 Passat and Passat Wagon) - (Model 3B*)
Body Labor
Labor Operation : Remove and install
front bumper cover
63 29 19 00= 90 TU
Labor Operation : Remove and
install signal on fender
94 52 19 99 = 10 TU
Labor Operation : Remove rust from
one door fold and seal off
50 55 41 99 = 30 TU
Labor Operation : Seal off Fender
(PU adhesive)
50 55 51 99 = 30 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 33 = 190 TU
Labor Operation: Paint one front fender
50 55 79 03 = 90 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front fender
4 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Replace Fender (B5 Passat and Passat Wagon) - (Model 3B*)
Body Labor
Labor Operation : Remove and install
front bumper cover
63 29 19 00= 90 TU
Labor Operation : Remove and
install signal on fender
94 52 19 99 = 10 TU
Labor Operation : Remove and
install front fender
50 55 19 50 = 90 TU
Labor Operation : Seal off Fender
(PU adhesive)
50 55 51 99 = 30 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 one front fender
50 55 61 50 = 70 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front fender
5 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Repair Fender (B6 Passat and Passat Wagon) - (Model 3C*)
Body Labor
Labor Operation : Remove and install
front bumper cover
63 29 19 00= 90 TU
Labor Operation : Remove rust from
one door fold and seal off
50 55 41 99 = 30 TU
Labor Operation : Seal off Fender
(PU adhesive)
50 55 51 50 = 30 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 33 = 190 TU
Labor Operation: Paint one front fender
50 55 79 03 = 90 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front fender
4 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Replace Fender (B6 Passat and Passat Wagon) - (Model 3C*)
Body Labor
Labor Operation : Remove and install
front bumper cover
63 29 19 00 = 90 TU
Labor Operation : Remove and
install front fender
50 55 19 50 = 70 TU
Labor Operation : Seal off Fender
(PU adhesive)
50 55 51 50 = 30 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 33 = 160 TU
Labor Operation: Paint one front fender
50 55 61 50 = 70 TU
Multiply claim time units x
warranty labor rate. Enter
in SAGA under Outside
Labor Operation:
L00#0000*
*Please see warranty table for
proper labor operation
Outside Materials
Labor Operation: Paint one front fender
5 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF