571409

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Passat
2006 – 2010
All
All
All
All
Passat Wagon
2006 – 2010
All
All
All
All
CC
2009 – 2012
All
All
All
All
Condition
57 14 09 December 19, 2014 2038995 Supersedes Technical Bulletin V571406 dated December 16, 2014 to
update the attachments.
Corrosion on the Front Door in Trim Strip Area
Figure 1 (the red ellipses show the area which can be affected by the corrosion)
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 9 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
Because of incomplete bonding of the trim strip (Figure 2, red circle) water can get between trim strip and door.
Because of water ingress, corrosion is possible in the area of the guide holes (Figure 1, red circles).
Figure 2 (the red circle shows the opening of the incomplete bonding)
Production Solution
Not Applicable.
Page 2 of 9 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
Service
Procedure:
1a. Repair Front Door Only perform this operation if the total repair cost is 80% or less of the total replacement
cost.
Or
1b. Replace Front Door
Step 2 should be performed whether the door was repaired or replaced.
2. Replace the Trim strip and apply butyl sealer on trim strip:
1a. Repair the front door as follows:
• Disassemble the door according to the repair manual. See Repair Group 57 in Elsa
• Remove the corrosion on the inner and outer door in the area of the guide holes.
• Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer to both sides of the door
(locally sourced).
• Repaint the front door according to Volkswagen guidelines.
Note:
If through-corrosion (perforation) is not present, door 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”).
1b. Replace the front door as follows:
• Replace the door according to the repair manual. See Repair Group 57 in Elsa.
• Paint the front door according to Volkswagen guidelines.
Step 2 should be performed whether the door was repaired or replaced.
Page 3 of 9 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
2. Replace the Trim strip and apply butyl sealer on trim strip:
• To avoid repeated water ingress, close the open areas on the trim strips in the end points of the adhesive tape
with butyl sealing cord (part number AKL 450 005 05 - Figure 3 and 4, red arrows).
Figure 3 (rear end of a trim strip)
Figure 4 (front end of a trim strip)
• Form two balls of butyl sealing cord (part number: AKL 450 005 05) per trim strip with a diameter of 4-5 mm.
Attach the butyl balls centrally in the end areas of the trim strip from the inside (Figures 5 and 6).
Figure 5 (rear trim strip area)
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© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Figure 6 (rear trim strip area)
• The open areas of the adhesive tape must be closed by pressing the butyl balls into the gaps of the tape
(Figure 7).
Figure 7 (front trim strip area)
• Install the trim strip on the door according to the repair manual. See Repair Group 66 in Elsa.
• Assemble and install the door according to the repair manual. See Repair Group 57 in Elsa.
Page 5 of 9 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
Warranty
Note:
• Dealers may complete the repair as described without prior authorization (through a WISE Warranty Repair
Acceptance request).
• Documentation required: Clear pictures, completed estimate and body shop invoice must be saved and kept on
file at the Dealership for audit purposes.
• This bulletin applies for 1 door repair or replacement. If both doors exhibit the corrosion they should be
evaluated individually and claimed on separates lines. Total Body Painting Prep Time for both doors should be
claimed on the first line only.
• Labor time units (TU), Material units (MU), and Material unit rate are correct at the time of publication. The time
units and/or material units may differ if the repair catalogue is updated. The information in the repair catalogue
applies, except for the open time items (labor operations ending in 99) which are calculated at actual time
multiplied by the body shop labor rate. The material allowance (Paint material price per unit) is subject to
change. Refer to WISE > Resource Center > Forms > Paint/Corrosion for the most current forms.
• This section is applicable for vehicles within the terms of Volkswagen’s Limited Warranty Against Corrosion
Perforation. For vehicles outside the terms of the Limited Warranty Against Corrosion Perforation this section is
for information only.
• This bulletin may be provided to outside shops to ensure the proper repair is completed.
Note:
Claim Processing Options
Option 1: Utilize the attached form examples and interactive forms on WISE to assist with calculating the
reimbursement amounts. This will expedite the claim review process and reduce the time to pay the claim.
Note that miscalculations are subject to claim adjustment.
For the complete set of pre-populated Paint/Corrosion Claim Form templates associated with this Technical
Bulletin, refer to WISE > Resource Center > Forms > Paint/Corrosion.
Option 2: Email repair estimates to [email protected]. The Paint and Corrosion Team will calculate the
warranty allowance and complete the required form(s) on behalf of the dealer.
Page 6 of 9 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
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
2006 – 2010
All
All
All
All
Passat Wagon
2006 – 2010
All
All
All
All
CC
2009 – 2012
All
All
All
All
SAGA Coding
1)
Claim Type:
160
Damage
Service Number:
HST
Damage Location
(Depends on Service No.)
--
060 or 062
Code
5751
0003
CC (357)
060 or 062
2)
Passat Sedan and Passat Wagon
(3C*)
060 or 062
2)
Parts Manufacturer
Repair
Please use the following part number in “Outside Materials”
4)
LACKMATF: Paint and Materials
MU @ $12 per unit
Epoxy Primer (Locally Sourced)
Claim Dollar Amount (MAX: $40)
Please use the following Labor Operation in “Outside Labor”
4)
Select the appropriate Labor Operation below:
- L0010000: External Painting-straight color
Claim Dollar Amount
- L0020000: External Painting-metallic/2-layer
- L0030000: External Painting-pearl color
Use this for all body repair in this bulletin:
Claim Dollar Amount
- A0041000: Body Shop repair no paint
Page 7 of 9 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
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
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 2038995” 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 8 of 9 plus attachments
© 2014 Volkswagen Group of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Volkswagen Group of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice.
No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
Technical Bulletin
Required Parts and Tools
Repair and Replace
Part number
AKL 450 005 05
Designation
Butyl sealing cord (Quantity 0.05)
One of the following
3C0 853 515 C 2ZZ
Front Left Door Trim Strip
3C0 853 516 C 2ZZ
Front Right Door Trim Strip
Replace (One of the following)
3C4 831 055 J
Front Left Door
3C4 831 056 J
Front Right Door
For Special Tools see Repair Manual.
Additional Information
All part and service references provided in this Technical Bulletin are subject to change and/or removal.
Always check with your Parts Dept. and Repair Manuals for the latest information.
Page 9 of 9 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
400000
Dealer No.
Repair
Order No.
910000
VIN (17-Digits)
XXXXXXXXXXXXXXXXX
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)
5751
0003
060
060
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint Front Door
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
57517903
110
51017133
190
9
Verify ALL Labor Operation Time Units
and Material Units
If multiple doors 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
Description of Repair
Front Door Parts removed and
40.00
Paint Subtotal
Repair/Replace Labor
Operation(s)
300
9
Time
Units
57516500
110
Repair door (Remove Corrosion)
57516300
70
Wax Body
51017500
30
Bond trim strip with butyl
66214199
10
reinstalled for painting
Example Part Qty and Part Price per Unit only
All other parts should be claimed separately in
the SAGA claim
Example Time Units
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
220
Total Paint Material Amount
$
108.00
Total TU/MU
520
Total Parts Amount
$
148.00
VW Representative
Authorization No.
Authorization Date
TB 2038995
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
9
L00#0000 $
300.00
A0041000 $
220.00
Parts and Materials: $
148.00
Total: $
668.00
Paint/Corrosion Claim Form
Dealer No.
400000
Repair
Order No.
910000
VIN (17-Digits)
XXXXXXXXXXXXXXXXX
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)
5751
0003
060
060
12.00
Dealer-owned paint shop?
Yes
Original paint material?
Yes
Description of Repair
Paint New Front Door
Paint Labor Operation(s)
No
No
Time
Units
Mat'l
Units
57516150
130
51017153
160
12
Verify ALL Labor Operation Time Units
and Material Units
If multiple doors 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
12
Time
Units
Remove and install front door
57511900
40
Replace rear door
57515550
190
Wax body
51017500
30
Bond trim strip with butyl
66214199
10
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
$
144.00
Total Parts Amount
$
144.00
VW Representative
Authorization No.
Body Labor Subtotal
Total TU/MU
Authorization Date
TB 2038995
Authorization
valid until:
Warranty
VW Representative Name (printed)
VW Representative Signature
270
560
12
L00#0000 $
290.00
A0041000 $
270.00
Parts and Materials: $
144.00
Total: $
704.00
SRT Reference Table for TPI# 2038995
Repair Front Door (B6 Passat and Wagon) – Models(3C2/3C5)
Body Labor
Labor Operation: Front Door Part
remove & reinstall for painting
Labor Operation: Repair door
(remove corrosion)
57 51 65 00 = 110 TU
57 51 63 00 = * TU
Labor Operation: Wax body
51 01 75 00 = 30 TU
Labor Operation: Bond trim strip
with butyl sealer
66 21 41 99 = 10 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 front door
57 51 79 03 = 110 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 front door
9 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
* Door replacement should be considered if the total repair cost will exceed 80% of the total replacement cost. Refer
to the Reimbursement Policy section of the Warranty Policies and Procedure Manual. This section provides
important guidelines when considering component repair vs. replacement options (the “ 80% rule” ).
Repair Front Door (CC) – Models(357)
Body Labor
Labor Operation: Remove and
install front door trim
57 51 65 00 = 90 TU
Labor Operation: Replace trim strip
for front door
66 21 55 00 = 30 TU
Labor Operation: Repair door
(remove corrosion)
57 51 63 00 = * TU
Labor Operation: Wax body
51 01 75 00 = 30 TU
Labor Operation: Bond trim strip
with butyl sealer
66 21 41 99 = 10 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 front door
57 51 79 03 = 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 front door
9 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
* Door replacement should be considered if the total repair cost will exceed 80% of the total replacement cost. Refer
to the Reimbursement Policy section of the Warranty Policies and Procedure Manual. This section provides
important guidelines when considering component repair vs. replacement options (the “ 80% rule” ).
Replace Front Door (B6 Passat and Wagon) – Models(3C2/3C5)
Body Labor
Labor Operation: Remove and install
front door
57 51 19 00 = 30 TU
Labor Operation: Replace front door
57 51 55 50 = 190 TU
Labor Operation: Wax body
51 01 75 00 = 30 TU
Labor Operation: Bond trim strip with
butyl sealer
66 21 41 99 = 10 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 New Lift gate
(Removed)
57 51 61 50= 110 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 lift gate
11 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF
Replace Front Door (CC) – Models(357)
Body Labor
Labor Operation: Remove and install
front door
57 51 19 00 = 40 TU
Labor Operation: Replace front door
57 51 55 50 = 190 TU
Labor Operation: Wax body
51 01 75 00 = 30 TU
Labor Operation: Bond trim strip with
butyl sealer
66 21 41 99 = 10 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 New Lift gate
(Removed)
57 51 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 lift gate
12 MU
Multiply claim material units x
$12.00. Enter in SAGA
under Outside Materials:
LACKMATF