601302

Technical Bulletin
Model(s)
Year
Eng. Code
Trans. Code
VIN Range From
VIN Range To
Routan
2012
All
All
All
All
Part No:
Quantity per
repair
Estimated
Part Ordering
vehicles
Note: at time of
release
Parts Description
1.
2.
Glass, Sunroof
7B0877071
1
586
Normal ordering
process
Tape, Flock/Felt
7B0867910
4
586
Normal ordering
process
Condition
60 13 02 September 19, 2013 2033728
Sunroof Opens But Will Not Close and / or Cycles Back to Open and / or Sunroof Glass Scratched
The customer may experience the sunroof opens, but will not close, and/or, cycles back to open, and/or, the outer
surface of the sunroof glass is scratched.
Note:
Please read this document in its entirety before performing repairs.
Note:
This bulletin applies to vehicles built after May 31, 2012(MDH 0531XX) and
prior to November 1, 2012 (MDH 1101XX).
Technical Background
This bulletin involves inspecting sunroof glass clearance, and if necessary, modifying the sunroof reinforcement, to
allow adequate clearance for sunroof glass travel.
Production Solution
Vehicles produced after November 1st 2012 will have improved sunroof opening dimensions.
Page 1 of 13
© 2013 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:
Step 1
Adjust sunroof panel flushness along the front of the glass (1) & (2) to 2mm under flush. Adjust the rear of the
sunroof glass panel (3) & (4) to zero/flush (Fig. 1).
Refer to ElsaWeb Body > Body exterior > 60 – Sunroof > General Information > Sunroof Glass Adjustments
Passenger Side Front Panel Flushness
(Adjust to 2mm Under flush)
Driver Side Front Panel Flushness
(Adjust to 2mm Under flush)
Driver Side Rear Panel Flushness
(Adjust to 0mm-Flush)
Passenger Side Rear Panel Flushness
(Adjust to 0mm-Flush)
Fig. 1 Sunroof overview
Note:
Once the proper glass position has been achieved, tighten the six glass panel attaching
screws to 3.5 Nm (31 in. lbs.).
Page 2 of 13
© 2013 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
Step 2
To protect the Sunroof Glass panel for scratching during the inspection apply two pieces of felt/flock tape
(7B0.867.910) to each side of the sunroof glass panel. Apply the tape end to end along the side edge of the
sunroof glass panel starting at the end of the rear corner radius running forward (see red marked areas in Fig.2).
Fig. 2 Applying protection Tape
Page 3 of 13
© 2013 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
Step 3
Cycle the sunroof panel to the full open position and use a 2mm feeler gage (1) to check left and right sunroof
glass (3) to inner sheet metal reinforcement (4) gap. Use a flashlight to locate the lowest point between the sheet
metal reinforcement (4) and sunroof glass (3) (Fig. 3).
1 - Feeler Gage (2mm-taped to extension
device)
2 - Lock Out Tool/”Slim Jim” (or equivalent
device)
3 - Sunroof Glass Panel
4 - Sheet Metal Reinforcement (inner sunroof
structure shown)
5 - Sunroof opening (rear passenger corner
shown)
Fig. 3 Inspect gap between sunroof glass and roof
reinforcement.
Is the clearance between the inner sunroof sheet metal reinforcement and sunroof glass 2mm or greater?
Yes >>> This bulletin does not apply, further diagnosis required.
No >>> Cycle the sunroof to the fully closed position and remove the felt/flock tape.
Proceed to Step 4.
Page 4 of 13
© 2013 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
Step 4
Remove the sunroof module assembly. Refer to the detailed procedures available in ElsaWeb: Body > Body
exterior > 60 – Sunroof > Removal and installation > Sunroof
Concerned Area (driver side) is
shown in Fig. 4.
Fig. 4 Concerned Area
Page 5 of 13
© 2013 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
C-4150A mini ball joint press.
Alternative T10187
Step 5
Page 6 of 13
© 2013 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
Using a backer plate or heavy (3/8”/10mm minimum thickness) cardboard to protect and disburse any pressure
applied against the outer roof sheet metal, insert the C-4150A ball joint press/special tool (1) into the low hanging
sunroof reinforcement feature (Fig. 5).
WARNING:
A backer plate must be used to protect the exterior roof sheet metal panel from deformation and
evenly disburse any pressure placed on the exterior roof panel. Failure to do so will result in
damage to the outer roof panel as the raised center of the reinforcement will contact the outer
panel creating a dimple or dent from focused pressure at the point of contact.
Step 6
Insert a 30mm socket or equivalent (2), between the sunroof reinforcement (3) and spindle of the C-4150A ball
joint press/special tool (1), to take up space between the frame and spindle of the press.
Carefully tighten the spindle of the press to compress the center of the sunroof reinforcement upward (Fig. 5/6).
C-4150A Ball Joint Press
1 - Backer Plate (scrap metal shown) or 3/8
(10mm) cardboard
2 - C-4150A Ball Joint Press/Special Tool
3 - Socket (30mm shown)
4 – Sunroof Reinforcement (low hanging
features shown)
5 – Ratchet
6 – Sunroof Opening (view from inside vehicle)
Fig. 5 Modify Using Special Tool
Page 7 of 13
© 2013 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
Alternative T10187
1 - Backer Plate (scrap metal shown) or 3/8
(10mm) cardboard.
2 - T10187 / Special Tool
3 - Socket (30mm shown) or equivalent
4 - Roof Reinforcement
Fig. 6 Modify Using Special Tool
Step 7
Using a backer plate or heavy (3/8”/10mm minimum thickness) cardboard to protect and disburse any pressure
applied against the outer roof sheet metal, carefully push the remaining left and right side of the low hanging
sunroof reinforcement feature upward using a hammer handle or equivalent blunt tool to provide additional
clearance. (Fig 7)
WARNING:
A backer plate must be used to protect the exterior roof sheet metal panel from deformation and
evenly disburse any pressure placed on the exterior roof panel. Failure to do so will result in
damage to the outer roof panel, as the raised center of the reinforcement will contact the outer
panel creating a dimple or dent from focused pressure at the point of contact.
1 – Backer Plate (scrap metal shown)
2 – Left and Right side (sunroof
reinforcement to be modified)
3 – Blunt Tool (Hammer handle shown)
Fig. 7 Verify Modification
Page 8 of 13
© 2013 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
Step 8
Using an index card or folder stock, create a verification gage (4) that will ensure the proper clearance is achieved
as a result of modifying the sunroof reinforcement. The gage should measure 13.5mm down from the outer roof
panel and 30mm inward from the outer edge of the sunroof reinforcement. Move the verification gage back and
forth along this area to ensure proper clearance is achieved (Fig. 8).
Note:
Repeat the modification procedure for the opposite side of the vehicle or on existing side until desired clearance is
achieved.
4 – Verification Gage (desired clearance
shown)
Fig. 8
Fig. 8 Before and After
Page 9 of 13
© 2013 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
Step 9
Reinstall the sunroof module. Refer to the detailed procedures available in ElsaWeb: Body > Body exterior > 60
– Sunroof > Removal and installation
Step 10
If the glass panel is scratched please replace the sunroof glass panel (7B0.877.071). Refer to the detailed
procedures available in ElsaWeb: Body > Body exterior > 60 – Sunroof > Removal and installation
Note:
Adjust sunroof glass to fit flush with the roof line. (Refer to ElsaWeb: Body - Body/Exterior - 60 - Sunroof –
Removal and installation – Sunroof – Sunroof Glass Adjustments).
Page 10 of 13
© 2013 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
All Routan pre and post road test and StarMOBILE time units are included in the labor operation. Therefore, no
road test time units will appear in the designated area within the warranty table.
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
Routan
2012
All
All
All
All
SAGA Coding
Claim Type:
Use applicable Claim Type
1)
Damage
HST
Damage Location (Depends
on Service No.)
CWM2033728
Use applicable when
indicated in ElsaWeb (L/R)
Service Number:
Code
6040
0017
Parts Manufacturer
Routan
3)
Labor Operation :
USM
60400199 = 30 TU
Inspect Sunroof Glass Clearance Only
OR
3)
Labor Operation :
60404199 = 290 TU
Inspect and Repair Sunroof Support Flange
OR
3)
Labor Operation :
60405599 = 320 TU
Inspect and Repair Sunroof Support Flange and
Replace Sunroof Glass
Causal Part: Select Labor
6040****
Diagnostic Time
4)
Page 11 of 13
© 2013 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
GFF Time expenditure
01500000 = 00 TU max.
NO
Road Test
01210002 = 00 TU
NO
01210004 = 00 TU
Technical Diagnosis
01320000 = 00 TU max.
NO
Claim Comment: Input “As per Technical Bulletin 2033728” in comment section of Warranty Claim.
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 Policy Procedures Manual.
Required Parts and Tools
Parts Description
Part No:
Quantity per repair
Glass, Sunroof
7B0877071
1
Tape, Flock/Felt
7B0867910
4
Tool Description
Tool No:
Press, Ball Joint
C-4150A (Routan Tool Package)
Press, Ball Joint (Alternative)
T10187 Special Tool
Feeler Gage (2mm)
NN
30mm Socket or Equivalent
NN
Lock Out Tool/“Slim Jim“ or equivalent
NN
Backing Plate or Equivalent (Approximate
Dimension = Length-150mm x Width50mmxDepth/Thickness-2mm)
NN
Page 12 of 13
© 2013 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.
Page 13 of 13
© 2013 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.