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 16 08 December 5, 2016 2038995 Supersedes Technical Bulletin V571607 dated June 13, 2016 to update
Required Parts Table.
Corrosion on the Front Door in Trim Strip Area

Figure 1 (the red ellipses show the area which can be affected by the 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
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
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 11
© 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
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 11
© 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
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)

Page 4 of 11
© 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
 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)

Figure 6 (rear trim strip area)

Page 5 of 11
© 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
 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 6 of 11
© 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
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
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 paintcamp@vw.com. 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 7 of 11
© 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

Passat

2006 – 2010

All

All

All

All

Passat Wagon

2006 – 2010

All

All

All

All

CC

2009 – 2012

All

All

All

All

SAGA Coding
Claim Type:

1601)
Damage

Service Number:

Code

5729

0003

HST

Damage Location
(Depends on Service No.)

--

060 or 062

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
- 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

Page 8 of 11
© 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
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)
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 9 of 11
© 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
Repair and Replace
Part number
AKL 450 005 05

Designation
Butyl sealing cord (Quantity 0.05)
Passat (One of the following)

3C0 853 515 C 2ZZ

Front Left Door Trim Strip

3C0 853 516 C 2ZZ

Front Right Door Trim Strip
CC (One of the following)

3C8 853 071 B 2ZZ

Front Left Door Trim Strip

3C8 853 072 B 2ZZ

Front Right Door Trim Strip
Replace
Passat (One of the following)

3C4 831 055 J

Front Left Door

3C4 831 056 J

Front Right Door
Passat (Additional Required Parts, One of the following)

3C4 837 701 D 5AP

Front Left Outer Door Seal

3C4 837 702 D 5AP

Front Right Outer Door Seal
CC (One of the following)

3C8 831 055 H

Front Left Door

3C8 831 056 H

Front Right Door
CC (Additional Required Parts, One of the following)

3C8 837 701 B 5AP

Front Left or Right Outer Door Seal

For Special Tools see Repair Manual.

Page 10 of 11
© 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

2038995/5

12/5/16

V571608

To Update Req. Parts
Table.

2038995/1

12/16/14

V571406

Original publication.

Page 11 of 11
© 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)

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)

5729

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