Technical Bulletin
Model(s)

Year

Eng. Code

Trans. Code

VIN Range From

VIN Range To

Phaeton

2004 –2006

All

All

All

All

Condition
58 16 02 June 13, 2016 2039211 Supersedes Technical Bulletin V581502 dated July 21, 2015 to update Claim
Processing statement.
Corrosion on Rear Doors (Multiple Locations)

Outer door areas (Figure 1-4):

Figure 1 – Upper window channel strip

Figure 1.1

Figure 2 – Central protective strip

Figure 2.1

Page 1 of 12 Plus attachment
© 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

Figure 3 – Lower protective strip

Figure 3.1

Figure 4 – Surface/edge corrosion

Figure 4.1

Inner door area (Figure 5).
Holes and edges in the flange area

Figure 5

Page 2 of 12 Plus attachment
© 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
Alignments in production can lead to hairline cracks in the top coat and paint damage (edges on holes) on the
already painted door. Humidity then penetrates paint and causes blistering and/or white corrosion.

Production Solution
Corrections in the production process after discovering deviations.

Page 3 of 12 Plus attachment
© 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:
A. Repair rear door Only perform this operation if the total repair cost is 80% or less of the total replacement
cost.
or
B. Replace rear door
Steps 1 and 2 should be completed regardless of repair or replacement of the door.
1. Central protective strip
2. Lower protective strip
Note
 In most cases the protective strips are damaged when they are removed. Order, and as necessary,
paint the required parts before the repair.
 Inspect the outer and inner doors in the visible area for further paint bubbles. As necessary repair
according to Volkswagen guidelines.
 Inspect the fine seam sealing in the inner edge area of the doors for cracks, and as necessary, repair
according to Volkswagen guidelines.

A. Repair the rear door as follows:
 Disassemble the door according to the repair manual. See Repair Group 58 in Elsa
If the affected area is only lightly corroded (no through-corrosion), proceed as follows:
 Inspect the inner edge area of the doors for cracks, particularly the fine seam sealing.
 Completely remove the corrosion in the damaged area.
 Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer to both sides of the door
(locally sourced).
 Seal the edges/metal sheathings with adhesive (part number: AKD 476 KD505) before painting.


Repaint door according to Volkswagen guidelines

B. Replace the rear door as follows:
 Replace the door according to the repair manual. See Repair Group 58 in Elsa.
 Paint new door according to Volkswagen guidelines.

Page 4 of 12 Plus attachment
© 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
Steps 1 and 2 should be completed regardless of repair or replacement of the door.
1. Central protective strip
 Before installing the side protective strip, attach from outside, and only on the front and rear holes/elongated
hole (Figure 6 and 7, red arrows), a trim protective foil (part number: AKL 448 030 05) or similar as additional
anti-chafing protection.

Figure 6

Figure 7: (example)

Page 5 of 12 Plus attachment
© 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
 Before installing the side protective strip, adhere (press) the foil around the hole lightly (e.g. with a ball pen,
illustration 8).
Note
Make sure that the painted edges do not get damaged when attaching the foil.

Figure 8: (example)

2. Lower protective strip
 Before installing the lower protective strip, attach on every front and rear hole (Figure 9, red arrows) from
outside, trim protective foil (part number: AKL 448 030 05) as additional anti-chafing protection.

Figure 9
 Before installing the protective strip adhere (press) the foil around the hole lightly.

Page 6 of 12 Plus attachment
© 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
 Attach new and loose plastic adjustment screws (Figure 10, red circle) with locking compound (part number: D
185 410 A2).

Figure 10: (example)
 Adjust the protective strip (according to the repair manual) within the hardening time of the locking compound
(part number: D 185 410 A2).

Page 7 of 12 Plus attachment
© 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 multiple 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 8 of 12 Plus attachment
© 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

Phaeton

2004-2006

All

All

All

All

SAGA Coding
Claim Type:

1601)
Damage

Service Number:

Code

5829

0003

Parts Manufacturer

HST

Damage Location
(Depends on Service No.)

--

160 or 162

Phaeton (3D8)

160 or 1622)

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
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)
Page 9 of 12 Plus attachment
© 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
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:

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 2039211” 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_ref_table.pdf” for labor time reference.

Page 10 of 12 Plus attachment
© 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

Designation

AKD 476 KD505

Polyurethane adhesive sealant – Quantity: 0.25

AKL 448 030 05

Protective Foil

D 185 410 A2

Liquid locking fluid (Compound) – Quantity: 0.25
One of the following

3D7 853 073 B GRU

Rear Left Side Protective Strip

3D7 853 074 B GRU

Rear Right Side Protective Strip

3D7 854 949 A V7S

Rear Left Lower Protective Strip (Cover for door)

3D7 854 950 A V7S

Rear Right Lower Protective Strip (Cover for door)
Replace (One of the following)

3D7 833 051 F

Rear Left Door

3D7 833 052 F

Rear Right Door

For Special Tools see Repair Manual.

Page 11 of 12 Plus attachment
© 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

2039211/4

6/13/16

V581602

To update Claim
Processing statement.

2039211/3

7/21/15

V581502

To update service number.

2039211/1

12/18/14

V581404

Original publication.

Page 12 of 12 Plus attachment
© 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)

WVWZZZ3DZA6000000

Color No. (4-digit ElsaWeb Paint No.)

LB5N
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