Technical Bulletin
Model(s)

Year

Eng. Code

Trans. Code

VIN Range From

VIN Range To

Passat Wagon
(B5)

1998-2001

All

All

All

All

Passat Wagon
(B5.5)

2001-2005

All

All

All

All

Passat Wagon
(B6)

2007-2010

All

All

All

All

Condition
51 16 02 June 7, 2016 2039000 Supersedes Technical Bulletin V511403 dated December 16, 2014 to update
Claim Processing statement.
Corrosion on the Roof in the Area of the Roof Rails
Corrosion on the roof (in the contact area of roof rail/roof rail base) - Figures 1 and 2.

Figure 1 (corrosion on the roof – B5/5.5 Passat shown)

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Technical Bulletin

Figure 2 (corrosion around the roof openings – B6 Passat shown)
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
Paint abrasion on the roof from contact and relative movement of the roof rail (Figure 1).
Humidity is absorbed into the seals on the roof rail base, this leads to corrosion in the roof openings / surface
(Figure 2).

Production Solution
Corrections in the production process after discovering deviations.

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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:
Repair the roof only.

Repair the roof:
Follow next steps according to vehicle model year / chassis type

1998-2005 Passat Wagon 3B5, 3B6 (B5/5.5):
 Before removing the roof rails, visually check if the roof rail base is contacting the roof in the affected areas.
 Remove the roof rails. See Repair Group 66 in Elsa.
 Remove the corrosion with a pneumatic brush grinder. Make sure that the edges of the roof do not get
damaged.
 Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer (locally sourced).
 Re-paint the roof according to the Volkswagen guidelines.
Note:
DO NOT replace the roof rails for this concern.
If the roof rail base was contacting the roof, the following step must be performed:
 Before installing the roof rail, increase the gap of the roof rails to the roof by installing a washer (Figure 3, red
arrow 1), part number: WHT 000 808 over the threaded pin.

Figure 3
 Remove the seals on the roof rail bases (left and right roof rails) and replace them with a new sealing kit (part
number: 3B9 860 151).
 Re-install the roof rails. See Repair Group 66 in Elsa.
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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
2007-2010 Passat Wagon 3C5 (B6):
 Before removing the roof rails check for movement / free play in the rails.
 Remove the roof rails. See Repair Group 66 in Elsa.
 Remove the corrosion with a pneumatic brush grinder. Make sure that the edges of the roof do not get
damaged.
 Apply a VOC compliant epoxy primer as an anti-corrosion treatment and primer (locally sourced).
 Re-paint the roof according to the Volkswagen guidelines.
 Remove the seals on the roof rail bases (left and right roof rails) and replace them with a new sealing kit (part
number: 3C9 860 151 - Figure 4, Number 1).

Figure 4

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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
 Re-install the roof rails. See Repair Group 66 in Elsa.
Note:
DO NOT replace the roof rails for this concern.
If the roof rails were loose, check and if necessary adjust and tighten the support bracket (Figure 5,
Number 1). See Repair Group 66 in Elsa.

Figure 5

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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.
 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.

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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 Wagon

1998-2010

All

All

All

All

SAGA Coding
1601)

Claim Type:

Damage

Service Number:

Code

5103

0003

Parts Manufacturer

HST

Damage Location
(Depends on Service No.)

--

010

Passat Wagon (3B5, 3B6, 3C5)

010 2)

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:

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
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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 Diagnosis

01320000 = 00 TU

NO

Claim Comment: Input “As per Technical Bulletin 2039000” 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.

Required Parts and Tools
1998-2005 Passat Wagon 3B5, 3B6 (B5/5.5)
Part No:

Part Description

Quantity

WHT 000 808

Washer

6

3B9 860 151

Roof rail sealing kit

1

2007-2010 Passat Wagon 3C5 (B6)
Part No:

Part Description

Quantity

3C9 860 151

Roof rail sealing kit

1

For Special Tools see Repair Manual.

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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

2039000/2

6/7/16

V5116XX

Update Claim Processing
statement.

2039000/1

12/16/14

V511403

Original publication.

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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)

If repeat repair, provide explanation in box below:

WVWXK73CX9E000000

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

LA7W

Dealer Labor Rate

100.00

Paint material price per unit

Service No.

Damage
Code

Dmg
Loc

Part manufacturer
(Vendor Code)

5103

0003

010

010

12.00

Dealer-owned paint shop?

Yes

Original paint material?

Yes

Description of Repair

Paint roof w/ sunroof

Paint Labor Operation(s)

No
No
Time
Units

Mat'l
Units

51037933

290

51017133

190

23

Verify ALL Labor Operation Time Units
and Material Units

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

Remove and install 2 roof rails

40.00

Example Part Qty and Part Price per Unit only
All other parts should be claimed separately in
the SAGA claim

Paint Subtotal

Repair/Replace Labor
Operation(s)

480

23

Time
Units

66872050

30

Remove and install headliner

70841910

250

Remove and install antenna

91381999

10

Remove corrosion on roof