FRONT DOOR DEFORMED BY ICE
TECHNICAL SERVICE BULLETIN
Reference Number(s): GROUP 57, NO. 11-05 (2014599), Date of Issue: September 30, 2011
Superceded Bulletin(s): GROUP 57, NO. 08-15, Date of Issue: December 10, 2008
APPLICABLE MODELS AND YEARS
CONDITION
57 11 05 September 30, 2011 2014599 Supersedes T. B. V570815 dated December 10, 2008 to
include additional models and model year applicability.
Front Door Deformed By Ice
In cold climates door(s) becomes damaged in the lower area while opening.
TECHNICAL BACKGROUND
Water draining from the front cowl drains into the rear of the front fender area. Water
seeps out behind the lower front door and freezes causing door obstruction and damage
to door panel. This condition may also occur at rear lower corner of front fender.
VOLKSWAGEN:
Rabbit, GTI, R32 2006; (A5) Jetta, Jetta Wagon 2005-2010; Jetta SportWagen,
Golf Wagon 2010
GROUP: 57 - Doors - Front
Model(s) Year Eng. Code Trans. Code VIN Range
From
VIN Range To
Rabbit, GTI, R32 2006 - 2009 All All All All
(A5) Jetta, Jetta
Wagon
2005 - 2010 All All All All
Jetta SportWagen,
Golf Wagon
2010 All All All All
2010 Volkswagen Golf TDI
FRONT DOOR DEFORMED BY ICE
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PRODUCTION SOLUTION
N/A
SERVICE
Perform the following counter-measures to prevent thawing water from getting to
critical areas behind door, but allow the thawed water to drip on Front Wheel Housing
Liner, from where it can flow away.
NOTE: The condition as described WILL NOT cause water ingress to the passenger
compartment.
NOTE: Perform this procedure to both front doors.
NOTE: Components and material must be at room temperature 20°C (68°F).
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BONDING OF DRAIN
Remove both Front Wheel Housing Liner(s), see Repair Manual Group 66 in ElsaWeb.
Clean Front Wheel Housing Liner(s) in outlined area with soap and water mixture,
and then with 3M? General Purpose Adhesive Cleaner, Part No. 08987.
2010 Volkswagen Golf TDI
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2010 Volkswagen Golf TDI
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In both front wheel housing openings below the drain:
Clean outlined area with soap and water mixture, and then with 3M? General Purpose
Adhesive Cleaner, Part No. 08987.
Allow to air dry for at least 5 minutes.
NOTE: DO NOT grind the surfaces.
2010 Volkswagen Golf TDI
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Bond a 630 mm long piece of a door seal, Part No. 1K4837701E9B9 to the cleaned
upper sides of both Front Wheel Housing Liner(s) where shown.
Press down well to ensure good bond.
NOTE: DO NOT stretch seal.
2010 Volkswagen Golf TDI
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2010 Volkswagen Golf TDI
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On the clean and dry surface below the water drain:
Create a bead of sealing cord, Part No. AKD49701004R10, and seat well.
Tip: The bead will change the water flow and cause the water to drip. The upper side of
the bead must be a bit hollow to catch water. At it's lower end the bead should have a
hanging tip from where the water will drip off.
Install both Front Wheel Housing Liner(s), see Repair Manual Group 66 in ElsaWeb.
BONDING FOAM PIECE
Install foam piece Part No. 1K0 867 453/454 where indicated in following procedure
below:
Thoroughly clean the contact area of the foam piece with soap and water mixture,
and then with 3M? General Purpose Adhesive Cleaner, Part No. 08987.
Warm the area with the hot air blower VAS1416 to a maximum of 40°C (104°F) to
ensure good adhesion of the foam piece.
2010 Volkswagen Golf TDI
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If the door panel cannot be repaired:
Replace the door panel, see Repair Manual Group 57 Front Door, in ElsaWeb.
NOTE: Ensure that the foam piece is not installed into the hole on the lower
fender or cover the hole on the fender. To prevent paint damage, the
foam piece must be positioned so that the door skin doesn't touch the
foam.
2010 Volkswagen Golf TDI
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2010 Volkswagen Golf TDI
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WARRANTY
WARRANTY INFORMATION
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
Rabbit, GTI, R32 2006 - 2009 All All All All
(A5) Jetta,
Jetta Wagon
2005 - 2010 All All All All
Jetta
SportWagen, Golf
Wagon
2010 All All All All
SAGA Coding
Claim Type: Use applicable Claim Type (1)
Service Number: Damage Code Damage Location (Depends on Service
No.)
5137 0030 Use applicable when indicated in
ElsaWeb (L/R)
Parts Manufacturer Rabbit, GTI, R32 WWO (2)
Jetta, Jetta Wagon, Jetta SportWagen,
Golf Wagon
3ME (2)
Labor Operation (3) :
Remove and Install 2 wheels
44052000 = 20 TU
Labor Operation (3) :
Remove and Install Front Wheel Housing
Liner (left and right side)
66161999 = 40 TU
Labor Operation (3) :
Modify Hinge Pillars
Includes
Modify water drain (left and right
side)
Install sealing cord (left and right
side)
Install foam pieces (left and right
side)
51374299 = 70 TU
Labor Operation (3): Body Damage
NOTE:
In case of body damage, repairs are not to exceed
ElsaWeb SRT
Refer to Volkswagen Warranty Paint and
Corrosion Claim Coding Manual
If the repairs are sublet, please use the
following part number in "Outside
Materials"
LACKMATF: Paint and Materials
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REQUIRED PARTS AND TOOLS
PARTS INFORMATION
TOOL INFORMATION
ADDITIONAL INFORMATION
All part and service references provided in this Technical Bulletin are subject to
If the repairs are sublet, please use the
following part number in "Outside Labor"
L0010000: External Paintingstraight
color
L0020000: External Paintingmetallic/
2-layer
L0030000: External Painting-pearl
color
A0041000: Body Shop repair no
paint
Causal Part: 1K4837701E9B9
Outside Material: 3M? General Purpose
Adhesive Cleaner
Part No:
08987
$6.15
Diagnostic Time (4)
GFF Time expenditure 01500000 = 00 TU max. NO
Road Test 01210002 01210004 NO
Technical Diagnosis 0132xxxx = 00 TU max. NO
Claim Comment: Input "As per Technical Bulletin 2014599" 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.
Part Description Part No: Quantity
Foam Pieces-Rabbit, GTI, R32 1K0 867 453 left 1
1K0 867 454 right
Foam Pieces-Jetta, Jetta Wagon,
Jetta SportWagen
1K5 867 453 left 1
1K5 867 454 right
3M? General Purpose Adhesive
Cleaner
08987 .20
Sealing cord AKD49701004R10 As required
Door Seal 1K4837701E9B9 2
Tool Description Tool No: Quantity
Blower, Hot Air VAS 1416 1
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change and/or removal. Always check with your Parts Dept. and Repair Manuals for the
latest information.
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