2021-2025 Audi A6/S6/RS 6 Headlight Washer Jet TSB

Owners of 2021-2025 Audi A6, A6 allroad, S6, and RS 6 models may experience an issue where the headlight washer jet does not retract automatically after a wash cycle. This condition, often described as the "headlamp washer nozzle jammed in the extended position," is addressed by Audi Technical Service Bulletin (TSB) 92 24 39 2065982/3.

This TSB, which supersedes an earlier bulletin (23-34 dated March 3, 2023), provides comprehensive diagnostic and repair procedures for this specific problem affecting the Audi A6 headlight washer jet and related models.

Symptoms

The primary symptom reported by customers is that the headlamp washer nozzle/pressure cylinder fails to retract automatically after completing a wash cycle. This leaves the headlamp washer nozzle jammed in the extended position, as visually depicted in Figure 1 of the TSB.

Root Causes

Audi has identified several potential root causes for the Audi A6 headlight washer jet malfunction:

• Tolerance Issues: A very precise tolerance between the headlamp washer system nozzle cover and the bumper cover aperture can prevent full closure, especially if dirt and debris accumulate in the area.
• Excessive Spring Force: The return spring for the headlamp washer system nozzle cover might be exerting too much force, hindering the nozzle's ability to retract.
• Physical Interference: Inadequate positioning of the headlamp washer nozzle/pressure cylinder can lead to physical interference between the nozzle cover and the bumper cover.

Important Warning

Audi explicitly states in TSB 92 24 39 2065982/3: "Do not replace the headlamp washer cylinders as a replacement will not remedy this problem." This means that simply replacing the entire headlight washer cylinder assembly will not resolve the underlying issue if the problem persists after performing the outlined inspections and adjustments.

Repair Procedure Summary

The repair procedure involves a series of inspections and adjustments, which should be performed on both the left and right sides of the vehicle if the symptom is duplicated. The steps include:

1. Inspect for Interference: Technicians must remove the headlamp washer outer cover and carefully inspect for any interference with the cover mechanism and the bumper cover (Figure 2). If interference is found, the area on the cover mechanism should be carefully trimmed to allow free movement.
2. Adjust Nozzle Position: The headlamp washer cylinder's position can be adjusted. This involves loosening two mounting bracket screws (Figure 3), rotating the nozzle end away from the vehicle's centerline towards the turn signal lamp (Figure 4), and then re-tightening the screws.
3. Check Spring Clip Version: The pressure exerted on the headlamp washer system nozzle cover should be checked. If the nozzle retracts after relieving cover pressure, the cover spring clip version should be examined. An older version of the spring clip (Figure 5) has been identified as exerting excessive pressure and preventing smooth nozzle retraction.
4. Replace Spring Clips (If Applicable): If an old spring clip version is installed and the nozzle retracts after relieving cover pressure, replacing the spring clips on both sides with the improved version (Figure 6) may resolve the problem. Only the improved version spring clip is available for replacement.

Required Parts

For vehicles requiring a spring clip replacement, the following part is specified:

• Part Number: 4K0955339
• Part Description: Spring clip
• Quantity: 2 (for both left and right sides)

Warranty Information

This Technical Service Bulletin is informational only if the vehicle is outside of its warranty period. For in-warranty repairs, claims must be submitted according to the Audi Warranty Policies and Procedures Manual, referencing TSB 2065982/3. The service number for this repair is 9274, with a damage code of 0017. Labor operations include "Front bumper cover remove and reinstall" (6329 1900) and "Modify headlamp washer system components" (9274 5099), with an estimated 25 time units (TU) for the modification.

What Owners Should Do

If your Audi A6 headlight washer jet is not retracting, it is recommended to schedule an appointment with an authorized Audi service center. Inform them about the specific symptom and mention TSB 92 24 39 2065982/3. The technicians will perform the necessary diagnostics and repairs as outlined in the bulletin.

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Source: NHTSA ID: 11007280