2021-2025 Audi A6 / S6 / RS 6 Headlight Washer Jet Not Retracting

Audi has issued Technical Service Bulletin (TSB) 92 24 39 2065982/3, dated August 27, 2024, to address a common issue where the headlight washer jet does not retract automatically. This bulletin supersedes an earlier version, TSB 23-34, from March 3, 2023, and provides updated information for diagnosis and repair.

This TSB specifically applies to 2021-2025 Audi A6, S6, and RS 6 models. Owners experiencing this problem should be aware of the potential causes and the recommended solutions.

Symptoms

Owners will notice that the headlamp washer nozzle/pressure cylinder does not retract automatically after a wash cycle. This leaves the nozzle jammed in its extended position, as illustrated in Figure 1 of the original bulletin.

Root Causes

Audi has identified several potential root causes for the headlight washer jet not retracting:

• Tolerance Issues: A precise tolerance between the headlamp washer system nozzle cover and the bumper cover aperture can prevent full closure, especially when dirt and debris accumulate in the area.
• Excessive Spring Force: The return spring for the headlamp washer system nozzle cover may exert 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 Warnings

Owners and technicians should note a crucial point from the TSB: Do not replace the headlamp washer cylinders as a replacement will not remedy this problem. If the issue persists after performing the outlined inspections and adjustments, further root cause diagnosis is required, as the TSB's solutions will not resolve it.

Repair Procedure Summary

The TSB outlines a multi-step repair process to address the Audi headlight washer jet not retracting issue. Technicians are instructed to perform these repairs on both the left and right sides of the vehicle.

1. Inspect and Trim for Interference: The headlamp washer outer cover must be removed. Technicians then inspect for possible interference between the cover mechanism and the bumper cover. If interference is found (as shown in Figure 2), the area on the cover mechanism should be carefully trimmed to allow free movement.
2. Adjust Washer Cylinder Position: The headlamp washer cylinder's position can be adjusted. This involves loosening the two mounting bracket screws (Figure 3) and rotating the cylinder. The nozzle end should be rotated away from the vehicle's centerline, towards the turn signal lamp on the side being serviced (Figure 4). The screws are then tightened in the adjusted position.
3. Check and Replace Spring Clip: Technicians should attempt to manually relieve pressure on the nozzle cover. If the nozzle retracts, the cover spring clip version needs to be checked. Figure 5 illustrates the old version, which is known to exert excessive pressure. If the old version is installed, it should be replaced with the improved version (Figure 6). The improved spring clip should be installed on both the left and right sides.

Required Parts

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

• Part Number: 4K0955339
• Part Description: Spring clip
• Quantity: 2 (one for each side)

Warranty Information

For warranty claims related to TSB 2065982/3, the following codes apply:

• Claim Type: Informational only if the vehicle is outside of warranty.
• Service Number: 9274
• Damage Code: 0017
• Labor Operations:
  • Front bumper cover remove and reinstall: 6329 1900
  • Modify headlamp washer system components: 9274 5099 (25 Time Units)
• Diagnostic Time: GFF (No allowance), Road test prior to service (No allowance), Road test after service (No allowance, only if Driver's Assistance System calibration is required).