2021-2022 Audi e-tron Detached Outer Door Seal TSB

Symptoms

Owners of affected Audi e-tron vehicles may notice that "The outer door seal has come loose." Technicians performing inspections have confirmed that "The bonding of the outer door seal has detached from the door."

Technical Background

Audi has identified that several factors can contribute to the outer door seal detaching. These include pressure, temperature fluctuations, and contamination in the bonding area. These conditions can negatively impact the adhesive bond between the outer door seal and the door frame. The adhesive bond can come loose in the entire area where the outer door seal makes contact with the door.

Repair Procedure Summary

To address the Audi e-tron detached door seal, technicians are instructed to replace the affected door seals following the procedures outlined in the Elsa Repair Manual. Several critical requirements must be met during this repair:

• The vehicle and the new seal must be at room temperature before starting the repair.
• All bonding surfaces must be thoroughly cleaned and free of dirt and grease.
• It is crucial that technicians "Do not stretch the seal during installation" to ensure proper fit and adhesion.
• After installation, to prevent the outer door seal from becoming detached or misaligned, the door must not be closed for at least 30 minutes.
• If the old door seal has been removed, the routing of the outer door seal on the opposite side of the vehicle should be used as a guide for positioning the new seal.
• Any remaining adhesive tape from the door must be removed using adhesive strip remover VAS 6349.
• Finally, the bonding surface on a painted area must be cleaned with cleaning solution D 009 401 04 and allowed to dry.

Required Tools or Parts

Technicians will need specific tools and parts to perform this repair:

• Fasteners, Bolts, Nuts, and Screws: As needed per the Repair Manual (refer to ETKA/ELSA).
• All-purpose cleaner: Part number D00940104 (Shop Supply).
• Adhesive strip remover: Tool number VAS 6349.

Warranty Information

This repair is covered under warranty for up to 48 months or 50,000 miles. For Audi Certified Pre-Owned (CPO) vehicles, coverage is G10, but owners must be verified. If the vehicle is outside of warranty, this Technical Service Bulletin is for informational purposes only. Claims are subject to review and audit by Audi Warranty.

Labor Operations:

• Outer front door seal remove + reinstall: Service Number 5765, Labor Code 1950.
• Rear door outer seal remove + reinstall: Service Number 5864, Labor Code 19XX.

Owner Action

If you own a 2021-2022 Audi e-tron and notice that your outer door seal has come loose or appears to be detaching, it is recommended to contact your authorized Audi dealership. They can diagnose the issue and perform the necessary repair as outlined in TSB 2064183/1.

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NHTSA ID: 10199635