2021-2024 Audi Sunroof Seal Wind Noise and Leaks TSB

Owners of 2021-2024 Audi vehicles, including the e-tron, Q3, Q5, Q7, Q8, A4, and SQ models, may experience issues related to a loose Audi e-tron sunroof seal. This Technical Service Bulletin (TSB) 2063187/2, issued by Audi on January 9, 2023, supersedes an earlier bulletin (21-53 dated May 7, 2021) and outlines the symptoms and repair procedures for this condition.

Symptoms

Audi owners have reported one or a combination of the following symptoms indicating a problem with the sunroof opening perimeter seal:

• They hear "wind noise in the roof area with the sunroof panel closed."
• They have seen "water drip from the headliner area."
• The "sunroof opening perimeter seal is distorted and/or not flush with the roof panel."

Technical Background

The root cause of these issues is often compromised or failed adhesion of the sunroof opening perimeter seal to the roof panel. Even a slight detachment can create an entry point for wind and water into the cabin. Any detachment found during inspection requires correction by replacing the sunroof opening perimeter seal.

Repair Procedure Summary

The repair procedure involves a thorough inspection and, if necessary, replacement of the sunroof opening perimeter seal. Here's a summary of the steps technicians will follow:

1. Initial Inspection: The technician will fully open the front sunroof glass panel to begin inspecting the sunroof opening perimeter seal adhesion (as shown in Figure 1 of the TSB).
2. Adhesion Check: Using their fingers, the technician will press the seal downwards and inwards to make the adhesive tape visible (Figure 2). They will check that the foam adhesive tape is not stretched, loose, or detached from the roof panel.
3. Comprehensive Scan: This inspection process is repeated centimeter by centimeter along the entire length of the front sunroof opening. Once the front is complete, the front sunroof panel is closed.
4. Rear Section Check: The same inspection principle is applied to the rear portion of the sunroof opening perimeter seal (Figure 4).
5. Identify Detachment: Technicians look for clear evidence of adhesive detachment, which appears as gaps or obvious color and shape differences at the point of contact (Figures 5-8).
6. Seal Replacement: If any compromised or failed adhesion is found, the sunroof opening perimeter seal must be replaced. The procedure in ElsaPro must be followed explicitly, with particular attention to adhesion surface preparation.
7. Post-Replacement Adaptation: After reassembly, the sunroof panel and rollershade end stop adaptation must be set using the sunroof panel and rollershade switches. Refer to TSB 2054505 for detailed instructions on this step.

Required Tools or Parts

To perform this repair, specific materials and tools are required:

• Surface Preparation Solvent: D 00940104 (or equivalent, such as isopropyl alcohol).
• Adhesion Promoter: D 355205A2 (or equivalent, such as 3M™ 111 Adhesion Promoter or AC77 Adhesive Primer).
• Primer Applicator: D 00950025 (or equivalent).
• Hot Air Blower: VAS1978/14A.
• Roller: Tool number 3356.

Warranty Information

This TSB outlines the warranty coverage for the repair:

• Claim Type 110: Applicable for vehicles up to 48 months or 50,000 miles.
• Claim Type G10: For CPO (Certified Pre-Owned) Covered Vehicles, requiring owner verification.
• Out of Warranty: If the vehicle is outside any warranty, this Technical Service Bulletin is for informational purposes only, meaning the repair cost may not be covered.

The Service Number associated with this TSB is 6042. Labor operations for inspection include 6042 0199, and for seal removal/reinstallation, codes like 6042 1950 (for Q8, Q7, Q5, Audi e-tron quattro, and Audi e-tron Sportback) or 6042 1902 (for Q3) are used. Diagnostic time is GFF 0150 0000, and road tests (0121 0002, 0121 0004) are also covered.

Important Notes

• This TSB references other important documents: TSB 2054505, "60 Sunroof glass panel or sunroof rollershade do not operate," and TSB 2056944, "60 Water entry into cabin from the sunroof area." These may be necessary for a complete repair.
• All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual.

NHTSA ID: 10230643