2021-2023 Audi Sunroof Frame Modification TSB

Owners of various 2021-2023 Audi models, including the Audi e-tron, may experience issues related to the sunroof assembly. Audi has issued Technical Service Bulletin (TSB) 2065731/3 to address potential compatibility problems that can arise when replacing the front sunroof glass panel or the sunroof frame.

This TSB, superseding Group 60 number 22-59 dated May 6, 2022, provides crucial information for technicians to ensure proper fitment and operation of the sunroof system after component replacement.

Symptoms

Owners have reported various complaints that ultimately require the replacement of the front sunroof glass panel or sunroof frame. If these components are replaced without the prescribed modification, an interference can occur. This interference, caused by a protruding water guidance washer, can prevent the front glass panel from completing its closing sequence.

Technical Background

The design and development of the sunroof assembly have evolved over time. As a result, replacement components such as the sunroof frame and front sunroof glass panel may not be fully compatible with older assembly designs without modification. The TSB clarifies that the interference between the sunroof frame and the front sunroof glass panel has since been corrected in production for newer vehicles. However, models covered by this TSB may still require modification if a replacement is needed.

Repair Procedure Summary

If a technician determines that the sunroof frame or front sunroof glass panel requires replacement, the following high-level steps are involved:

1. Remove the front sunroof glass panel: This step is necessary to access the water guidance washer on the sunroof mechanism pivot.
2. Modify the water guidance washer: Using a small pair of diagonal cutters (side cutters), the technician will trim away the water guidance washer. The washer must be cut back so that it protrudes no further than the pivot pin. This operation needs to be performed on both sides of the sunroof mechanism.
3. Reinstall and adjust: After the modification, the front sunroof glass panel is reinstalled and adjusted according to specifications found in ElsaPro. This includes setting the sunroof panel and rollershade end stop adaptation using the sunroof panel and rollershade switches. Technicians should refer to TSB 2054505: "60 Sunroof glass panel or sunroof rollershade do not operate" for detailed instructions on adjustment.

Important Warnings

Technicians must exercise extreme caution during this modification procedure to prevent damage to surrounding components. It is recommended to surround the area being modified with masking tape if necessary to protect the sunroof frame and lifting mechanism from scratches or other damage.

Crucially, all plastic fragments generated from trimming the water guidance washer must be completely removed. Any stray fragments that remain can cause permanent damage to the sunroof frame mechanism. A vacuum cleaner should be used to ensure thorough removal of debris.

Warranty Information

This Technical Service Bulletin outlines specific warranty claim types and procedures:

• Claim Type: Generally, claims are covered for vehicles up to 48 months or 50,000 miles. For CPO (Certified Pre-Owned) vehicles, a G10 claim type is used, requiring owner verification. If the vehicle is outside of any warranty, this TSB serves as informational guidance only.
• Service Number: 6028
• Damage Code: 0010
• Labor Operations: Specific labor operations are provided for removing and reinstalling the glass tilting roof panel (60 39 19 00) and performing the water guidance washer modification on both sides (60 28 50 99), which is allotted 10 labor units (TU).
• Diagnostic Time: Diagnostic time for performing sunroof end stop adaptation (0150 0000) is 10 TU. Road tests before and after the service procedure are not allotted separate time units.
• Claim Comment: Claims should be submitted as per TSB 2065731/3, adhering to the Audi Warranty Policies and Procedures Manual.

Required Tools

Technicians will need a small pair of diagonal cutters (side cutters) to perform the trimming of the water guidance washer. Additionally, a vacuum cleaner is recommended for thorough cleanup of plastic fragments.