2021 Audi e-tron Sunroof Water Leak TSB

Owners of certain 2021 Audi models may notice a "water drip from the headliner area" or "water intrusion near the headliner" originating from the sunroof. Audi Technical Service Bulletin (TSB) 60 23 67 2056944/9, released on August 23, 2023, addresses this concern by outlining a comprehensive diagnostic and repair process for sunroof water leaks.

This TSB supersedes a previous bulletin, Group 60 number 21-56, and provides updated service and warranty information, including a QR code for a video guide to assist technicians with the repair.

Symptoms

The primary symptom reported by customers is a "water drip from the headliner area." This water intrusion can occur when the vehicle is exposed to water, such as during rain, a car wash, or when standing water is on the roof panel. The leak may be present whether the vehicle is stationary or driving, especially if the sunroof is opened or vented while wet. In some cases, the water may not appear until after driving, as it slowly migrates along the wind deflector hinge arms and into the headliner area.

Technical Background

Audi has identified four potential scenarios that can lead to water entry from the sunroof area. These include issues with the sunroof drain hose or outlet valve, the roof opening seal, the glass sunroof panels, or unexplained water entry due to the design of the wind deflector stowage area. The TSB emphasizes that all these areas must be inspected to identify the root cause of the Audi e-tron sunroof water leak.

Specifically, the stowage area for the wind deflector is noted as "Stowage area for wind deflector - NOT WATER TIGHT - NO DRAINAGE," indicating it is not designed to be watertight or to drain water effectively.

Important Warnings

• Sunroof Frame Replacement: It is not necessary to replace the sunroof frame unless actual damage, such as a crack or hole in the drainage structure, is found. If damage is identified, the area should be clearly marked, and any replaced sunroof frames may be requested for return to Audi of America (AoA) for analysis.
• Warranty Coverage: If your vehicle is outside of the applicable warranty period (typically 48 months/50,000 miles), this Technical Service Bulletin is for informational purposes only, and repair costs may not be covered.

Repair Procedure Summary

The repair process for an Audi e-tron sunroof water leak involves a thorough inspection and a series of corrective actions, which may include:

1. Sunroof Drain Hose and Outlet Valve Inspection: Technicians will use a VAS6620 Sunroof Drain Snake and follow cleaning procedures outlined in ElsaPro. Any kinks, pinches, or obstructions in the drain hoses or valves will be identified and addressed, with damaged components replaced.
2. Roof Opening Seal Inspection: The entire perimeter of the roof opening seal will be inspected for detachment, malformation, or damage. If issues are found, the seal will be replaced.
3. Glass Sunroof Panel Adjustment: The adjustment axes of the glass sunroof panels will be checked. If poor adjustment is found, the panels will be adjusted to proper specifications.
4. Sunroof Frame Leak Test: A complete leak test of the sunroof frame will be conducted. If no damage is found, the frame will not be replaced.
5. Wind Deflector Modification: The front sunroof panel will be opened to locate the mounting points for the sunroof wind deflector.
6. Wind Deflector Replacement (if necessary): A design change has been implemented for the wind deflector to improve water flow and drainage. Technicians will inspect the current wind deflector for small tabs cast into its structure. If the older design without these tabs is present, the wind deflector (part number 4M8877651) will be replaced with the redesigned version.
7. Surface Preparation: The area around the sunroof frame will be thoroughly cleaned using D 009 500 25 primer applicator and D 009 401 04 all-purpose cleaner to ensure it is free of lubricants or contaminants and completely dry.
8. Butyl Cord Application: Two 25mm strips of AKL 450 005 05 Butyl adhesive/sealing cord will be firmly pressed into specific grooves, ensuring both channels are completely filled.
9. Sunroof Glass Panel Modification: Two small pads will be bonded to the front corners of the sunroof glass panel, just inside the rubber 'skirt'. This modification creates a gap to prevent water from contacting the sunroof mechanism and breaching water channels.
10. Glass Panel Cleaning: The inside surface of the glass panel 'skirt' will be cleaned using D 009 401 04 all-purpose cleaner.
11. Bonding Agent Application: D 355 205 A2 Bonding Agent will be applied using a D 009 500 25 primer applicator and allowed to dry.
12. Pad Preparation: Two 10mm x 10mm pads will be cut from 251 201 525 packing material.
13. Pad Bonding: The prepared pads will be bonded to the front areas of the sunroof glass panel 'skirt' in precise positions.
14. Adhesion Reinforcement: A 3356 roller tool (or equivalent) will be used to apply firm pressure (~50 Nm) to the newly adhered pads, enhancing their adhesion strength.

Required Tools or Parts

To perform the repair for the Audi e-tron sunroof water leak, the following parts and special tools may be required:

• Cleaners & Adhesives:
  • D 00940104: All-purpose cleaner (0.2 quantity)
  • D 355205A2: Bonding Agent (0.2 quantity)
  • D 00950025: Primer Applicator (02 quantity)
  • AKL45000505: Butyl Adhesive / Sealing Cord (0.1 quantity)
• Packing Material:
  • 251201525: Packing (0.5 quantity)
• Seals & Hoses:
  • 83A877459 / 83A877459A: Roof opening perimeter seal (Audi e-tron quattro, e-tron Sportback, Q3) (01 quantity)
  • 4M0877459C: Roof opening perimeter seal (Q8) (01 quantity)
  • 4KE877201 / 4KE877201A: Front sunroof water drain hoses (Audi e-tron quattro, e-tron Sportback) (02 quantity)
  • 4KE877203 / 4KE877203A: Rear sunroof water drain hoses (Audi e-tron quattro) (02 quantity)
  • 4K4877203: Rear sunroof water drain hoses (Audi e-tron Sportback) (02 quantity)
  • 4M8877201: Front sunroof water drain hoses (Q8) (02 quantity)
  • 4M8877204: Right rear sunroof water drain hoses (Q8) (01 quantity)
  • 4M8877203: Left rear sunroof water drain hoses (Q8) (01 quantity)
  • 83A877201 / 83A877201A: Front sunroof water drain hoses (Q3) (02 quantity)
  • 83A877204 / 83A877204A: Right rear sunroof water drain hoses (Q3) (01 quantity)
  • 83A877203 / 83A877203A: Left rear sunroof water drain hoses (Q3) (01 quantity)
• Other Components:
  • 4M8877651: Wind Deflector (01 quantity)
• Special Tools:
  • VAS6620: Sunroof drain snake
  • 3356: Roller tool (or equivalent)
• General: Fasteners, Bolts, Nuts, and Screws as needed per the Repair Manual (See ETKA/ELSA)

Warranty Information

Warranty claims for this repair are typically covered for up to 48 months or 50,000 miles under Claim Type 110. For Certified Pre-Owned (CPO) vehicles, Claim Type G10 applies, requiring owner verification. If the vehicle is outside these warranty parameters, the bulletin serves as informational guidance only.

Specific labor operations and associated time units (TU) include:

• Service Number: 6039
• Damage Code: 0050
• Sunroof water drains check:
  • 6048 0250 (Q8, Audi e-tron quattro, and Audi e-tron Sportback)
  • 6048 0251 (Q3)
• Sunroof drain hose replacement: 6048 0299 (All) (10 TU per hose)
• Headliner loosen and fasten:
  • 7084 0950 (Q3)
  • 7084 0900 (Audi e-tron quattro, Audi e-tron Sportback, Q8)
• Cover (Plenum) remove and reinstall:
  • 8522 1900 (Q8, Audi e-tron quattro, and Audi e-tron Sportback)
  • 8522 1950 (Q3)
• Sunroof opening perimeter seal inspection: 6042 5599 (All) (10 TU)
• Sunroof opening perimeter seal replacement:
  • 6039 1900 (Q8, Audi e-tron quattro, and Audi e-tron Sportback)
  • 6042 1950 (Q8, Audi e-tron quattro, and Audi e-tron Sportback)
  • 6042 1902 (Q3)
• Sliding roof glass panels check adjustment: 6041 0199 (All) (10 TU)
• Sliding roof panel adjustment: 6039 1500 (All)
• Wind deflector check version: 6033 1999 (All) (5 TU)
• Replace sunroof wind deflector: 6033 1900 (All)
• Sunroof frame and front glass panel modifications: 6039 0199 (50 TU)

Diagnostic times include GFF (0150 0000 - 10 TU), road test prior (0121 0002 - 10 TU), and road test after (0121 0004 - 10 TU).

Source: NHTSA ID 10241241