2021 Audi e-tron Sunroof Water Leak TSB

Symptoms

Owners of affected Audi vehicles may notice a "water drip from the headliner area." This typically occurs after the vehicle has been exposed to water, such as during rain, a car wash, or when standing water is on the roof panel. The issue can be more pronounced if the sunroof is opened or vented while the vehicle is wet. Sometimes, the water drip may not appear until after a driving period, as water slowly migrates along internal components.

Diagnosis and Trigger Conditions

The TSB identifies several potential root causes for the water entry. These include obstructions in the sunroof drain hoses or outlet valves, detached or malformed roof opening seals, poor adjustment of the sunroof glass panels, or damage to the sunroof frame itself. Water can breach normal drainage channels, especially if the sunroof mechanism or wind deflector components allow water to enter areas not designed for drainage.

Important Warnings

Audi advises technicians that it is not always necessary to replace the entire sunroof frame unless clear damage, such as a crack or hole in the drainage structure, is found. If a sunroof frame is replaced, a complete leak test will be conducted. If this test reveals no water leak in the sunroof frame, the claim for the frame replacement will be debited back to the dealer. Owners should be aware that unnecessary frame replacements may not be covered if no actual damage is present.

Repair Procedure Summary

Addressing the Audi e-tron sunroof water leak involves a multi-step inspection and repair process:

1. Sunroof Drain Hoses and Outlet Valves: Technicians will use a special tool, the VAS6620 Sunroof Drain Snake, to clean the sunroof water drain hoses. If any obstruction is due to a pinched or kinked drain hose, the damaged hose(s) or valve(s) must be replaced.
2. Roof Opening Seal: The entire perimeter of the roof opening seal will be inspected for detachment, malformation, or damage. If issues are found, the sunroof opening seal will be replaced. Refer to TSB 2063187 for specific guidance on the panoramic sunroof opening outer perimeter seal.
3. Glass Sunroof Panels: All adjustment axes of the sunroof glass panels will be checked for poor adjustment and corrected as needed.
4. Sunroof Frame Inspection: The sunroof frame will be inspected for damage like cracks or holes in the drainage structure. Replacement is only necessary if damage is found.
5. Wind Deflector Modification: A design change to the wind deflector has been implemented to enhance water flow and drainage. If the vehicle has the older wind deflector design (without small tabs), it will be replaced with the redesigned version.
6. Sunroof Glass Panel Modification: Two small 10mm x 10mm packing pads (251 201 525) will be bonded to the front corners of the sunroof glass panel's 'skirt'. This modification creates a gap to prevent water from contacting the sunroof mechanism and potentially breaching water channels. The area will be cleaned with all-purpose cleaner (D 009 401 04), treated with bonding agent (D 355 205 A2) and primer (D 009 500 25), and sealed with butyl adhesive/sealing cord (AKL 450 005 05). A roller tool (3356) is used to ensure proper adhesion.

Required Tools or Parts

To perform the necessary repairs for the Audi e-tron sunroof water leak, specific tools and parts are required:

• VAS6620 (Sunroof drain snake)
• 3356 (Roller Tool)
• D 009 401 04 (or equivalent surface preparation solvent/all-purpose cleaner)
• D 355 205 A2 (or equivalent adhesion promoter/bonding agent)
• D 009 500 25 (or equivalent primer applicator)
• AKL 450 005 05 (Butyl Adhesive / Sealing Cord)
• 251 201 525 (Packing)
• Fasteners, Bolts, Nuts, and Screws as needed per the Repair Manual (See ETKA)

Owner Action

If you are experiencing a "water drip from the headliner area" in your 2021 Audi e-tron or other affected Audi model, it is recommended to contact an authorized Audi dealer. They can diagnose the issue according to TSB 2056944/10 and perform the necessary inspections and repairs. This repair may be covered under warranty for vehicles up to 48 months or 50,000 miles. For Certified Pre-Owned (CPO) vehicles, it falls under claim type G10. If your vehicle is outside of warranty, this bulletin serves as informational guidance.

Additional Information

This Technical Service Bulletin supersedes TSB Group 60 number 23-67 dated August 23, 2023. It also references TSB 2063187, which addresses issues with the panoramic sunroof opening outer perimeter seal.

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Source: NHTSA ID 10244501