2019-2021 Audi A6/A7 Water Ingress into Footwell TSB 2060335/4

Owners of 2019-2021 Audi A6, A7, S6, S7, RS 6 Avant, RS 7, A6 allroad, and A7 e-quattro vehicles may experience significant issues due to water entering the vehicle's interior. This problem, detailed in Audi Technical Service Bulletin (TSB) 50 23 10 2060335/4, specifically targets water ingress into the longitudinal member and footwell area. This TSB, issued on January 19, 2023, supersedes an earlier bulletin, Group 50 number 20-05 dated December 18, 2020, to provide updated warranty and repair information.

TSB Revision History

Technical Service Bulletin 50 23 10 2060335/4 has undergone several revisions to refine the repair procedure and warranty information:

• Revision 4 (January 19, 2023): Revised Warranty (Updated Labor Operations).
• Revision 3 (December 18, 2020): Revised Required Parts and Tools (Added alternative sealant and application tool).
• Revision 2 (November 10, 2020): Revised Service (Added alternative sealant) and Revised Required Parts and Tools (Added alternative sealant).

This current version, Revision 4, supersedes Technical Service Bulletin Group 50 number 20-05 dated December 18, 2020.

Symptoms Owners May Notice

If your 2019-2021 Audi A6 water ingress issue is present, you might observe several concerning symptoms. The most direct sign is "Water is in the footwell area." Beyond visible water, owners may also experience "malfunctions of various infotainment features" or see "various error messages in the instrument cluster."

Workshop Findings and Technical Background

When technicians investigate, they often confirm the owner's reports, finding "Water is discovered under the carpet." They also note that "The error messages are confirmed." A critical finding is that "Electrical connectors may show signs of corrosion," indicating potential long-term damage if the water ingress is not addressed promptly.

The technical background provided by Audi explains that the root cause of this 2019-2021 Audi A6 water ingress is "incorrect bonding of the sound absorber inside of the longitudinal member." This allows water to penetrate the vehicle's structure. An ETKA drawing (803-000) helps locate this sound absorber within the longitudinal member. Access to the longitudinal member plugs requires removing any necessary underbody covers.

Important Note for Technicians

Audi emphasizes a crucial diagnostic step before proceeding with the repair outlined in TSB 2060335/4. Technicians are instructed: "Only perform the following repair if water intrusion is confirmed as coming from the sound absorber in the longitudinal member. The following repair will only correct this root cause. If the water intrusion is confirmed but the longitudinal members are not at issue, continue diagnosis outside the scope and instruction provided in this TSB." This ensures the correct problem is being addressed.

Repair Procedure Summary

The repair for the 2019-2021 Audi A6 water ingress involves a multi-step process to seal the longitudinal member and prevent further water intrusion. The procedure begins by checking for water ingress in the footwell. This involves removing plugs 1 and 5 from the longitudinal member's lower right and left sides. If a water leak is confirmed from the lower longitudinal member after removing these plugs, the sealing measure must be performed on the affected side. Both sides should be checked, and repaired if necessary.

Technicians will also check the cabin floor areas (as shown in Figure 4 of the TSB) where water intrusion is likely. Electrical connectors under the floor covering must be inspected for corrosion, and any found corrosion must be repaired according to the Elsa repair manual. If water intrusion is found in the interior, the floor covering needs to be propped up and the interior thoroughly dried.

To access the repair area, the front wheel housing liner is removed from the affected side of the vehicle. A specific plug (indicated by a red arrow in Figure 5) is removed, revealing the opening where the sealer will be applied. Another opening (yellow arrow in Figure 5) is used to inspect the area with a borescope.

The sound absorber is then completely sealed within the longitudinal member using a 1k adhesive sealant, specifically part number D 511 500 A2 or alternatively Loctite 5510. This sealant is injected using a VAG1628 cartridge gun (or equivalent) through the opening shown in Figure 6 and Figure 8, onto the sound absorber. An amount of sealer sufficient to cover the surface and perimeter of the sound absorber (Figure 9) is applied and spread using a gloved finger (Figure 10). Alternatively, a modified brush (Figure 11) can be used to distribute the sealer, but it is critical to ensure no brush fragments are left inside the longitudinal member.

After sealant application, a borescope (inserted through the opening indicated by the yellow arrow in Figure 12) is used to visually confirm complete sealer coverage, as illustrated in Figure 13.

Once the sealing procedure is completed and the sealer has fully cured, the inside of the longitudinal member is coated with cavity preservative D 330 KD2 A1 through the opening shown (Figure 14). Finally, the removed plugs 1 and 5 on the right and left are replaced with new plugs, part number 8K0 805 267, which feature an integrated drain (Figure 15).

Required Parts and Tools

To perform the repair described in TSB 2060335/4, specific parts and tools are necessary:

• 1k Adhesive Sealant: D 511 500 A2 or Loctite 5510 (Shop supply)
• Anti-Corrosion Wax: D 321M16M2 (Quantity 0.3) or 3M 08852 Cavity Wax Plus (Shop Supply, available through Audi Top Service Supplies & Touch Up Paint eStore)
• Plug: 1K0899183 (Quantity 02)
• Drain Tube Grommet: 8K0 805 267 (Quantity 04)
• Cartridge Gun: VAG1628 (or equivalent)
• Spray Gun: VAG 1379 (or equivalent)
• Borescope: VAS 6748 B (or equivalent)
• Wiring Harness Repair Set: VAS 1978A
• Diagnostic System: VAS 6160/VAS 6150 (Windows 10 with the current version of ODIS)

Fasteners, bolts, nuts, and screws as needed per the repair manual are also required and can be found in ETKA.

Warranty Information

This repair is covered under warranty for vehicles up to 48 months or 50,000 miles. If the vehicle is outside of warranty, this Technical Service Bulletin is for informational purposes only. The Service Number for this operation is 5079, and the Damage Code is 0010. All warranty claims must adhere to the Audi Warranty Policies and Procedures Manual and are subject to review or audit by Audi Warranty.

Diagnostic Time:

• GFF or (when applicable) GFF – Checking and clearing fault codes included in existing labor operations: 0150 0000 (Time stated on the diagnostic protocol, Max 50 TU)
• Road test prior to the service procedure: No allowance (0 TU)
• Road test after the service procedure: No allowance (0 TU)

Labor Operations:

• Repair longitudinal member – one side:

  • Wheel remove and reinstall: 4405 1900 (See SRT with associated operations)
  • Front-wheel housing liner remove and reinstall: 6616 1900 (See SRT with associated operations)
  • Gain access to longitudinal member opening, remove plugs, and reseal sound absorber: 5079 1999 (30 TU)
  • Front floor covering loosen - 1 side. Dry interior: 7041 1199 (120 TU)

• Repair longitudinal member – both sides:

  • Remove and install 2 wheels: 4405 2000 (See SRT with associated operations)
  • Front-wheel housing liners remove and reinstall: 6616 2000 (See SRT with associated operations)
  • Gain access to both the right and left longitudinal member openings, remove plugs and reseal sound absorbers – both sides: 5079 2099 (50 TU)
  • Body cavity conserved: 5101 7501 (See SRT with associated operations)
  • Front floor covering loosens - both sides. Dry interior: 7041 1299 (210 TU)

• In all cases:

  • Inspect electrical connectors and wiring for damage and repair as necessary: 9709 41XX (Use the appropriate labor operation corresponding with the number of wires repaired, See SRT with associated operations)

NHTSA ID: 10230987