Technical Service Bulletin
94 Moisture accumulation in headlights
94 13 11 2028277/6 March 6, 2013. Supersedes Technical Service Bulletin Group 94 number 13-01 dated
January 2, 2013 for reasons listed below.
Model(s)

Q7

Year

VIN Range

2010

All

2011

All

2012

All

2013

All

2014

All

Vehicle-Specific Equipment

Not Applicable

Condition
REVISION HISTORY
Revision

Date

Purpose

6

-

Revised Service (added information on vent tube)

5

1/2/2013

Revised Service (added air duct install)
Revised Warranty
Revised Required Parts and Tools

4

11/21/2012

Revised Service
Revised Warranty
Revised Required Parts and Tools
Revised Header data (added model years)

3

10/24/2012

Revised Required Parts and Tools
Revised Production Solution

2

3/1/2012

Revised Service
Revised Required Parts and Tools

1

12/20/2011

© 2013 Audi of America, Inc.

Original publication

Page 1 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
• There is considerable moisture present in the
headlamp (Figure 1).
• The moisture disappears only after extended drives
(greater than 10 minutes).
• There is no external damage to the headlamp which
could introduce moisture.

Figure 1. Moisture in headlamp.

Technical Background
Humid air settles on the inside of the glass, causing moisture to appear on the inside of the headlamp lens.
Because of the headlamp circulation system, outside air is allowed to flow through the headlamps. The open,
water-protected ventilation system (needed for pressure compensation) creates different “climate zones” inside
the headlamp, where the lens is either warmed up by the light or cooled down by passing air.
When high air humidity and temperature differences exist between the inside of the headlamps and the outside,
condensation can form on the inside of the lens, especially in cold and wet weather. This moisture buildup can
happen, for example, after a car wash, after steam cleaning of the engine or the front end, or after overnight
temperature changes.
This condition is more easily visible with headlamps made from clear glass. The moisture is an optical condition
which does not affect the headlamp function (light performance) and does not lead to corrosion or damage of the
internal headlamp parts.
This condition is common to all exterior vehicle lights, and can occur on every headlamp, fog lamp, or rear lamp.

Production Solution
• Optimized headlamp ventilation hose placed into production for all xenon headlamps.
• Charge air ducts placed behind intercoolers.

© 2013 Audi of America, Inc.

Page 2 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
Service

1.

Remove the headlamps and dry the inside using compressed air or a hot air blower. Check for any loose
caps, loose or unsealed control modules, or cracks in the headlamp housing(s) as the culprit of moisture
exposure.

2.

If the vehicle’s build is prior to VIN # *CD004736 and the updated ventilation hoses are not currently
installed, replace the headlamp ventilation hose for each headlamp with the new part number to help
reduce any further humidity ingress into the headlamps (see Required Parts and Tools, below). Otherwise,
proceed to step 3.
Tip: The updated ventilation hose can
be recognized by the integrated filter
(Figure 2, arrow).

Figure 2. Updated ventilation hose with integrated filter.
Tip: The updated ventilation hose is
not connected directly to the headlamp
housing. The house routes downward from
the headlamp carrier and between the
radiator and bumper (Figure 3, arrow).

Figure 3. Mounting of updated ventilation hose.
© 2013 Audi of America, Inc.

Page 3 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
3.

Cut two sections of butyl cord sealant, each
8cm long (Figure 4).

Figure 4. Butyl cord sealant, 10mm diameter
4.

Each headlight ventilation guide tube must
be sealed to protect against further
moisture ingress (Figure 5).

Figure 5. Headlamp ventilation guide tube.

© 2013 Audi of America, Inc.

Page 4 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
5.

Wrap butyl cord sealant around the left and
right ventilation tubes, taking care not to
block the air passage tube (Figure 6).

Figure 6. Initial butyl cord shown on guide tube.
6.

Knead the butyl cord sealant in place. The
butyl sealant must be excessive enough so
that the headlamp housing squeezes it and
creates a robust seal at the housing (Figure
7).

Figure 7. Butyl cord kneaded in place.

© 2013 Audi of America, Inc.

Page 5 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
7.

Leave an uncovered section of the air tube
so that there is no chance the sealant will
clog the air passage tube (Figure 8).

Figure 8. View of direction of headlamp engagement, with
appropriate butyl cord application.
8.

Reinstall headlamps. The headlamp housings will take more force than usual to install, as the butyl must be
compressed down and backwards.
Tip: When installing the headlamp, do not work back and forth during reinstallation, as this will disrupt
the butyl seal. If the seal does get disrupted, remove the headlamp completely and knead the sealant back
in place to ensure a good seal.
Tip: If the headlamps were removed after the butyl cord was already installed from a prior procedure,
remove the old sealant and replace with new sealant.

9.

Check vehicle for left and right air ducting for exiting air behind charge coolers. Vehicles built from June
2010 will not have these exit air ducts installed. Check vehicle regardless of build date. If air ducts are not
installed, continue with steps 10 – 14. Otherwise, proceed to step 15.

© 2013 Audi of America, Inc.

Page 6 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
10. Remove front wheels and wheel housing
liners. The rear of the charge air coolers
will be exposed (Figure 9).

Figure 9. View of charge air cooler with wheel well liner
removed.
11. Locate exit air duct attachment hooks on
the left and right air charge coolers
(Figures 10 and 11).

Figure 10. Lower exit air duct attachment point to charge air
cooler.

© 2013 Audi of America, Inc.

Page 7 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin

Figure 11. Upper exit air duct attachment points to charge a
cooler.
12. Affix left and right exit air ducts over the
rear of the charge air coolers (Figure 12).

Figure 12. Charge air cooler exit air duct installed.

© 2013 Audi of America, Inc.

Page 8 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
13. Inspect exit air duct attachment points to
be sure that ducts are engaged properly
over charge air cooler hooks (Figure 13).

Figure 13. View of exit air duct affixed to mounting hook.
14. Reinstall wheel well liners and wheels.
15. Please inform the customer the new ventilation hoses and sealant are only to help reduce the moisture
condition, but will not eliminate the condition completely. Moisture in the headlamp lens is normal and can
occur even with the improved filtration.

© 2013 Audi of America, Inc.

Page 9 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
Warranty
Claim Type:

Use applicable claim type. If vehicle is outside any warranty, this Technical Service
Bulletin is informational only.

Service Number:

9415

Damage Code:

0010

Labor Operations:

Remove and reinstall both headlamps

9415 2001

50 TU

Modify both headlamps and mounting

9415 5099

40 TU

Installation of left and right air ducts

6616 2000

110 TU

GFF – Checking and clearing fault codes
included in existing labor operations

No allowance

0 TU

Road test prior to service procedure

No allowance

0 TU

Road test after service procedure

No allowance

0 TU

Diagnostic Time:

Technical diagnosis at dealer’s discretion
(Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance details)
Claim Comment:

As per TSB #2028277/6

All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures
Manual. Claims are subject to review or audit by Audi Warranty.

Required Parts and Tools
Part Number

Part Description

Quantity

4L0941717A

Left Headlamp Ventilation Hose

1 (if necessary)

4L0941718A

Right Headlamp Ventilation Hose

1 (if necessary)

AKD49701004R10

Butyl Cord Sealant

0.1

7L0117339

Left charge air cooler exit duct

1 (if necessary)

7L0117340

Right charge air cooler exit duct

1 (if necessary)

© 2013 Audi of America, Inc.

Page 10 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.

Technical Service Bulletin
Additional Information
The following Technical Service Bulletin(s) will be necessary to complete this procedure:
• TSB 2012749, 94 Exterior lights, moisture accumulation
All parts and service references provided in this TSB are subject to change and/or removal. Always check with
your Parts Department and service manuals for the latest information.

© 2013 Audi of America, Inc.

Page 11 of 11

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written
permission of the publisher.