NHTSA ID Number: 10181372
Manufacturer Communication Number: A6020442056944_4
TSB/Document Date: 2020-11-05
Summary
This bulletin contains repair instructions for when the customer sees water drip from the headliner area.
60 Water entry into cabin from the sunroof area
60 20 44 2056944/4 October 7, 2020. Supersedes Technical Service Bulletin Group 60 number 20-43 dated May
28, 2020 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
Audi e-tron
Sportback
2020 - 2021
All
Not Applicable
Q3, Q8, and
Audi e-tron
quattro
2019 - 2021
All
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
4
-
Revised header (Added Audi e-tron Sportback)
Revised Warranty (Added Test Drive SRT allowance)
3
05/28/2020
Revised Production Solution (Production solutions implemented)
Revised Service (Modified work procedure)
Revised Warranty (Added Claim Types)
2
02/05/2020
Revised Technical Background (Additional root causes)
Revised Production Solution (Solution pending)
Revised Service (Added work procedure)
Revised Warranty (Added labor operations and SRTs)
Customer states:
They see a water drip from the headliner area (Figure
1).
Figure 1. Water intrusion near the headliner.
Page 1 of 14
© 2020 Audi of America, Inc.
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 Background
One or a combination of the following four possible scenarios may be present. These areas of the sunroof
system will need to be inspected as possible root causes.
1. Sunroof drain hose or outlet valve:
Visually inspect all 4 sunroof drain
hoses and valves for any damage
or obstruction (Figure 2).
Figure 2. Sunroof drain hose pinched by pillar trim.
Page 2 of 14
© 2020 Audi of America, Inc.
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.
2. Roof opening seal:
Inspect the entire perimeter of the
roof opening seal for any
detachment or malformation
(Figure 3).
Figure 3. Detached and malformed roof opening seal.
Page 3 of 14
© 2020 Audi of America, Inc.
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.
3. Glass sunroof panels:
Check all adjustment axes of the
sunroof glass panels for poor
adjustment (Figure 4).
Figure 4. Front and rear glass panel adjustment.
4. Unexplained or unduplicated water entry:
When the vehicle is exposed to water (rain, car wash, or standing water on the roof panel) either with the
vehicle stationary or driving it is possible for water to enter the sunroof frame, breach the normal water
drainage channeling, and leak into the cabin area. This is heightened if the sunroof is opened or vented
when the vehicle is wet.
Page 4 of 14
© 2020 Audi of America, Inc.
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.
This water drip may not appear
until after a driving period when the
water travels to the underside of
the headliner area during the
normal course of driving (Figures
5-7). This occurs due to a slow
migration of water along the wind
deflector hinge arms and water
entry into the stowage area for the
wind deflector. This stowage area
does not provide water drainage
away from the vehicle.
Figure 5. Front sunroof opening with drainage exposed.
Page 5 of 14
© 2020 Audi of America, Inc.
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.
Figure 6. Areas of sunroof opening water elimination capabilities.
Figure 7. Sunroof water channeling diagram.
Page 6 of 14
© 2020 Audi of America, Inc.
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.
Production Solution
Production solutions have been implemented in production. The instructions that follow are service solutions that,
when performed accurately and completely, are effective in stopping water intrusion and helps to avoid
unnecessary parts replacements.
Service
1.
Sunroof drain hose or outlet valve:
Ensure that any water in the sunroof frame drainage areas flows freely. Replace any pinched or otherwise
obstructed drain hose(s) or valve(s).
2.
Roof opening seal:
If after inspecting the roof opening seal any detachment, malformation or damage is discovered, replace the
sunroof opening seal.
3.
Glass sunroof panels:
If after all dimensional measurements are made on the sunroof glass panels a problem is found make the
necessary adjustments to the sunroof glass panels.
4.
Water entry for what appears to be through the sunroof frame:
It is not necessary to replace the sunroof frame unless there is damage found (e.g. crack in the drainage
structure, hole in the drainage structure). If damage to the sunroof frame is found, clearly mark the area of
damage. Sunroof frames replaced for damage will be requested for return to AoA for analysis. If no damage
to the sunroof frame structure is found, proceed as follows.
5.
Open the front sunroof panel
completely and locate the
mounting points for the sunroof
wind deflector (Figure 8).
Figure 8. Locating points for the sunroof wind deflector.
Page 7 of 14
© 2020 Audi of America, Inc.
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.
6.
Using a primer applicator D 009
500 25 (or equivalent) and D 009
401 04 all purpose cleaner (or
equivalent) thoroughly clean the
area shown in Figure 9. It should
be free of any lubricant or
contaminants and completely dry. Figure 9. Area of sunroof frame to be cleaned.
7.
Cut two 25mm strips of AKL 450
005 05 Butyl adhesive/sealing
cord. Firmly press each strip into
the groove shown in Figure
10. Both channels shown in the
cut away must be completely filled
with the butyl cord.
Figure 10. Preparation and application of butyl cord.
8.
Next, a small modification will be
made to the sunroof glass panel
shown in Figure 11.
Figure 11. Area of sunroof glass panel to be modified.
9.
Clean the inside surface of the
glass panel ‘skirt’ using D 009
401 04 all purpose cleaner (or
equivalent) and a clean dry cloth
as shown in Figure 12.
Figure 12. Area of glass panel ‘skirt’ to be cleaned and dried.
Page 8 of 14
© 2020 Audi of America, Inc.
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.
10. Apply D 355 205 A2 Bonding
Agent using a primer applicator
D 009 500 25 (or
equivalent). Allow bonding agent
to thoroughly dry.
Figure 13. Area of glass panel ‘skirt’ where bonding agent is to be
applied.
11. Using 251 201 525 packing cut 2
x 10mm x 10mm pads.
Figure 14. Preparing 2 – 10mm x 10mm pads of 251 201 525 packing.
12. Bond each pad to the front areas
of the sunroof glass panel ‘skirt’
as shown in figure 15. A cut away
drawing is included to illustrate
the precise positioning of each
pad from the inside.
Figure 15. Positioning and application of the 10mm x 10mm pads.
Page 9 of 14
© 2020 Audi of America, Inc.
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.
13. Using a 3356 roller tool (or
equivalent), apply firm pressure to
the newly adhered pads to
enhance the strength of adhesion.
Figure 16. Applying pressure to bonded area with 3356 roller (or
equivalent).
Warranty
Claim Type:
110 up to 48 Months/50,000 Miles.
G10 for CPO Covered Vehicles – Verify Owner.
If the vehicle is outside any warranty, this Technical Service Bulletin is informational
only.
Service Number:
Check and/or repair or replace sunroof drain hose(s): 6048.
Check and/or replace the roof opening seal: 6042.
Check and/or adjust the front and / or rear sunroof glass panel: 6039.
Perform sunroof frame modifications: 6039.
Damage Code:
0050
Labor Operations:
Check and, if necessary, repair or replace
sunroof drain hoses.
Use the
See SRT with
appropriate labor
associated
operation(s)
operations
consistent with the
necessary repair
Page 10 of 14
© 2020 Audi of America, Inc.
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.
Diagnostic Time:
Claim Comment:
Check and, if necessary, replace the roof
opening seal.
Use the
See SRT with
appropriate labor
associated
operation(s)
operations
consistent with the
necessary repair
Check and, if necessary, adjust the front
sunroof glass panel.
Use the
See SRT with
appropriate labor
associated
operation(s)
operations
consistent with the
necessary repair
Check and, if necessary, adjust the rear
sunroof glass panel.
Use the
See SRT with
appropriate labor
associated
operation(s)
operations
consistent with the
necessary repair
Perform sunroof frame modifications.
6039 9999
50 TU
GFF
No allowance
0 TU
Road test prior to the service procedure
0121 0002
10 TU
Road test after the service procedure
0121 0004
10 TU
As per TSB #2056944/4
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.
Page 11 of 14
© 2020 Audi of America, Inc.
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.
Required Parts and Tools
Always check with your Parts Department and/or ETKA for the latest information and parts bulletins.
Part Number
Part Description
Quantity
D 00940104
or equivalent
surface
preparation
solvent (e.g.
isopropyl
alcohol or
adhesion
promoter).
0.2
All Purpose Cleaner
D 355205A2
0.2
Bonding Agent
Page 12 of 14
© 2020 Audi of America, Inc.
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.
D 00950025
(or equivalent)
2
Primer Applicator
AKL45000505
0.1
Butyl Adhesive / Sealing Cord
251201525
0.5
Packing
See ETKA
Fasteners, Bolts, Nuts, and Screws as needed per the Repair Manual
Tool Number
See ETKA/ELSA
Tool Description
Page 13 of 14
© 2020 Audi of America, Inc.
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.
3356 (or equivalent tool)
Roller Tool
Additional Information
All parts and service references provided in this TSB (2056944) are subject to change and/or removal.
©2020 Audi of America, Inc. All rights reserved. The 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.
Page 14 of 14
© 2020 Audi of America, Inc.
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.
- Recommended for automotive headliners in vehicles.
- Formula dries in 30 to 60 minutes.
- Adjustable nozzle.
- Product dries clear.
- Pack of 2
- Exceptional strength bonds heavyweight automotive headliners
- Versatile formula effectively bonds headliners to metal and...
- Aerosol can dispenses a controlled, even layer on surfaces
- Recommended for automotive headliners in vehicles
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TSB/Document ID: A6020442056944_4
Replacement Service Bulletin Number:
MFR Communication Date: 2020-10-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
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