2028277/11

Technical Service Bulletin
94 Moisture accumulation in headlamps
94 14 44 2028277/11 June 26, 2014. Supersedes Technical Service Bulletin Group 94 number 13-30 dated
December 20, 2013 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
Q7
2010 - 2014
All
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
11
-
Revised Warranty (Corrected labor operation)
10
12/20/2013
Revised Service (Clarity)
Revised Warranty (Updated labor operations)
Revised Required Parts and Tools (Updated part numbers)
9
8/13/2013
Revised Warranty (Updated Labor Operations)
8
7/18/2013
Revised Required Parts and Tools (Added alternate part numbers)
7
7/3/2013
Revised Service (Added sealing ring instructions; removed butyl cord instructions)
Revised Required Parts and Tools (Removed butyl cord sealant; added sealing
ring)
6
3/6/2013
Revised Service (Added information on vent tube)
5
1/2/2013
Revised Service (Added air duct install)
Revised Warranty
Revised Required Parts and Tools
© 2014 Audi of America, Inc.
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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.
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 source of moisture
exposure.
2.
Vehicles prior to VIN # *CD004736 were not built with the updated ventilation hoses. If the updated
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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
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). 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
hose routes downward from the headlamp carrier
and between the radiator and bumper (Figure 3,
arrow).
Figure 3. Mounting of updated ventilation hose.
© 2014 Audi of America, Inc.
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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.
Each headlamp air ventilation tube must be
sealed to protect against further moisture
ingress (Figure 4).
Figure 4. Headlamp ventilation guide tube.
4.
Install ring seal on headlamp air ventilation
tube (Figure 5). The larger diameter of the
seal faces the headlamp.
Figure 5. Ring seal installed on headlamp air tube.
5.
Reinstall headlamps.
Tip: If the headlamps were removed after butyl cord or other rubber type of sealant was already applied
to air tubes from a prior procedure, remove the old sealant before installing headlamps.
6.
Check vehicle for left and right air ducting for exiting air behind charge coolers (3.0 TDI air-air heat
exchange) or additional water radiators for charge air cooling (3.0 TFSI water-air heat exchange). 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 7 – 11. Otherwise, proceed to step 12.
© 2014 Audi of America, Inc.
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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.
Remove front wheels and wheel housing
liners. The rear of the charge air coolers or
additional radiators will be exposed (Figure
6).
Figure 6. View of additional radiator with wheel well liner
removed.
8.
Locate exit air duct attachment hooks on
the left and right charge air coolers or
additional radiators (Figures 7 and 8).
Figure 7. Lower exit air duct attachment point to additional
radiator.
© 2014 Audi of America, Inc.
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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 8. Upper exit air duct attachment points to additional
radiator.
9.
Affix left and right exit air ducts (Figure 9).
Figure 9. Exit air duct installed.
© 2014 Audi of America, Inc.
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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. Inspect exit air duct attachment points to
be sure that ducts are engaged properly
over hooks (Figure 10).
Figure 10. View of exit air duct affixed to mounting hook.
11. Reinstall wheel well liners and wheels.
12. Inform the customer that the new ventilation hoses and sealant are only to help reduce the moisture
condition, and will not eliminate the condition completely. Moisture in the headlamp lens is normal and can
occur even with the improved filtration and ducting. Vehicle may need to be driven at sufficient highway
speeds to help aid in clearing out headlamps.
© 2014 Audi of America, Inc.
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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 2000
40 TU
Adjust both headlamps
9415 1600
20 TU
Modify both headlamps and mounting
9415 5099
40 TU
Installation of left and right air ducts
6616 2000
90 TU
GFF – Perform basic settings for headlight adjustment
0150 0000
Time stated on
diagnostic
protocol
(Max 30 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 #2028277/11
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.
© 2014 Audi of America, Inc.
Page 8 of 9
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
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)
4L0941123
Sealing Ring
2
7P5117339D (if not available, use 7L0117339)
Left charge air cooler exit duct, 3.0TFSI
1 (if necessary)
7P0117340 (if not available, use 7L0117340)
Right charge air cooler exit duct, 3.0TFSI
1 (if necessary)
7L0117339
Left charge air cooler exit duct, 3.0TDI
1 (if necessary)
7L0117340
Right charge air cooler exit duct, 3.0TDI
1 (if necessary)
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 (2028277) are subject to change and/or removal. Always
check with your Parts Department and service manuals for the latest information.
© 2014 Audi of America, Inc.
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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.