2028277/5

Technical Service Bulletin
94 Moisture accumulation in headlamps
94 13 01 2028277/5 January 2, 2013. Supersedes Technical Service Bulletin Group 94 number 12-98 dated
November 21, 2012 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
Q7
2010-2014
All
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
5
-
Revised Service (added air duct install)
Revised Warranty
Revised Required Parts and Tools
4
11/21/12
Revised Service
Revised Warranty
Revised Required Parts and Tools
Revised Header data (added model years)
3
10/24/12
Revised Required Parts and Tools
Revised Production Solution
2
3/1/12
Revised Service
Revised Required Parts and Tools
1
12/20/2011
Original publication
Page 1 of 10
© 2013 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 Service Bulletin
Customer Complaint:
 Considerable moisture present in
headlamp.
 The moisture disappears only after
extended drives (greater than 10
minutes).
Workshop Findings:
 No external damage to 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. The moisture in the
headlamps can be compared with condensation on the windshield, which is cleared by the "defroster vent". 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 nor does it lead to
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.
Page 2 of 10
© 2013 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 Service Bulletin
Service
1. Remove the headlamps and dry the inside using compressed air or hot air blower.
2. If vehicle’ s build is prior to VIN #
*CD004736, replace the
headlamp ventilation hose for
each headlamp with the new part
number to help reduce any further
humidity ingress into the
headlamps (see Part information
table below). Otherwise, move to
step 3.
The updated ventilation hose can
be recognized by the integrated
filter (Figure 2).
Figure 2. Updated ventilation hose with integrated filter.
3. Cut two sections of butyl cord
sealant, 8cm long each (Figure 3).
Figure 3. Butyl cord sealant, 10mm diameter.
Page 3 of 10
© 2013 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 Service Bulletin
4. Each headlight ventilation guide
tube must be sealed to protect
against further moisture ingress
(Figure 4).
Figure 4. Headlamp ventilation guide tube.
5. Wrap butyl cord sealant around
the left and right ventilation tubes,
taking care not to block the air
passage tube (Figure 5).
Figure 5. Initial butyl cord shown on guide tube.
Page 4 of 10
© 2013 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 Service Bulletin
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 6).
Figure 6. Butyl cord kneaded in place.
7. Leave an uncovered section of
the air tube so that there is no
chance the sealant will clog the
air passage tube (Figure 7).
Figure 7. View of direction of headlamp engagement, with
appropriate butyl cord application.
Page 5 of 10
© 2013 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 Service Bulletin
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 this occurs, remove the headlamp completely and knead the sealant back
in place to ensure a good seal.
If the headlamps were removed after butyl cord was already installed from a prior procedure,
remove old sealant and replace with new sealant.
9.
Check vehicle for left and right air ducting for exiting air behind charge air 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, follow instructions below.
10. Remove front wheels and wheel
housing liners. The rear of the
charge air coolers will be exposed
(Figure 8).
Figure 8. View of charge air cooler with wheel well liner
removed
Page 6 of 10
© 2013 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 Service Bulletin
11. Locate exit air duct attachment
hooks on the left and right charge
air coolers (Figure 9 and 10).
Figure 9. Lower exit air duct attachment point to charge air
cooler.
Figure 10. Upper exit air duct attachment points to charge air
cooler.
Page 7 of 10
© 2013 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 Service Bulletin
12. Affix left and right exit air ducts
over the rear of the charge air
coolers (Figure 11).
Figure 11. Charge air cooler exit air duct installed.
13. Inspect exit air duct attachment
points to be sure ducts are
engaged properly over charge air
cooler hooks (Figure 12).
Figure 12. 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 this condition completely. Moisture in the headlamp lens is
normal and can occur even with the improved filtration.
Page 8 of 10
© 2013 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 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
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:
included in existing labor operations
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 #2028277/5
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 9 of 10
© 2013 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 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)
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)
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.
Page 10 of 10
© 2013 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.