A5120162060145_2

51 Cracking noises in right rear roof area during steering thrust
51 20 16 2060145/2 October 16, 2020. Supersedes Technical Service Bulletin Group 51 number 20-14 dated July
24, 2020 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
Q8, SQ8
2019 - 2021
All
Not Applicable
RSQ8
2020 - 2021
All
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
2
-
Revised header (Add MY 2021)
1
07/24/2020
Initial publication
Customer states:
 They hear a noise specifically in the right rear roof area of the cabin with an abrupt steering thrust or when the
vehicle is flexed.
 The noise is characterized as a ‘cracking’ or ‘snap’ type of noise.
Workshop findings:
 The noise is diagnosed as being from the right rear-most area of the sunroof opening, specifically in the roof
structure.
Technical Background
The current structural tolerances between the roof panel and the roof support sheet metal can generate these
noises intermittently under driving conditions that cause the body to flex such as during an acute steering
maneuver.
Production Solution
Not applicable.
Page 1 of 9
© 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.
Service
Note:
Ask the customer if they could duplicate the symptom by accompanying them for a test drive. If the noise cannot
be duplicated during a test drive with the customer do not perform the repair in this TSB. Be certain that the
noise type and location is clearly attributable to the issue described in the Technical Background in this
TSB. The following work procedure must only be carried out if the symptom described has been duplicated and
the source of the noise is as described in the Technical Background.
In spite of the noise source coming from the right rear of the sunroof opening, the following work procedure is to
be performed to the corresponding side on the left rear-most area of the sunroof opening as well.
1.
Remove the headliner and
sliding sunroof assembly. Figure
1 shows the area to be reworked
in the rear of the sunroof
opening, beginning with the right
rear.
Figure 1. Right rear area of sunroof opening to be reworked.
2.
A 10 mm diameter hole is to be
drilled in the spot marked with
the red dot shown in Figure 2.
Figure 2. The red dot shows the location of the 10 mm hole to be drilled.
Page 2 of 9
© 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.
Note:
The penetration depth of the drill bit must not exceed 3 mm. If this depth is exceeded irreparable damage can be
done to the roof structure requiring replacement.
3.
There are a number of methods
for limiting the drill depth. Among
them is the use of a drill bit
depth stop (Figure 3).
Figure 3. 10 mm drill bit with a depth stop installed.
4.
Drill the 10 mm hole no deeper
than 3 mm (Figure 4). Make
certain to contain the drilling
shavings so they can be
removed from the cabin.
Figure 4. Drilling the 10 mm hole.
Page 3 of 9
© 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.
5.
Figure 5 shows the drilled hole.
Figure 5. Hole drilled.
6.
2K insert foam D 506 KD1 A3 –
or- D 506 KD1 A4 will be
needed for the rework
procedure. Shake the can for
two full minutes plus an
additional 20 shakes to ensure a
homogenized mixture (Figure 6).
Figure 6. Foam to be used in the rework procedure.
Page 4 of 9
© 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.
7.
The canister must be held
vertically with the nozzle pointing
down whenever the foam is
ejected. Before injecting the
foam the nozzle and tube must
be purged of air released (Figure
7). Blow out about a 20 cm
stream of foam.
Remember to hold the can
vertically with the nozzle pointing
down. When the trigger is fully
pulled, about 0.25 liters of foam
is ejected per second. The foam
will expand up to 100%.
Figure 7. Purging air from the nozzle in preparation of the cavity fill.
8.
The shaded area in Figure 8 is
the area on each side where the
foam is to be injected. To do
this the foam must fill the cavity
by first inserting the hose in the
‘B’ direction to a length of 2 cm,
then inserted in the ‘A’ direction
3 – 4 cm and filling for 1 full
second of trigger activation per
hose direction shown in Figure
8. This should fill the area with
the appropriate volume. Do not
exceed 1 full second of trigger
pulse per fill as the volume of
foam injected will be too great.
Figure 8. Foam nozzle hose positioning and cavity fill area.
Page 5 of 9
© 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.
9.
Figure 9 illustrates the hose as it
will be inserted in the ‘B’
direction.
Figure 9. Hose insertion simulation in the ‘B’ direction.
10. Figure 10 illustrates the hose as
it will be inserted in the ‘A’
direction.
Figure 10. Hose insertion simulation in the ‘A’ direction.
Page 6 of 9
© 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.
11. Fill the cavity (Figure 11).
Figure 11. Filling the cavity with foam.
12. Cavity filled with the correct
volume of foam (Figure
12). Allow the foam to cure for
12 hours.
Figure 12. A filled cavity.
Again, perform this procedure to both rear corners. Test drive the vehicle thoroughly and ensure that the noises
have been eliminated.
Page 7 of 9
© 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.
Remember to set the sunroof panel and rollershade end stop adaptation after reassembly using the sunroof
panel and rollershade switches. Refer to TSB 2054505: 60 Sunroof glass panel or sunroof rollershade do not
operate for instructions.
Warranty
Claim Type:
 110 up to 48 Months/50,000 Miles.
 If the vehicle is outside any warranty, this Technical Service Bulletin is informational
only.
Service Number:
5103
Damage Code:
0020
Labor Operations:
Headliner remove and reinstall
7084 1900
See SRT with
associated
operations
Sunroof frame remove and reinstall
6028 1950
See SRT with
associated
operations
Perform roof rework
5103 9999
30 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
Diagnostic Time:
Claim Comment:
As per TSB #2060145/2
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 8 of 9
© 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 506KD1A3
01
Or
D 506KD1A4
2K-Insert Foam
See ETKA
Fasteners, Bolts, Nuts, and Screws as needed per the Repair Manual
See
ETKA/ELSA
Additional Information
The following Technical Service Bulletin(s) will be necessary to complete this procedure:
 TSB 2054505, 60 Sunroof glass panel or sunroof rollershade do not operate.
All parts and service references provided in this TSB (2060145) 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 9 of 9
© 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.