Body - Outer Door Seals Are Loose/Detached
57 Outer door seals loose
57 11 59
2019733/8
October 21, 2011.
Supersedes Technical DIAGNOSIS AND REPAIR Group 57 number 11 - 57 dated September 7, 2011 for reasons listed below.
Affected vehicles
Condition
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The outer door seals have become partially detached.
Technical Background
Loss of adhesion between the door structure and door seal due to a flaw in the attachment process in production.
Production Solution
Optimized production process.
Service
In cases where the outer door seal has become partially detached, it may not be necessary to replace the outer door seal. Seals can be reattached
provided they are not damaged, have not been previously repaired or previously reattached and the detachment length does not exceed 10 cm.
1. Inspect all four doors.
^ All undamaged, previously unrepaired, or loose seals with a detachment length less than 10 cm will be repaired. Complete steps 2-9 below to
repair the door seals.
^ If the door seal is damaged, has been previously repaired, or previously reattached or detached greater than 10 cm, replace the door seal according
to the repair instructions in Elsa Web >> Body >> Body Exterior >> 57 Front Doors, Central Locking System >> Removal and Installation >>
Doors >> Door Seals.
Note:
In addition to the repair manual instructions for replacing the door seals observe the following: Thoroughly clean the area of seal attachment with
plastic cleaner D 009 401 04. Allow the area of seal attachment to dry completely (at least 5 minutes). Apply bonding agent D 355 205 A2 using a D
009 500 25 applicator to the seal attachment area. Allow to dry an additional 5 minutes.
If repairing the door seals, proceed as follows:
2. Ensure that the temperature of the door and outer door seal are not cooler than 70锟斤拷F (21锟斤拷C). This is vital to ensure optimum adhesion of the outer
door seal.
3. Thoroughly clean the bonding surfaces of the doors to be repaired with plastic cleaner D 009 401 04. Allow the bonding surfaces to dry
completely (at least 5 minutes). The bonding surfaces must be dry and free of any dust, grease, silicone or any other similar contaminant that might
compromise the adhesion.
4. Apply bonding agent D 355 205 A2 using a D 009 500 25 applicator in the area to be bonded. Allow the treated surface to dry an additional 5
minutes.
5. Thinly coat the outer door seal with rubber profile adhesive D 477 KD1 A2 in the area that has become detached.
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6. Press the door seal lightly to the door surface and then detach it again (Figure 2). This ensures that the glue is distributed as evenly as possible on
the surfaces to be bonded.
7. Allow the now detached area to dry for 5 minutes.
8. After this time attach the seal firmly to the door surface. Roll over this area several times with special tool 3356 (or equivalent).
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9. Apply force to the seal with the 3356 only at the base of the seal (area 3 shown in Figure 4).
10. Remove any residual adhesive that may be visible with adhesive remover D 002 000 A2.
Tip: The repaired door should not be closed for two hours. During this time, any freshly glued surfaces should not be tested by pulling on the seal to
see if they have bonded.
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Warranty
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
Additional Information
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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.
