headlight condensation ?

[yeldarb]

i'm buying an 05 a4 and i noticed before i drove it there was a little condensation in the headlights, when i came back the lens was almost completely fogged up.i asked the guy about it and he proceeded to tell me that they just had it to the shop for the 35,000 mile checkup and the mechanic told him this was perfectly normal for an audi. i guess what i'm asking is do you guy's think this is a problem and should i be persistent and have them fix it? it is under warranty..

[pondside36]

That is not normal unless he had already done the CC or Joey mod, where he drilled the headlight to remove the orange reflector or opened the hole headlight to paint the silver part. What do your headlights look like? Do they have the orange reflector or are they say black or color matched inside? If so it may just be a matter of removing the headlight and re-siliconing the holes from the CC mod... if they are stock I would get the dealer to replace them.

[widgget]

LOL, perfectly normal for your headlights to fill with water?? guy is blowing smoke up your ass. not as good as the "you'll never find an A4 in a stick, they are so rare" i got from from my bitch dealer back before i knew any better, but i was in a jam and needed a car that day.

-Pondside (Edit), even with the clear corner mod the lights should not have any water in them if it was done right, the drill holes should be sealed with something once it's done to prevent exactly this.

[pondside36]

^^ I know it should be sealed but blowing smoke about that is normal may be his way around saying "I messed up the headlights"

[kastro]

i read up on this.. something to do with faulty "o-rings" try searching that, it's somewhat common but Not "normal" in the sense.. from what i read, the guy on the post got it fixed under warranty, lightsshould not condence, try the dealer, if they give u shit.. tell them i read on forums this is a warranty job.

[noyerrole2]

I work for an Audi dealer and the condensation on the b6's is definately normal. They are vented headlights. The condensation should go away after you have your lights on for a couple mins.

To prove it is normal, audi has sent us all bulletins that show us NOT to switch the headlights due to condensation. I will be happy to email it to you.

Also, there is a way to fix it by changing the O-Rings which one of my customers did. Its actually fairly easy but takes a little time.

Let me know if you want me to email that bulletin to you.

[yeldarb]

i Work For An Audi Dealer And The Condensation On The B6's Is Definately Normal. They Are Vented Headlights. The Condensation Should Go Away After You Have Your Lights On For A Couple Mins.

To Prove It Is Normal, Audi Has Sent Us All Bulletins That Show Us Not To Switch The Headlights Due To Condensation. I Will Be Happy To Email It To You.

Also, There Is A Way To Fix It By Changing The O-rings Which One Of My Customers Did. Its Actually Fairly Easy But Takes A Little Time.

Let Me Know If You Want Me To Email That Bulletin To You.

Yes If You Could I Would Greatly Appreciate It

[Pr0n]

As said before, this is normal, ESPECIALLY in S4 bi-xenon headlights. Yes, it is annoying but Audi won't replace it under warranty.

This is how mine looked once, and it wasn't the worse I've seen after heavy rainfall.



Here's the fix with pictures, it helped me a lot and I know nothing about cars. clicky click and another clicky click.

[Arclight]

That type of condensation looks a little bit extreme IMHO. I have gotten a light fogging at the bottom corners on a extremely humid & rainy day (once or twice in the last 2 years). It should not be a regular occurence and should clear up almost immediately. I would warranty those...

[Pr0n]

Check the filename.
Those are S4 bi-xenon's, and are a common problem with them (search the forums). Audi won't replace them under warranty, many including myself have tried.

[gdawg'05a4]

I had the same issue. Dealer took apart the headlights, dried them out and re-sealed them. Mine were just as bad as the picture above. It did work but only for a few weeks. The condensation came back. They got the regional rep involved and ended up replacing both headlights right before my warranty was up.

Rare but some have gotten them replaced. I guess it depends on your dealer.

[vc1492a]

my driver's side looks just like the red a4. it sucks

[diagnosticator]

OK, I will try and clarify the situation here. First, it is normal for the housings, either A4 or S4 Bi Xenon, to occasionally develop a very light misting of condensation inside the lens, usually associated with high humidity and cool night time air temps. This type of misting will clear away quickly as the car is driven, and won't reoccur immediately or at all. The second case is when heavy, persistent condensation exists, and does not clear completely and is more or less always present. Like shown in the pic of the red Audi in this thread. When heavy condensation is present, it is caused by water leaking into the housing and accumulating inside in the bottom of the housing. On S4 Bi Xenon housings, with the single rear cover, the most likely cause is the O ring fitted to seal the vertical shaft of the outer beam adjusters. The original O rings are too small, and allow wash and rain water to seep into the housing. On both housing types, other leak points can exist at the lens/housing joint, or the rear cover gaskets, etc. It is important to understand the difference between "Light misting", and "Heavy, persistent" condensation symptoms. The Heavy and persistent case is NOT normal, and is due to a water leak. If there is water accumulation inside the housing, that is never normal or acceptable, even if it only results in light misting in certain situations.

[T0M3K]

^^ No need for more words, he covered it perfectly.

[dantm]

So will Audi replace the lenses if there is heavy condensation present? Misty lens is one thing but some of the cars I test drove had lots of water in the headlights which would never dry out from the bulb heat.

Thoughts, comments?

Thanks.

[A4natomical]

so now we know that we need "larger" O-rings. but which ones? we go to buy new ones and theres thirty different kinds.

if you go to Lowes, Danco #6 O-Ring is the one our headlights need.

dimensions are as follows: 7/16" O.D. X 5/16" I.D. X 1/16"


i used to get condensation after every wash. I thought my condensation was
too bad to fix. Put the new O-Rings in and I have never got any condensation since.

[A4natomical]

here. this is easier. even tho its backwards. you get the jist.

[Pr0n]

In my case, I couldn't find a "#6 O-Ring" at Home Depot or Rona, so I bought an "assorted O-Ring set" and used one that was bigger than the stock ones. Don't forget powdered graphite!

[vc1492a]

I just went to advance auto parts and they matched up the o-ring size nicely, gave me one slightly larger to help as well. Headlight hasnt fogged since.

[dantm]

Is there an instruction on how to replace the o-rings? How hard are they?
Thanks!

[vc1492a]

See Links under pic for DIY. Its an easy job

As said before, this is normal, ESPECIALLY in S4 bi-xenon headlights. Yes, it is annoying but Audi won't replace it under warranty.

This is how mine looked once, and it wasn't the worse I've seen after heavy rainfall.



Here's the fix with pictures, it helped me a lot and I know nothing about cars. clicky click and another clicky click.

[Gondi Stylez]

Mine look like the red one Guess it's time to replace the O-rings....

[A4natomical]

Mine look like the red one Guess it's time to replace the O-rings....

so did mine.

when you take your headlights out. dont just replace the O-ring and put them back in. i took the xenon bulb out and shoved a microfiber towel into the housing to wipe the condensation off, then replaced the O-Ring.

[Gondi Stylez]

so did mine.

when you take your headlights out. dont just replace the O-ring and put them back in. i took the xenon bulb out and shoved a microfiber towel into the housing to wipe the condensation off, then replaced the O-Ring.

Thanks! I'll do that for sure!

[h_curtis]

I am about to do this, but that new O-Ring looks excessive. It is unlikely the Germans would be that far off. Hope to fine one in a size between those two.

[Seerlah]

So, Audi in a nutshell f*cked up on the o-ring size and coughed it up to your headlights fogging up being normal? Another AoA production, at it's finest.

[h_curtis]

So, Audi in a nutshell f*cked up on the o-ring size and coughed it up to your headlights fogging up being normal? Another AoA production, at it's finest.

I took it apart at my buddies garage. Been working on cars for 30 years and he has been working on them professionally for 35 years, has his own shop with porsche, Audis and BMWs roaming around all the time. It isn't the "wrong size". It sits in a bad spot where water can sit. What happens is water sits and dries over and over again. The lights don't fog up when new or a year or two old. Therefore the o-ring is the correct size, it is that it dry rots. That is what happened to mine as I inspected it. I took it out and replaced it with the same size o-ring. Only difference this time is I put some thick grease that will probably last many years and to not have water sit in that spot anymore, I cut some inner tube and made a blanket overtop of that area. Not more water sitting there. This fix will be permanent. I wouldn't' put some huge o-ring in there, but you can do what you like.

[woofster]

Well...as luck would have it, I noticed some condensation in my driver's side headlight assembly for the first time today. I'm surprised it lasted this long until the first signs of water seepage. Thanks to all who posted photos or links in this thread.

[inlovewithaudi]

just use a sealant