My Superb went in yesterday to have the dealer apply the attached TSB.  Hopefully that finally sorts the sunroof creaks and rattles.

 

Dealer called last night and said it was taking longer than expected so they needed to keep her overnight.

 

I've got a 1.4 Rapid as a loaner which is quite a nice little car, although the dry 7 sp DSG is rough compared to the 6 speed wet.

SunroofNoiseTSB.pdf

Heh, dealer wants it for a 3rd day 

So the dealer took 3 days to do the TSB and it didn't fix the problem.

 

The wanted to replace the sunroof frame.  Surprisingly Allianz (the extended warranty provider) agreed to cover the parts and a small bit of labour for this.

 

After the frame replacement, the noise appears to be gone.  Apparently, the frame replacement took almost a full day and Allianz would only pay for 4 hours labour.  The dealer absorbed the rest.

 

Hopefully, the problem is now resolved.

 

The dealer, unfortunately, left the right-side motor for the boot roller cover retraction unplugged, so I had to re-attach that myself.  They also left various bits of trim not clipped in properly or not aligned which I've had to correct too, along with removing various dirty hand prints from the roof and pillar linings.

 

With all that fixed the car is back to being pretty much silent again.

 

This morning, however, I've received the dreaded "Bend Lighting (AFS) Fault".  So next I'll have to check and clean the connections on these units before hitting up eBay for a 2nd hand controller.  My car is not going back to the dealers again.  It'll be independents from here on.

 

 

For those doing this in future, the ELSA instructions to change the "headlight performance unit" 7L6941329B go something like this:

- Remove headlight;

- To remove headlight, remove front bumper;

- To remove front bumper, remove wheel arch lining;

- To remove wheel arch lining, remove wheel.

 

You can actually do it by just removing the fog light and going up from there.  One screw is directly accessible, one needs a ball-end allen key and the other you can get to from above.  This is for the left-side unit, the right-side I suspect access will be blocked upwards by the washer bottle.  An alternative may be a stubby torx driver.  I've printed and used these successfully in the past in similar tight spaces.

 

Then when you've replaced the module, the car will throw some codes.  One will be module not coded for the one you replaced, one will be basic settings not applied.

 

In VCDS:

Select module 55 "Headlight Range"

Select Coding

Just re-apply the same coding to the master unit, this will recode the replacement sub-unit.

Then clear codes on module 55.

Then basic settings, group 01, ON (this is to calibrate the headlight height).

I didn't change any heights using the hex adjusters, I just pressed NEXT to save the same settings.

Then clear codes.  

You should be good now.

 

As to why it failed, it seems that at some point the rubber seal on the headlight where you reach in to change the parking light has gone AWOL.  This has let water into the unit.  The plug for the headlight performance unit is at the bottom and got wet.  This let water into the module.  I found a replacement rubber thingy on ebay for around $20AUD shipped.  Just search for HELLA 153874 (it's written on the part).  I've used duct tape in the mean time to seal it up.

 

Regarding getting the 7L6941329B part, the dealer wanted $550AUD and said it would take 3 weeks to arrive.  I got a brand new one from Ebay, from Lithuania, shipped and arrived in 3 days for $130AUD.