Campaign - Replacement of Coolant Flange O-Ring
19 07 05May 16, 2007
2014992/2, Supersedes Technical Service Bulletin Group 19 number 07-04 dated May 4, 2007 to add permission to sublet replacement coolant.
Models
RVU - Replacement Of Coolant Flange O-ring (I5)
Condition
This RVU has been proactively released to prevent the following condition
from occurring in the vehicle:
Coolant leak under hood from engine coolant flange.
This Required Vehicle Update (RVU) is in effect for 15 months from date of publication. After that date, this RVU will expire and no longer be in effect.
Vehicle must meet all of the following criteria:
1. Procedure is valid only for vehicles that show the I5 code in the ElsaWeb Campaign/Action Information screen on the day of repair.
2. Vehicle must be within the Limited New Vehicle Warranty.
3. Procedure must be performed within the allotted time frame stated in this Technical Service Bulletin.
4. Procedure must be performed on applicable vehicles in Dealer inventory prior to sale.
Technical Background
The coolant leak is caused by the sealing 0-ring for the coolant flange.
Production Solution
Improvement in the material of the sealing 0-ring for the coolant flange.
Service:
For A3 models:
Replace the sealing 0-ring for the coolant flange.
1. Remove the engine cover and front sound insulation under the engine.
2. Drain coolant.
3. Disconnect the vacuum lines from brake booster and loosen wiring harness in the area of the flange.
4. Remove coolant flange from cylinder head (3 bolts).
5. Replace the 0-ring and lubricate with coolant.
6. Reinstall the coolant flange. (Torque bolts to 10 Nm.)
7. Secure the wiring harness. Reinstall all the wraps and clips.
8. Reconnect the vacuum line.
9. Refill coolant and check cooling system for proper operation.
10. Reinstall the engine cover and sound insulation.
For A4 models:
Replace the sealing 0-ring for the coolant flange.
1. Remove the engine cover and front sound insulation under the engine.
2. Drain coolant.
3. Loosen the wiring harness at rear of engine and remove harness brackets.
4. Remove the U-shaped crankcase breather tube.
5. Remove the upper coolant metal pipe attachment screws.
6. Remove the hose clamp and free rear coolant hose to coolant flange from metal pipe.
7. Move the coolant metal pipe as far as possible to drivers side.
8. Unplug the coolant temperature sensor electrical connector.
9. Remove the heater core hose from the coolant flange.
10. Remove coolant flange from cylinder head (2 bolts).
11. Replace the 0-ring and lubricate with coolant.
12. Reinstall the coolant flange. (Torque bolts to 10 Nm.)
13. Reinstall hoses, pipes and tubes.
14. Reinstall harness brackets. secure the wiring harness. Reinstall all the wraps and clips.
15. Refill coolant and check cooling system for proper operation.
16. Reinstall the engine cover and sound insulation.
Warranty
Required Parts and Tools
All parts and service references provided in this RVU are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.