19 Coolant Leak In Area Of Coolant Thermostat Housing/Coolant Pump - 2.0TFSI (GROUP 19, NO. 22-33)

19 COOLANT LEAK IN AREA OF COOLANT THERMOSTAT HOUSING/COOLANT PUMP - 2.0TFSI

TECHNICAL SERVICE BULLETIN

SERVICE INFORMATION

19 22 33 2061604/5 November 2, 2022. Supersedes Technical Service Bulletin Group 19 number 21-18 dated May 28, 2021, for reasons listed below.

CONDITION

Customer state: 

• The coolant temperature warning light is on.
• There are clear coolant marks under the front end/engine compartment.

Workshop findings: 

• The leak can be reproduced.
• The cause for the coolant loss is found around the coolant thermostat housing or the coolant pump.

TECHNICAL BACKGROUND

Coolant loss from the coolant thermostat housing (Figure 1, position 1) or the coolant pump (Figure 1, position 2).

PRODUCTION SOLUTION

Not applicable.

SERVICE

Check the cooling system for leaks according to the repair manual (pressure check).

Only replace the leaking component (coolant pump or coolant thermostat housing).

Proceed as follows: 

1. Remove the coolant thermostat housing including the coolant pump according to Elsa at repair manual: Engine >> 4 - Cylinder Direct Injection >> 19 Cooling System >> Coolant Pump/Coolant Thermostat > > Coolant Pump, Removing and Installing. 
2. Separate the water pump and coolant thermostat housing by removing the five connecting bolts (Figures 1 - 2).
3. Replacing the leaking component (coolant thermostat housing or coolant pump) with a replacement part, proceed as follows:
   • Assemble the coolant thermostat housing and the coolant pump and attach the five connecting bolts.
   • Align the two components against one another in such a way that both components are flush to one another in the areas marked in red (Figure 2). The thermostat housing must not be higher/lower than the coolant pump (run your finger over the three areas to check).
   • Torque the connecting bolts of the two components to 10 Nm.
4. Install the assembled coolant module to the engine. Make sure the bolts are only hand-tight at this point. 
5. Check the toothed belt tension (Figure 3) by pressing the toothed belt together centrally between the two toothed belt sprockets. The measured distance of the backs of the toothed belt should be between 28mm and 30mm. A measuring caliper can also be used for toothed belt compression and measurement.

   The measured distance is between 28mm and 30mm: 

6. Complete the installation of the coolant module according to the instructions in the Elsa repair manual (Step 7 is not necessary)  .

   The measured distance is smaller than 28mm and greater than 30mm: 

7. Adjustment of the toothed belt tension is necessary. Proceed as follows using Figure 4 for reference:
   • Make note of the measured value (e.g. 26mm) from step  5.
   • Remove the cooling module from the engine again, loosen the coolant pump bolts (Figure 2) and make adjustments as outlined below.
   • If the measured distance of the backs of the toothed belt (pressed together) is less than 28mm (e.g. 25mm), then the belt tension is too low. A slight adjustment away from the balance shaft is necessary (direction "a")  .
   • If the distance of the backs of the toothed belt (pressed together) is greater than 28mm (e.g. 32 mm), then the belt tension is too great. A slight adjustment towards the balance shaft is necessary (direction "b")  .
8. Tighten the five securing bolts of the coolant pump and repeat steps  4 and  5.

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

More information on this system can be found in the following resources:

• Warranty Online: Warranty Policy and Procedures section 3.21.9.
• Elsa: Engine >> 4 - Cylinder Direct Injection >> 19 Cooling System >> Coolant Pump/Coolant Thermostat >> Coolant Pump, Removing and Installing.

All parts and service references provided in this TSB (2061604  ) are subject to change and/or removal.

©2022 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.