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Jerry
Jerry, Master Mechanic
Category: Audi
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Experience:  ASE Master, 30+ years exp. imports and domestic, former shop owner
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Audi a4 2003 1.

Resolved Question:

audi a4 2003 1.8 no heat or very little
Submitted: 7 years ago.
Category: Audi
Expert:  Jerry replied 7 years ago.

Hello and welcome to Just answer.com, Super mechanic here. About your vehicle.

 

 

There has been a service bulletin for that type of concern. Here is what it states.

 

 

Notes

19 08 14

(NNN) NNN-NNNN4

November 21, 2008.

Supersedes Technical Service Bulletin Group 19 number 05-03 dated April 8, 2005 for reasons listed below.

19 Coolant Leak or No Heat in Passenger Compartment From HVAC

 

 

graphic

 

Customer concern of loss of coolant, but no leak in cooling system can be found.

 

-Customer concern of no heat or noticeable drop in heat output in passenger compartment from HVAC system when engine at idle.

 

Both concerns may be caused by a coolant leak from plastic plug.

 

 

 

graphic

 

 

 

Plug is installed in engine cylinder block near connection for thermostat housing (arrow).

Production Solution

Improved Coolant Plug.

Service

Other than loss of coolant, a leaking plug can cause air to enter into the cooling system and reduce the effectiveness of the passenger compartment heating system.

-Cooling system MUST be tested for leaks with engine cold (below

 

32 degree F / 0 degree C ) (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, checking for leaks").

Tip: The leak from this plug usually occurs only when the engine is cold (below 32 degree F / 0 degree C ).

If cooling system is tested for leaks with engine warm or hot:

-Leaks from this plug may not be detected.

 

Tip: Coolant leak from this plug can be sometimes misdiagnosed as a leaking coolant thermostat housing. Always carefully inspect suspected areas to detect the actual source of the leak.

-Carefully inspect area where plug is located.

 

If the plug is found to be leaking:

-Remove and replace the plug.-> Required Parts and Tools

 

-Remove sound insulation below engine.

 

-Drain coolant (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, draining and filling").

 

-Remove upper engine cover.

 

-Unfasten coolant reservoir and move to aside.

 

Electrical connector of coolant level sensor must be unplugged.

It is not necessary to remove coolant hoses from coolant reservoir.

-Remove oil dipstick bracket bolts (2x).

 

-Carefully remove upper dipstick tube (orange plastic

 

Ensure that the O-ring on lower steel tube is not lost when tube is removed).

-Remove bolt from plastic plug.

 

-Remove plastic plug from engine block.

 

-Install a new plastic plug and secure with bolt to engine block.

 

Fastener torque = 23 Nm .

-Reassemble dipstick tube and coolant reservoir.

 

-Use the VAS 6096/1 to refill and bleed the cooling system (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, draining and filling" for details and approved coolant antifreeze).

 

When refilling engine with coolant:

-Always ensure that any trapped air is bled out of cooling system (including heater core).

 

-Recheck for leaks on cooling system (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, checking for leaks").

 

-Reinstall sound insulation below engine.

 

-Reinstall upper engine cover.

 

Jerry and 2 other Audi Specialists are ready to help you
Expert:  Jerry replied 7 years ago.

Hello and welcome to Just answer.com, Super mechanic here. About your vehicle.

 

 

There has been a service bulletin for that type of concern. Here is what it states.

 

 

Notes

19 08 14

(NNN) NNN-NNNN4

November 21, 2008.

Supersedes Technical Service Bulletin Group 19 number 05-03 dated April 8, 2005 for reasons listed below.

19 Coolant Leak or No Heat in Passenger Compartment From HVAC

 

 

graphic

 

Customer concern of loss of coolant, but no leak in cooling system can be found.

 

-Customer concern of no heat or noticeable drop in heat output in passenger compartment from HVAC system when engine at idle.

 

Both concerns may be caused by a coolant leak from plastic plug.

 

 

 

graphic

 

 

 

Plug is installed in engine cylinder block near connection for thermostat housing (arrow).

Production Solution

Improved Coolant Plug.

Service

Other than loss of coolant, a leaking plug can cause air to enter into the cooling system and reduce the effectiveness of the passenger compartment heating system.

-Cooling system MUST be tested for leaks with engine cold (below

 

32 degree F / 0 degree C ) (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, checking for leaks").

Tip: The leak from this plug usually occurs only when the engine is cold (below 32 degree F / 0 degree C ).

If cooling system is tested for leaks with engine warm or hot:

-Leaks from this plug may not be detected.

 

Tip: Coolant leak from this plug can be sometimes misdiagnosed as a leaking coolant thermostat housing. Always carefully inspect suspected areas to detect the actual source of the leak.

-Carefully inspect area where plug is located.

 

If the plug is found to be leaking:

-Remove and replace the plug.-> Required Parts and Tools

 

-Remove sound insulation below engine.

 

-Drain coolant (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, draining and filling").

 

-Remove upper engine cover.

 

-Unfasten coolant reservoir and move to aside.

 

Electrical connector of coolant level sensor must be unplugged.

It is not necessary to remove coolant hoses from coolant reservoir.

-Remove oil dipstick bracket bolts (2x).

 

-Carefully remove upper dipstick tube (orange plastic

 

Ensure that the O-ring on lower steel tube is not lost when tube is removed).

-Remove bolt from plastic plug.

 

-Remove plastic plug from engine block.

 

-Install a new plastic plug and secure with bolt to engine block.

 

Fastener torque = 23 Nm .

-Reassemble dipstick tube and coolant reservoir.

 

-Use the VAS 6096/1 to refill and bleed the cooling system (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, draining and filling" for details and approved coolant antifreeze).

 

When refilling engine with coolant:

-Always ensure that any trapped air is bled out of cooling system (including heater core).

 

-Recheck for leaks on cooling system (see ElsaWeb Repair Manual, Engine Mechanical, 19 Engine Cooling, "Cooling system, checking for leaks").

 

-Reinstall sound insulation below engine.

 

-Reinstall upper engine cover.