2023-2024 Audi Thermostat Oil Seal Leak TSB 19PP

Symptoms

Audi has proactively released Technical Service Bulletin (TSB) 19PP to address a potential issue with the thermostat in certain 2023-2024 models. The primary symptom of this condition is a potential "leaks in the thermostat" due to wear or deformation of the oil seal located inside the thermostat. This proactive update aims to prevent the condition from occurring, meaning owners may not experience any symptoms before the service action is performed.

If left unaddressed, this wear could eventually lead to coolant loss and potential engine overheating issues, impacting the vehicle's cooling system efficiency. This TSB is a preventative measure to avoid such future problems, including a potential 2024 Audi Q7 thermostat leak.

Important Warnings and Eligibility

Audi Technical Service Bulletin 19PP outlines several critical points for both technicians and owners:

• High-Voltage Safety (Q5 Hybrid Only): For Audi Q5 hybrid models, working on or near the high-voltage system presents a risk of "severe bodily injury or death by electrocution or electric arcs." The high-voltage system must be de-energized by an Audi high-voltage technician (HVT) or expert (HVE) before any work. There is also a "Risk of injury - motor may start unexpectedly" in electric or hybrid vehicles, and "Risk of damage to high-voltage wiring" if not handled correctly.
• Cooling System Pressure: The cooling system is under pressure when the engine is warm. There is a "risk of scalding due to hot steam and hot coolant." Technicians must wear safety gloves and protective eyewear, and carefully reduce pressure.
• Radiator Fan: There is a "risk of injury if the radiator fan turns on by itself!" Technicians must disconnect connectors to prevent this.
• Eligibility Verification: The procedure is valid only for vehicles that show the 19PP code in the ELSA Campaign/Action Information screen on the day of repair. The vehicle must also be within its New Vehicle Limited Warranty. This update must be performed on applicable vehicles in dealer inventory prior to sale.
• ELSA System is Binding: The ELSA system is the only binding inquiry and verification system for vehicle eligibility. Other systems are not valid and may result in non-payment of a claim.
• Customer Notification: Audi requires dealers to inform customers in writing by recording all work conducted on the vehicle, including any updates completed under TSB 19PP, on the Repair Order.
• Repair Order: All campaigns/actions with a repair available must be performed in order of their start date, with the oldest performed first unless otherwise noted.

Diagnosis and Eligibility

This TSB is a proactive update, meaning it aims to prevent the condition from occurring rather than addressing an existing fault code or warning light. Therefore, there are no specific diagnostic trouble codes (DTCs) associated with this bulletin. Eligibility is determined solely by the Audi ELSA system.

To determine if your vehicle is eligible for this update, an authorized Audi dealer must check the ELSA Campaign/Action Information screen. The vehicle must display the 19PP code on the day of repair, indicating its eligibility for this specific service action. If the 19PP code appears to have been performed but still shows open in ELSA, the dealer must contact Audi Warranty before proceeding.

Repair Procedure Summary

The repair procedure outlined in TSB 19PP involves replacing the engine temperature control actuator, also known as the thermostat. This is a comprehensive process that requires specialized tools and expertise, particularly for Q5 hybrid models due to their high-voltage systems.

1. De-energize High-Voltage System (Q5 Hybrid Only): For Q5 hybrid models, the high-voltage system must first be safely de-energized. This critical step, performed by an Audi high-voltage technician, follows the ELSA repair manual path: Engine > 4-Cylinder Direct Injection 2.0L 4V TFSI Engine (EA 888 Generation III) > 93 Electric drive > High-Voltage System De-Energized. This step uses special tool T40262/1, a padlock, to secure the disconnected high-voltage system.
2. Prepare Cooling System: Before replacing the thermostat, technicians must carefully reduce pressure in the cooling system by covering the coolant expansion tank cap with a cloth and slowly opening it. Safety gloves and protective eyewear are mandatory.
3. Replace N493 Engine Temperature Control Actuator: The N493 engine temperature control actuator (thermostat) is replaced according to the ELSA repair manual. The specific manual path varies by model:
   • Q3 and Q5 Hybrid: Engine > 4-Cylinder Direct Injection 2.0L 4V TFSI Engine (EA 888 Generation III) > 19 Cooling System > Coolant Pump/Coolant Thermostat > Engine Temperature Control Actuator N493, Removing and Installing.
   • All other vehicles (including 2024 Audi Q7 thermostat leak repair): Engine > 4-Cylinder Direct Injection 2.0L 4V TFSI Engine (EA 888evo4 BZ) > 19 Cooling System > Coolant Pump/Coolant Thermostat > Engine Temperature Control Actuator N493, Removing and Installing. O-rings for coolant hose quick connectors can be reused unless damaged.
4. Re-energize High-Voltage System (Q5 Hybrid Only): After installation, the high-voltage system in Q5 hybrid models is re-energized by a qualified Audi high-voltage technician, following the ELSA repair manual path: Engine > 4-Cylinder Direct Injection 2.0L 4V TFSI Engine (EA 888 Generation III) > 93 Electric drive > High-Voltage System, Re-Energizing.
5. Fill Cooling System: A battery charger is connected, and the vehicle is scanned using GFF. The cooling system is then refilled per the ELSA repair manual, with specific paths for Q3/Q5 Hybrid models (EA 888 Generation III) and all other vehicles (EA 888evo4 BZ).
6. Adapt Actuator: Finally, the engine temperature control actuator is adapted by selecting guided functions for address 0001 and performing the test plan "Adapt N493-Engine temperature control actuator." Fault memory is cleared, and the GFF log is sent online upon exiting the ODIS session.

Required Parts

The following parts may be required for the thermostat replacement, depending on the specific vehicle criteria:

• THERMOSTAT: Part Number 06L-121-111-P
• SEAL: Part Number 06L-121-043-F
• GASKET: Part Number 06K-133-073 or 06K-133-073D (confirm part number in ETKA)
• ROUND SEAL: Part Number WHT-004-973
• COOLANT (USA ONLY): G 12E0501G RTU (Ready to Use), G 12E1001G CON (Concentrate), or G 12E050S0 (Pre-mix)
• COOLANT (CANADA ONLY): G 12E1001G CON (Concentrate), G 12E1002G CON (Concentrate)
• Additional GASKETS (for Criteria 03, e.g., Q5 Hybrid): Part Numbers 8W0-253-115-D, 8W0-253-115-P
• CLAMP (for Criteria 03): Part Number 8W0-253-141-A
• SEAL STRIP (for Criteria 03): Part Number 8W0-839-155
• CYLINDER HEAD SCREW WITH TORX HEAD, SELF (for Criteria 03): Part Number N 10518405
• SHOULDERED HEX. NUT, SELF-LOCKING (for Criteria 03): Part Number N 91130802

Required Special Tools

Specialized tools are necessary to perform this update correctly and safely:

• Cooling System Tester - Adapter: VAG1274/8
• Cooling System Charge Kit: VAS6096
• Hose Clip Pliers: VAS6362 (or equivalent)
• Socket - T30: T10405 (or equivalent)
• Engine Bung Set: VAS6122 (or equivalent)
• Hose Clamps - Up To 25mm: 3094 (or equivalent)

For Q5 hybrid models, additional high-voltage specific tools are required:

• Test Adapter - Hybrid Module: VAS6558A
• Warning Sign - "Do Not Switch On": VAS6650A
• Warning Sign - High Voltage: VAS6649
• Padlock: T40262/1 (from Service Disconnect Lock - T40262-)

Warranty Information

This service action is covered under warranty with Service Number 19PP. The Damage Code is 0099, and the Parts Vendor Code is 002. The Causal Indicator is marked as "THERMOSTAT*".

Claim Types:

• Sold vehicle: 710
• Unsold vehicle: 790

Labor Operations (Time Units vary by model criteria):

• Thermostat housing remove+reinstall: Labor Op 1955 19 15, 1955 19 83, or 1955 19 65
• Battery charge: Labor Op 2706 89 50
• GFF/Guided functions: Labor Op 0150 00 60
• Coolant pump remove+reinstall: Labor Op 1950 19 83 or 1950 19 33 or 1950 19 63
• Noise dampening pan remove+reinstall: Labor Op 1082 19 00
• Particle filter remove+reinstall (Q5 hybrid only): Labor Op 2674 19 13
• Disable HV system voltage deactivate and activate (Q5 hybrid only): Labor Op 9310 83 50

Dealers are instructed not to claim wash/loaner services under this action. If a vehicle has multiple applicable criteria, all should be completed and claimed on one claim.

Owner Action

If you own a 2023-2024 Audi A3, A4, A5, A6, Q3, Q5, Q5 Sportback, Q7, or S3, it is recommended to contact an authorized Audi dealer to check if your vehicle is eligible for this 19PP update. This is a proactive measure to prevent potential thermostat oil seal leaks. Ensure your vehicle is within its New Vehicle Limited Warranty for coverage. The dealer will verify eligibility using the ELSA system and perform the necessary replacement of the engine temperature regulation actuator.

NHTSA ID: 19PP