Cooling System - Coolant Leak/No or Poor Heater Output
19 07 01March 26, 2007
2009949/3 Supersedes Technical Service Bulletin Group 19 number 05-03 dated Apr. 8, 2005 due to revision of a part number.
Vehicle Information
Coolant Leak or No Heat in Passenger Compartment From HVAC
Condition
Coolant Leak or No Heat in Passenger Compartment From HVAC System
Technical Background
^ 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.
Plug is installed in engine cylinder block near connection for thermostat housing (arrow).
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°F / 0°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°F / 0°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.
Warranty
Required Parts and Tools
Plug - Part No: 06B 103 033 A
Tip:
Part numbers listed in this bulletin are for reference only. Always check with your Parts Dept. for the latest parts information.