Audi S8 Grille Shutter Fault Triggers Engine Overheating

The symptoms you describe match what I experienced with my 2018 Audi RS7. The active air flap system malfunction caused similar issues, elevated engine temperatures and persistent check engine light. The flap motor had failed, preventing proper thermal management system operation. The grille shutter was stuck in a closed position, restricting proper airflow to the cooling system. This is a serious issue that requires immediate attention as it can lead to engine overheating and potential damage to critical components. The repair involved replacing the complete flap motor assembly and recalibrating the thermal management system. The diagnosis confirmed that corrosion had affected the electromechanical components controlling the active air flaps. This is not a repair that can be postponed, as continued driving with impaired cooling system function risks expensive engine damage. The dealer service center needed two days to complete the repair with genuine parts and proper diagnostic equipment. These active air flap issues are relatively common on this platform after around 100000 KM. Having the repair done at a certified service center is crucial due to the complexity of the thermal management system calibration.

Thanks for sharing your experience. The same issue happened on my S8 last summer with the active air flap system. After checking the fault codes, it was indeed the flap motor that had failed. Fixed it right away since the cooling system is crucial and I didnt want to risk engine damage. Since the repair, everything has been working perfectly with normal engine temperatures. Just curious, do you remember the final repair cost? And has the system given you any other trouble after fixing it? Would be good to know what to expect long term.

Glad to hear you got it sorted. After my active air flap repair, the cooling system has worked flawlessly for over 15000 KM now. The diagnostic scan showed the fault code was completely cleared after replacing the faulty electromechanism. The total repair cost came to 590 Euro at my certified service center, which included parts, labor, and system recalibration. The price was worth it considering the potential engine damage that could have occurred. Since the fix, I have had zero issues with the thermal management system. The flap motor is operating as designed, and engine temperatures stay consistently normal. Regular diagnostic checks show everything is functioning correctly with the air intake system. Based on my experience, once properly repaired these systems tend to be quite reliable. Just keep an eye on your temperature gauge during normal operation, as this is often the first indicator if the active air flaps start acting up again.

Thanks everyone for the helpful insights. Wanted to share my repair experience, took the car to my trusted mechanic last week. The check engine light and thermal management issues were definitely from the faulty active air flap system. The total repair came to 780 Euro, bit more than expected but included a full diagnostic scan, replacement flap motor, and recalibration of the cooling system. They had it done in about 6 hours. Best decision was not waiting, the mechanic showed me how the flap was stuck closed, seriously restricting air intake. Could have caused major engine problems if left unfixed. Been driving for a few days now and the engine temperature stays perfectly normal. No more check engine light either. The air flaps are working smoothly again. Will definitely keep monitoring the temps just to be safe, but seems like the issue is properly resolved.