RS4 Air Flap Malfunction Leads to Engine Overheating

Had the same thermal management issue on my 2019 RS5. The active air flap malfunction triggered the check engine light and caused similar overheating problems. A diagnostic scan revealed fault codes pointing to the electromechanical air intake flap control. The flap was stuck in closed position, severely restricting proper airflow to the radiator. This is a serious issue that can lead to engine damage if not addressed promptly. The repair required: Complete diagnostic testing of the air flap system, Replacement of the air flap motor and actuator, Recalibration of the new components, Testing the thermal management system The problem never returned after proper repair. Would strongly recommend getting a proper diagnostic scan before replacing parts. A stuck flap might seem minor but impacts the entire cooling system performance. The repair should be done by a shop familiar with VAG thermal management systems to ensure proper calibration. Key signs it was the air flap: Intermittent temperature spikes, Check engine light staying on, Reduced cooling efficiency at low speeds, Mechanical noise from front air intake area

Thanks for sharing your experience with the air flap issue. I had very similar symptoms on my RS4 last summer and finally got it fixed. Your detailed explanation matches exactly what I went through with the thermal management system. Would you mind sharing what the total repair cost was for your case? For comparison, I am wondering if prices are similar. Also curious if you had any other cooling system related problems pop up since getting the flap motor replaced? My check engine light hasnt returned and temperatures have been stable, but always good to hear long-term experiences from others who had this fixed.

After getting the active air flap fixed last year, everything has been running perfectly. The total repair came to 590 Euro for replacing the defective electromechanism, which included the diagnostic scan and complete recalibration of the system. No other cooling issues have appeared since the repair. The check engine light has stayed off and engine temperatures remain stable across all driving conditions. The shop did a thorough job testing the entire thermal management system to ensure there were no related problems. It is reassuring to hear your RS4 is also running well after the fix. These active air flap failures are known weak points, but once properly repaired with quality parts, they typically dont cause recurring issues. Regular diagnostic scans during maintenance can help catch any potential problems early. The key is having the work done by technicians who understand these complex cooling systems. The proper repair prevents both overheating risks and potential engine damage that could result from restricted airflow.

I finally went to get my RS4 fixed last week after dealing with the overheating issues. The mechanic confirmed it was indeed the active air flap causing problems. They ran a full diagnostic scan which showed the flap motor had completely failed. The repair took about 4 hours total. They replaced the faulty flap motor and recalibrated the entire thermal management system. Total cost came to 620 Euro, which seems fair compared to other quotes I received. Since the repair, the car runs perfectly, no more check engine light and temperatures stay normal even in stop-and-go traffic. The mechanic showed me the old flap motor and it was clearly stuck. They also inspected the rest of the cooling system while they had it apart, which gave me peace of mind. Really glad I didnt wait any longer to get it fixed. The mechanic explained how restricted airflow from a failed air flap can lead to serious engine damage over time. After this experience, I will definitely pay more attention to any early warning signs related to the cooling system.