OVERVIEW - ATTACHMENTS FOR HEATER AND A/C UNIT AND AIR INTAKE HOUSING, "Basis" VERSION

-- Remove the A/C unit. Refer to HEATER AND A/C UNIT, REMOVING AND INSTALLING .

Fig 1: Identifying A/C System, Basis

Courtesy of AUDI OF AMERICA, LLC

1. Bolt
2. Bracket for Coolant Pipes
3. Evaporator Housing
   • For disassembling and assembling. Refer to OVERVIEW - EVAPORATOR HOUSING .
   • There are different versions based on the manufacturing date and on the vehicle version. Refer to OVERVIEW - EVAPORATOR HOUSING  .
   • Evaporator housing, removing from A/C unit and installing. Refer to EVAPORATOR HOUSING, REMOVING AND INSTALLING .
4. Coolant Pipe
   • Removing from the heater core and installing. Refer to HEATER CORE, REMOVING AND INSTALLING .
   • For the coolant supply from the engine
5. Coolant Pipe
   • Removing from the heater core and installing. Refer to HEATER CORE, REMOVING AND INSTALLING .
   • For coolant return to engine
6. O-Ring Seal
   • Replacing
   • Coat lightly with coolant before installing. Refer to HEATER CORE, REMOVING AND INSTALLING .
7. Clamp
   • These clamps are installed by the manufacturer; they hold the coolant pipes in the heater core installed by the manufacturer, refer to -item  8- "Heat Exchanger".
8. Heat Exchanger
   • This version is installed by the manufacturer.
   • Removing and installing. Refer to HEATER CORE, REMOVING AND INSTALLING .
9. Bracket for Coolant Pipes in Replacement Heater Core
   • Included with the replacement heater core.
   • Removing and installing. Refer to HEATER CORE, REMOVING AND INSTALLING .
10. Washer
    • Included with the replacement heater core.
11. Bolt
    • Included with the replacement heater core.
    • Tightening specification: 2.5 Nm
12. Replacement Heat Exchanger
    • With the A/C unit installed, removing and installing. Refer to HEATER CORE, REMOVING AND INSTALLING .
    • This version is a replacement part.
    • Included with the replacement heater core, refer to -item  6- "O-Ring Seal", and -item  9- "Bracket for Coolant Pipes in Replacement Heater Core", through -item  12- "Replacement Heat Exchanger".
    • Cover the heater core according to the version of the A/C system installed in the vehicle with foam seals. Refer to HEATER CORE, REMOVING AND INSTALLING  .
13. Honeycomb
    • Designed for gasoline and diesel engines equipped with an optional parking heater that is activated like an auxiliary heater (there is no Auxiliary Heater Heating Element -Z35- installed). Refer to Auxiliary Heater Heating Element -Z35-, CHECKING .
    • With the A/C unit installed, removing and installing. Refer to Auxiliary Heater Heating Element -Z35-, REMOVING AND INSTALLING .
    • Cover the honeycomb with foam seals according to the version of the A/C system. Refer to Auxiliary Heater Heating Element -Z35-, REMOVING AND INSTALLING  (Auxiliary Heater Heating Element -Z35-, Removing and Installing).
14. Auxiliary Heater Heating Element -Z35-
    • On vehicles with a diesel engine (and also on vehicles which have a parking heater installed as an optional equipment that also functions as an auxiliary heater) and on certain gasoline engines. Refer to Auxiliary Heater Heating Element -Z35-, CHECKING .
    • Checking function. Refer to Auxiliary Heater Heating Element -Z35-, CHECKING .
    • With the A/C unit installed, removing and installing. Refer to Auxiliary Heater Heating Element -Z35-, REMOVING AND INSTALLING .
    • Cover the Auxiliary Heater Heating Element -Z35- with foam seals according to the version of the A/C system. Refer to Auxiliary Heater Heating Element -Z35-, REMOVING AND INSTALLING  (Auxiliary Heater Heating Element -Z35-, Removing and Installing).
      NOTE:

      In MY 2009, as a running change, a new version of the Auxiliary Heater Heating Element -Z35- is being installed (the heating elements are a bit more narrow); be sure to use the correct version and note the allocation.

15. Bracket
16. Left Radiator Housing (with the Temperature Doors)
    • The activation of the temperature doors and with it the left radiator housing is different between vehicles equipped with "Convenience" and "Basis" A/C systems. On the "Basis" A/C system, both temperature doors (for the left instrument panel vents and the left footwell vents) are controlled by the same shaft. Refer to OVERVIEW - AIR DISTRIBUTION HOUSING DOORS AND PARTITIONS  .
    • Different versions (with one or two lower attaching points. Refer to LEFT RADIATOR HOUSING WITH TEMPERATURE DOORS, REMOVING AND INSTALLING  )
    • With the A/C unit installed, removing and installing. Refer to LEFT RADIATOR HOUSING WITH TEMPERATURE DOORS, REMOVING AND INSTALLING .
    • Lightly coat the curved washer guides, the shaft bearings, the toothed segments as well as to the pins on the door levers with lubricant (for example, with Lubricant G 000 150 ).
17. Defroster Door Motor -V107-
    • Removing and installing. Refer to Defroster Door Motor -V107-, REMOVING AND INSTALLING .
18. Left Retaining Plate with the Footwell Door Motor -V261-
    • With curved washer, actuating arms and connecting rods
    • Footwell Door Motor -V261-, removing and installing. Refer to Left Footwell Door Motor -V108- /Footwell Door Motor -V261-, REMOVING AND INSTALLING .
    • Left retaining plate with the Footwell Door Motor -V261-, removing and installing. Refer to LEFT RETAINING PLATE WITH Footwell Door Motor -V261-, REMOVING AND INSTALLING .
    • Retaining plate with the Footwell Door Motor -V261-, disassembling and assembling. Refer to LEFT RETAINING PLATE WITH Footwell Door Motor -V261-, DISASSEMBLING AND ASSEMBLING .
    • The actuation of the temperature doors differs between vehicles equipped with the "Basis" A/C system and the "Convenience" A/C system On the "Basis" A/C system, the doors (for the left and right instrument panel vents and the left and right front footwells) are connected to each other by connecting rods in the air distribution housing. The doors for the left and right rear footwell vents are connected to each other by a shaft. These doors are all actuated by the Footwell Door Motor -V261-. Refer to OVERVIEW - AIR DISTRIBUTION HOUSING DOORS AND PARTITIONS .
    • Lightly coat the curved washer guides, the shaft bearings as well as to the pins on the door levers with lubricant (for example, with Lubricant G 000 150 ).
19. Toothed Segment
20. Retaining Plate with the Temperature Regulator Door Motor -V68-
    • Removing and installing the retaining plate with the Temperature Regulator Door Motor -V68- ; removing the actuator from the retaining plate. Refer to Temperature Regulator Door Motor -V68- /Rear Temperature Door Motor -V137-, REMOVING AND INSTALLING .
    • The actuation of the left and right temperature doors differs between vehicles equipped with the "Basis" A/C system and the "Convenience" A/C system On the "Basis" A/C system, the shaft for the left temperature doors are actuated by the Temperature Regulator Door Motor -V68- via a toothed segment, refer to -item  19- "Toothed Segment". The right temperature door is also actuated by the Temperature Regulator Door Motor -V68- via the connecting rod, refer to -item  23- "Connecting Rod for the Temperature Doors" which engaged in this toothed segment. Refer to OVERVIEW - AIR DISTRIBUTION HOUSING DOORS AND PARTITIONS .
    • Lightly coat the shaft bearings, the toothed segments as well as to the pins on the door levers with Lubricant G 000 150 ).
21. Connecting Rod to the Defroster Door
22. Actuating Arm to Defroster Door Motor -V107-
23. Connecting Rod for the Temperature Doors
    NOTE:

    There are different connecting rods -A- (different version of the connecting element to the toothed segment and to the right temperature doors), depending on the date of production. .

    Depending on the production date, there are different versions of the levers and connecting elements on the A/C unit. At the start of production, the levers -A- were installed with a closed pin and the connecting rod -B-. In MY 2008, the levers -C- have a slotted pin and connecting rod -D-. When replacing, be sure to use the correct version..

    Fig 2: Air Conditioner, Levers And Connecting Elements

    Courtesy of AUDI OF AMERICA, LLC
24. Footwell Vent Temperature Sensor -G192-
    • Removing and installing. Refer to Footwell Vent Temperature Sensor -G192- /Left Footwell Vent Temperature Sensor -G261-, REMOVING AND INSTALLING .
    • The Footwell Vent Temperature Sensor -G192- is installed in the left footwell vent.
25. Center Vent Temperature Sensor -G191-
    • Removing and installing. Refer to Center Vent Temperature Sensor -G191-, REMOVING AND INSTALLING .
    • The Center Vent Temperature Sensor -G191- is installed in the air guide channel to the instrument panel vent.
26. Wiring Harness, "Basis" Version
    • There are different versions.
    • Mark the allocation before disconnecting the connectors (danger of interchange, connectors of same shape for different motors and temperature sensor).
    • Secure wiring harness to mounting points provided on housing (using cable ties, refer to -item  27- "Cable ties", or on mounts) so that it does not come into contact with moving components.
27. Cable Ties
28. A/C System Air Distribution Housing, "Basis" Version
    • Do not disassemble further
    • Different versions between vehicles equipped with the "Convenience" A/C system and the "Basis" A/C system.
    • Lightly coat the curved washer guides, the shaft bearings, the toothed segments as well as to the pins on the door levers with lubricant (for example, with Lubricant G 000 150 ).
      NOTE:

      On the "Basis" version, the various doors (for example, for the left and right vents) are connected to each other by connecting rods; they are actuated by only one actuator. Refer to OVERVIEW - AIR DISTRIBUTION HOUSING DOORS AND PARTITIONS .

29. Right Radiator Housing (with the Temperature Doors)
    • The activation of the temperature doors and with it the right radiator housing is different between vehicles equipped with "Convenience" and "Basis" A/C systems. On the "Basis" A/C system, both temperature doors (for the right instrument panel vents and the right footwell vents) are operated together via the shaft. Refer to OVERVIEW - AIR DISTRIBUTION HOUSING DOORS AND PARTITIONS  .
    • Different versions (with one or two lower attaching points. Refer to LEFT RADIATOR HOUSING WITH TEMPERATURE DOORS, REMOVING AND INSTALLING  ).
    • With the A/C unit installed, removing and installing. Refer to RIGHT RADIATOR HOUSING, REMOVING AND INSTALLING (WITH TEMPERATURE DOORS) .
    • Lightly coat the curved washer guides, the shaft bearings, the toothed segments as well as to the pins on the door levers with lubricant (for example, with Lubricant G 000 150 ).
30. Center Vent Adjustment Motor -V102-
    • Removing and installing. Refer to Center Vent Adjustment Motor -V102-, REMOVING AND INSTALLING .