Air distribution housing, disassembling and assembling

• Disassembling and assembling air conditioner unit, see A/C UNIT, DISASSEMBLING AND ASSEMBLING .

NOTE:

• Starting September 1998, there was a running change in production from the version "1" air conditioner to the version "2" air conditioner. See AIR CONDITIONING CHANGES .
• From model year 2002 air conditioner version "3" is installed. See AIR CONDITIONING CHANGES .
• From model year 2002 for vehicles with compressor using A/C Compressor Regulator Valve -N280-, an additional Evaporator Vent Temperature Sensor is installed. See EVAPORATOR VENT TEMPERATURE SENSOR -G263-, REMOVING AND INSTALLING . (On vehicles without -G263- the opening is closed with a plug).

NOTE: The following list refers to items in Fig 1.

1. Bolt 
2. Clip 
3. Foam sealing pad 
   • For condenser drainage duct
4. Bottom section of air distributor housing 
   • With condensation drainage duct
   • Lower part of version "2" was adapted to modified evaporator
5. Drip pan 
   • For condensation from evaporator
6. Evaporator 
   • With seal
   • From version "2", the width of the evaporator is 32 mm less than the width of the evaporator in version "1".
   • Starting with version "2", the evaporator can no longer be removed from the air distributor housing (the housing must be disassembled, due to the changed refrigerant line connection).
7. Bolt 
8. Refrigerant lines 
   • With insulation
   • Refrigerant lines from version "2" were adapted to the modified evaporator
   • After assembly, refrigerant lines and connector flange of evaporator must be wrapped completely with foam (for insulation)
9. Bracket 
10. Bolt 
11. O-ring seals
    • Always replace
    • Check for correct diameter. See O-RING SEALS FOR REFRIGERANT CIRCUIT .

      Different diameters, version "1":

    • 2 piece 13.4 mm x 2.4 mm

      From version "2":

    • 1 piece 13.4 mm x 2.4 mm
    • 1 piece 10.8 mm x 2.4 mm
12. Central Air Flap Motor -V70-. 
    • With Potentiometer actuator for temperature flap left -G112-.
    • Removing and installing, see CENTRAL AIR FLAP MOTOR -V70-, REMOVING AND INSTALLING .
13. Bolt 
14. Actuator for temperature flap right -V159- 
    • With Potentiometer actuator for temperature flap left -G221-.
    • Removing and installing, see ACTUATOR FOR TEMPERATURE FLAP LEFT -V158-, REMOVING AND INSTALLING .
15. Defroster flap motor -V107 
    • With Potentiometer actuator for temperature flap left -G135-.
    • Removing and installing, see DEFROSTER FLAP MOTOR -V107-, REMOVING AND INSTALLING .
    • The lever arm on Defroster Flap Motor -V107- is different between air conditioning units "1" and "2".
16. Bolt 
17. Bracket for Defroster Flap Motor -V107- 
18. Air distribution housing 
    • Do not disassemble further
    • On vehicles that do not have additional heater element -Z35- the opening for the heater is closed. On air distributor housing units supplied as replacement parts the opening is open; if used on vehicles which do not have additional heater elements, the opening must be closed off using cap -29-.
    • Housing, air flaps, drip pan, evaporator and various other parts are different in versions "1" and "2".
    • On air conditioning version "1", the air guide to the intermediate piece (spacer) for defroster channel has two openings. Starting from version "2" the two openings have been combined into one opening.
    • The position of the central flaps is different. From version "2", when the center flap is closed the two outer flaps remain slightly open (angle between both flaps approx. 40 degrees). On version "1" all flaps close simultaneously.
    • Version "3" has an additional opening for the installation of Evaporator Vent Temperature Sensor -G263-. See EVAPORATOR VENT TEMPERATURE SENSOR -G263-, REMOVING AND INSTALLING . (On vehicles without Evaporator Vent Temperature Sensor -G263- this opening is closed with a plug).
19. Coolant pipe 
    • Return tube
20. Coolant pipe 
    • Supply tube
21. Bracket for refrigerant lines 
22. Cover 
    • On version 2 with bracket for refrigerant lines
23. Bracket for refrigerant lines 
    • Only present on version "1"
24. Actuator for temperature flap left -V158- 
    • With Potentiometer- actuator for temperature flap left -G220-.
    • Removing and installing, see ACTUATOR FOR TEMPERATURE FLAP LEFT -V158-, REMOVING AND INSTALLING .
25. Clamp 
    • Always replace
    • Check for proper seating
26. O-ring seals 
    • Always replace
27. Heater core 
    • Removing and installing, see HEATER CORE, REMOVING AND INSTALLING .
28. Heater element for auxiliary heater -Z35- (not for USA) 
29. Cover 
    • Only on vehicles with no heater element for additional heater
    • The cap is the same as cap on heater element for additional heater, except openings for connectors are sealed (air tight)
30. Rubber mounting 

Fig 1: Exploded View Of Air Distribution Housing

Courtesy of AUDI OF AMERICA, INC.