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Air Conditioning: Overhaul Audi A6 C5 facelift

Automatic HVAC System 2 illustrations ~1319 words

A/C unit, disassembling and assembling

  1. Air conditioner unit removing, see «COMPLETE AIR CONDITIONER UNIT, REMOVING AND INSTALLING»(ref-196290-S16025120622005100800000) .

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 .

Note. The following list refers to items in see scheme 172.

  1. Sender for outlet temperature, floor outlet -G192- Removing and installing, see «SENDER FOR OUTLET TEMPERATURE, FLOOR OUTLET -G192-, REMOVING AND INSTALLING»(ref-196290-S32046035392005100800000) .
  2. Bolt
  3. Footwell vent
  4. Air distributor housing With evaporator and heater core. Disassembling and assembling, see «A/C UNIT, DISASSEMBLING AND ASSEMBLING»(ref-196290-S42340630472005100800000) . Housing, air flaps, drip pan, evaporator and various other parts are different in versions 1 and 2. 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. On air conditioning version "1", the air guide to the intermediate piece (spacer) for defroster channel had two openings. Starting with version "2" the two openings have been combined into one opening. Starting with version "2", the evaporator can no longer be removed of the air distributor housing (the housing must be disassembled, due to the changed refrigerant line connection). Version "3" has an additional opening for installation of the Evaporator Vent Temperature Sensor -G263-. See «EVAPORATOR VENT TEMPERATURE SENSOR -G263-, REMOVING AND INSTALLING»(ref-196290-S28872281782005100800000) (on vehicles without Evaporator Vent Temperature Sensor -G263- this opening is closed with a plug).
  5. Combination bolt
  6. Air flow duct with intake duct. Disassembling and assembling, see «A/C UNIT, DISASSEMBLING AND ASSEMBLING»(ref-196290-S42340630472005100800000) . The blower wheel for the fresh air blower installed in version "2" air conditioning unit is approx. 10 mm shorter than the one for version "1". From version "2", the air duct has been adapted to the changed fresh air blower. From version "2", the air duct at the fresh air blower fan is narrower than the air duct in version "1". From version "3" a second positioning motor has been installed at the intake duct. See «AIR FLOW FLAP MOTOR -V71-, REMOVING AND INSTALLING (VEHICLES UP TO MODEL YEAR 2002)»(ref-196290-S23175560772005100800000) and «RECIRCULATION FLAP MOTOR -V113-, REMOVING AND INSTALLING (VEHICLES FROM MODEL YEAR 2002)»(ref-196290-S40783912602005100800000) . From version "3", the air recirculating/fresh air flap is actuated by Recirculation Flap Motor -V113- and no longer by the Air Flow Flap Motor -V71-. See «AIR FLOW FLAP MOTOR -V71-, REMOVING AND INSTALLING (VEHICLES UP TO MODEL YEAR 2002)»(ref-196290-S23175560772005100800000) and «RECIRCULATION FLAP MOTOR -V113-, REMOVING AND INSTALLING (VEHICLES FROM MODEL YEAR 2002)»(ref-196290-S40783912602005100800000) .

Scheme 8

Scheme 8
Scheme 8

Air distribution housing, disassembling and assembling

  1. Disassembling and assembling air conditioner unit, see «A/C UNIT, DISASSEMBLING AND ASSEMBLING»(ref-196290-S42340630472005100800000) .

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 see scheme 173.

  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»(ref-196290-S10479645292005100800000) . 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»(ref-196290-S17317351462005100800000) .
  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»(ref-196290-S16316253142005100800000) .
  15. Defroster flap motor -V107 With Potentiometer actuator for temperature flap left -G135-. Removing and installing, see «DEFROSTER FLAP MOTOR -V107-, REMOVING AND INSTALLING»(ref-196290-S09032655542005100800000) . 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»(ref-196290-S28872281782005100800000) . (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»(ref-196290-S16316253142005100800000) .
  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»(ref-196290-S10051831692005100800000) .
  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

Scheme 9

Scheme 9
Scheme 9

Air duct with intake housing, disassembling and assembling

  1. Air conditioner unit removing, see «COMPLETE AIR CONDITIONER UNIT, REMOVING AND INSTALLING»(ref-196290-S16025120622005100800000) .
  2. Disassembling and assembling air conditioner unit, see «A/C UNIT, DISASSEMBLING AND ASSEMBLING»(ref-196290-S42340630472005100800000) .

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 version "3" a second positioning motor has been installed at the intake duct. See AIR FLOW FLAP MOTOR -V71-, REMOVING AND INSTALLING (VEHICLES UP TO MODEL YEAR 2002) and RECIRCULATION FLAP MOTOR -V113-, REMOVING AND INSTALLING (VEHICLES FROM MODEL YEAR 2002) . From version "3", the air recirculating/fresh air flap is actuated by Recirculation Flap Motor -V113- and no longer by the Air Flow Flap Motor -V71-. See AIR FLOW FLAP MOTOR -V71-, REMOVING AND INSTALLING (VEHICLES UP TO MODEL YEAR 2002) and RECIRCULATION FLAP MOTOR -V113-, REMOVING AND INSTALLING (VEHICLES FROM MODEL YEAR 2002) .

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