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Heating Air Conditioning: Overhaul Audi S8 D3 facelift

A/c Compressor 2 illustrations ~1244 words

Heating and A/C unit, disassembling and assembling

Note. On removal, mark the various control motors and the associated connecting elements between flap and motor to prevent mix-ups with connecting elements of other control motors. When removing, mark various connectors to actuators and actuators themselves (risk of interchange with identical connectors and actuators). If connecting elements are interchanged, actuators with incorrect connecting elements do not reach their specified end position, and fault "upper or lower limit exceeded" may be displayed in DTC memory after basic setting. Levers and cam disks are provided with code numbers. In case of doubt about assignment of one of these components, observe assignment --> Air distributor housing, disassembly and reassembly At present, actuators are identical, the shaft of each motor however is positioned differently because of different connecting elements and attachment of connecting element may not be possible if interchanged. Lightly coat guides of cam disks as well as lugs on levers of flap with grease G 000 150 .

Air distributor housing, disassembly and reassembly

Note. Levers and cam disks are provided with code numbers. In case of doubt about assignment of one of these components, observe assignment Lightly coat guides of cam disks as well as lugs on levers of flap with grease G 000 150 .

Scheme 11

Scheme 11: Air distributor housing, disassembly and reassembly
Scheme 11: Air distributor housing, disassembly and reassembly

1 - Seal

2 - Air guide

  1. With shut-off flaps
  2. Air guide to right chest vent and to indirect ventilation of right instrument panel
  3. Do not dismantle

3 - Oval head self-tapping screw

4 - Lever

  1. Not to be removed (risk of interchange)
  2. Heed assignment (code number "862")

5 - Lever

  1. Not to be removed (risk of interchange)
  2. Heed assignment (code number "861")

6 - Cam disk

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "154")

7 - Bracket

  1. Mark before removing (risk of interchange)
  2. Heed assignment (no code number)

8 - Oval head self-tapping screw

9 - Right Front Defrost/Upper Body Shut-off Flap Motor V199

  1. With Right Center Vent Motor Position Sensor G317
  2. Removing and installing --> «Right Front Defrost/Upper Body Shut-off Flap Motor V199 removing and installing»(ref-289225-S11364670872008062700000)

10 - Oval head self-tapping screw

11 - Seal

12 - Seal

13 - Air guide

  1. With shut-off flaps
  2. Air guide to left chest vent and to indirect ventilation of left instrument panel
  3. Do not dismantle

14 - Lever

  1. Not to be removed (risk of interchange)
  2. Heed assignment (code number "863")

15 - Cam disk

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "155")

16 - Bracket

  1. Mark before removing (risk of interchange)
  2. Heed assignment (no code number)

17 - Left Front Defrost/Upper Body Shut-off Flap Motor V200

  1. With Right Center Vent Motor Position Sensor G318
  2. Removing and installing --> «Left Front Defrost/Upper Body Shut-off Flap Motor V200 removing and installing»(ref-289225-S40486847262008062700000)

18 - Defroster Flap Motor V107

  1. With Right Center Vent Motor Position Sensor G135
  2. Removing and installing --> «Defroster Flap Motor V107 removing and installing»(ref-289225-S42572212272008062700000)

19 - Lever

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "837")
  3. Lever at flap is marked "838" (remains with coupling rod at defroster flap in air distributor housing)

20 - Oval head self-tapping screw

21 - Left Vent Temperature Sensor G150

  1. Removing and installing --> «Left Vent Temperature Sensor G150 , removing and installing»(ref-289225-S27189746682008062700000) .

22 - Air guide

  1. With shut-off flaps
  2. Air duct to left footwell vents
  3. Do not dismantle

23 - Lever

  1. Not to be removed (risk of interchange)
  2. Heed assignment (code number "842")

24 - Cam disk

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "157")

25 - Bracket

  1. Mark before removing (risk of interchange)
  2. Heed assignment (no code number)

26 - Left Footwell Flap Motor V108

  1. With Right Center Vent Motor Position Sensor G139
  2. Removing and installing --> «Left Footwell Flap Motor V108 , removing and installing»(ref-289225-S31021624902008062700000)

27 - Lever

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "835")
  3. Lever at flap is marked "836" (remains at cold-air flap in air distributor housing)

28 - Center Vent Adjustment Motor V102

  1. With Right Center Vent Motor Position Sensor G138
  2. This actuator operates cold-air flap (flap in air duct which bypasses heater core) --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000)
  3. Removing and installing --> «Center Vent Adjustment Motor V102 , removing and installing»(ref-289225-S21014432372008062700000)

29 - Air distribution housing

  1. Do not dismantle
  2. Different versions
  3. On vehicles with Rear A/C Control Head (Climatronic) E265 , flaps are installed in rear air guides and connection to rear cold-air duct is open.
  4. On vehicles without Rear A/C Control Head (Climatronic) E265 , there are no flaps installed in rear air guides and connection to rear cold-air duct is sealed.

Scheme 12

Scheme 12
Scheme 12

30 - Seal

31 - Right Vent Temperature Sensor G151

  1. Removing and installing --> «Right Vent Temperature Sensor G151 , removing and installing»(ref-289225-S01873010522008062700000)

32 - Lever

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "833")
  3. Lever at flap is marked "834" (remains at warm-air flap in air distributor housing)

33 - Temperature Regulator Flap Motor V68

  1. With Right Center Vent Motor Position Sensor G92
  2. This actuator operates warm-air flap (flap in air duct starting in mixing chamber downstream heater core) --> «Air distribution system, block diagram»(ref-289225-S08694407202008062700000)
  3. Removing and installing --> «Temperature Regulator Flap Motor V68 , removing and installing»(ref-289225-S41322577942008062700000)

34 - Air guide

  1. With shut-off flaps
  2. Air duct to right footwell vents
  3. Do not dismantle

35 - Lever

  1. Not to be removed (risk of interchange)
  2. Heed assignment (code number "840")

36 - Cam disk

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "156")

37 - Bracket

  1. Mark before removing (risk of interchange)
  2. Heed assignment (no code number)

38 - Right Footwell Flap Motor V109 2)

  1. With Right Center Vent Motor Position Sensor G140
  2. Removing and installing --> «Right Footwell Flap Motor V109 , removing and installing»(ref-289225-S27518629242008062700000)

39 - Right Rear Air Outlet Motor V219

  1. With Right Center Vent Motor Position Sensor G350
  2. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.
  3. Removing and installing --> «Left Rear Air Outlet Motor V218 and Right Rear Air Outlet Motor V219 , removing and installing»(ref-289225-S31122125862008062700000)

40 - Left Rear Air Outlet Motor V218

  1. With Right Center Vent Motor Position Sensor G349
  2. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.
  3. Removing and installing --> «Left Rear Air Outlet Motor V218 and Right Rear Air Outlet Motor V219 , removing and installing»(ref-289225-S31122125862008062700000)

41 - Bracket

  1. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

42 - Cam disk (to Right Rear Air Outlet Motor V219)

  1. Mark before removing (risk of interchange)
  2. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.
  3. Heed assignment (code number "158")

43 - Lever (to Right Rear Air Outlet Motor V219)

  1. Not to be removed (risk of interchange)
  2. To warm-air flap
  3. Heed assignment (code number "845")
  4. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

44 - Lever (to Right Rear Air Outlet Motor V219)

  1. Not to be removed (risk of interchange)
  2. To cold-air flap
  3. Heed assignment (code number "844")
  4. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

45 - Lever (to Left Rear Air Outlet Motor V218)

  1. Not to be removed (risk of interchange)
  2. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.
  3. Heed assignment (code number "863")

46 - Cam disk (to Left Rear Air Outlet Motor V218)

  1. Mark before removing (risk of interchange)
  2. Heed assignment (code number "159")
  3. Installed only on vehicles with Rear A/C Control Head (Climatronic) E265.

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