Heating & Air Conditioning: Overhaul Audi TT 8N facelift

Heating and A/C unit (with heater core and evaporator), disassembly and assembly

1 - Seal

1. Seals intake duct against air intake plenum.
2. Check and replace if damaged.

2 - Air flap

1. Lightly lubricate hinge pivots with grease G 052 745 A3 or equivalent.

3 - Grommet

4 - Lever

5 - Air distribution housing, upper part

1. Assembly. See «Air distribution housing, assembly»(ref-276291-S21189901002008022600000) .
2. Installing seal at refrigerant pipes. See «Refrigerant pipe seal at evaporator, installing»(ref-276291-S01743939282008022600000) .

6 - Fresh/recirculation flap

1. Lightly lubricate hinge pivots with grease G 052 745 A3 or equivalent.

7 - Evaporator

1. Installing seal at refrigerant pipes. See «Refrigerant pipe seal at evaporator, installing»(ref-276291-S01743939282008022600000) .
2. Installing seal. See «Evaporator seal, installing»(ref-276291-S02791165182008022600000) .
3. Removed evaporator contains refrigerant oil that must be accounted for in refrigerant system when evaporator replacement is necessary. Refer to «For leaky or damaged components (except for the compressor and receiver drier) there is still refrigerant oil in the system component that must be accounted for when replacing»(ref-276291-S13536529682008022600000) . Also. Refer to «A/C refrigerant system, replacing components»(ref-276291-S19715115502008010300000) ("Replacing components").

8 - Pivot bushing

1. Lightly lubricate with grease G 052 745 A3 or equivalent.

9 - Air distribution housing, lower part

1. Assembly. See «Air distribution housing, assembly»(ref-276291-S21189901002008022600000) .
2. Installing seal at refrigerant pipes. See «Refrigerant pipe seal at evaporator, installing»(ref-276291-S01743939282008022600000) .

10 - Screw

11 - Pivot bushing

1. Lightly lubricate with grease G 052 745 A3 or equivalent.

12 - Central flap lever

13 - Screw

14 - Temperature flap lever

15 - Central flap

1. Note installation position (shorter section of flap faces up).

16 - Footwell/defroster flap

1. Lightly lubricate hinge pivots with grease G 052 745 A3 or equivalent.

17 - Temperature flap

18 - Seal

1. Installing seal at refrigerant pipes. See «Refrigerant pipe seal at evaporator, installing»(ref-276291-S01743939282008022600000) .

19 - Threaded bracket

20 - O-Ring

1. Removing and installing. Refer to «Expansion valve, removing and installing»(ref-276291-S33617408142008010300000) .

21 - O-Ring

1. Removing and installing. Refer to «Expansion valve, removing and installing»(ref-276291-S33617408142008010300000) .

22 - Expansion valve

1. Removing and installing refrigerant pipes. Refer to «Refrigerant pipes on expansion valve, removing and installing»(ref-276291-S23422309862008010300000) .
2. Removing and installing. Refer to «Expansion valve, removing and installing»(ref-276291-S33617408142008010300000) .
3. Removing and installing insulation. Refer to «Expansion valve insulation, removing and installing»(ref-276291-S41197850412008010300000) .

23 - Bolt

1. Tightening torque: 8 Nm (71 in lb).

24 - Air deflector

Air distribution housing, assembly

1. Secure both halves of the housing with screws -A- at locations (example) -B-.