Heater Cable/Flap Check, Replace & Adjust

On vehicles up to VIN 44E 161 000
- check to see if new style Bowden cable with sleeve has been installed

CAUTION

Be careful not to overbend or kink Bowden cable during installation

Note

Also see item 9

BOWDEN CABLE:

- check Bowden cable for correct positioning
- open glove box door
- set climate control temperature from maximum cold 60~F (15~C) to maximum heat 90~F (32~C)

- check lever on programmer
^ lever must be in full heat position (all the way to right) after 2 minutes

If lever moves slowly or stops before reaching maximum heat position, - do the following:
- set temperature to 90~F (32~C) and wait until lever stops

PROGRAMMER LEVER:

- remove Bowden cable from lever on programmer
- attach pull-type spring scale to eye of Bowden cable
- pull scale in horizontal direction
- record force required to close heater flap
^ force must be 15N or less

If force required to close heater flap is greater than 15N
- remove heater box and replace heater flap
Heater flap, removing/installing

Note

In vehicles up to VIN 44G 016 229, check heater flaps and adjusting mechanisms of heater for freedom of movement.

- remove heater housing from vehicle
- disassemble heater housing and remove old heater flap. See Repair Manual, Group 80, Audi 5000, 1978 - 1983

HEATER HOUSING:

- push heater flap into left half of heater housing
- install felt ring (A) and thrust washer (B) on heater flap
- install retaining (C) clip on flap, - align heater flap and assemble heater housing halves
- install heater housing in vehicle
- connect Bowden cable

- set climate control temperature to 90~F (32~C)

BOWDEN CABLE SLEEVE:

- loosen mounting clamps at Bowden cable sleeve
- push Bowden cable sleeve in direction of arrow until heater flap is fully seated

- install mounting clamp on Bowden cable
Programmer and motor, removing/installing

On vehicles up to VIN 44E 125 105
- install new style programmer with assist spring (Part no. 443 820 503)

Note

Be sure that new style programmer has new higher output motor. Higher output motor is identifiable by black operating lever.

If programmer does not have higher output motor, - install higher output motor (with black operating lever)

On vehicles up to VIN 44F 125 105
- remove old programmer motor (with white operating lever)
- install new higher output programmer motor (with black operating lever)

PROGRAMMER:

In older vehicles, check to see if programmer bracket (C) has tab (D) If tab (D) is present, - remove bracket from programmer
- cut tab (D) off of bracket
- re-install bracket on programmer

MOTOR, REMOVING/INSTALLING:

Motor, removing/installing
- remove mounting screw (A)
- carefully remove brown connector from circuit board
- remove motor

- install new motor in reverse order

Note

Brown connector must "click" into circuit board

- install programmer
- install Bowden cable

Note

The eye of the Bowden cable must point upward when installed (arrow).