Removing and installing evaporator housing — AUDI

🧭 Before you start

Fits: Audi A5 (8T, 2007–2016), Audi Q5 (8R, 2008–2017), Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015); platform code 83

• Renewed: if necessary

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• The following illustrations show a "“basic”" air conditioning unit. The layout of the components may differ on a "“deluxe”" air conditioning unit (e.g. arrangement and number of control motors).
• When detaching the coolant pipes (A), make sure that the seals (B) do not drop into the heat exchanger or the air conditioning unit.Do not re-use seals (B) and clips (D); renewing Electronic parts catalogue
• Removing and installing heater housing (left-side) (C)
• It is not really necessary to remove the heat exchanger (I) and the honeycomb element (or Z35). However, these components can be removed easily as they are now loose in the heater housing (left-side).
• Currently the evaporator housing should not be dismantled any further; for information on design of evaporator housing, refer to .

📋 Procedure

1. Remove air conditioning unit . [Note: The following illustrations show a "“basic”" air conditioning unit. The layout of the components may differ on a "“deluxe”" air conditioning unit (e.g. arrangement and number of control motors).]
2. Remove bolt (B), release retaining tabs and detach bracket (A).
3. Remove bolts (E), release retaining tabs and detach bracket (D).
4. Remove coolant pipe clips (F) and detach coolant pipes (G). [Note: When detaching the coolant pipes (A), make sure that the seals (B) do not drop into the heat exchanger or the air conditioning unit.Do not re-use seals (B) and clips (D); renewing Electronic parts catalogue]
5. Remove bolts (A) (securing heater housing, left-side (C), to evaporator housing (B)). [Note: Removing and installing heater housing (left-side) (C)]

6. Remove heater housing (right-side) (H).
7. If applicable, remove heat exchanger (I) and honeycomb element/auxiliary air heater element Z35 and . [Note: It is not really necessary to remove the heat exchanger (I) and the honeycomb element (or Z35). However, these components can be removed easily as they are now loose in the heater housing (left-side).]
8. Detach evaporator housing (A) from heater housing (left-side) (B) / air distribution housing (C). [Note: Currently the evaporator housing should not be dismantled any further; for information on design of evaporator housing, refer to .]
9. Check evaporator housing (A), heater housing (left-side) (B) and air distribution housing (C) for dirt or damage, and clean or renew if necessary.
10. Assemble evaporator housing (A) and heater housing (left-side) (B) / air distribution housing (C). [Note: Slide guides (D) on top and bottom of evaporator housing (A) into grooves (E) of heater housing (left-side) (B).]
11. Fit bolts (A) (securing heater housing, left-side (C), to evaporator housing (B)).
12. Install heat exchanger (I) and honeycomb element/auxiliary air heater element Z35, observing correct installation position and .
13. Install heater housing (right-side) (H).
14. Check the two connections (C) of heat exchanger and coolant pipes (A) for dirt or damage, and clean or renew if necessary.
15. Lubricate coolant pipes (A) and two connections (C) of the heat exchanger lightly with silicone grease. [Note: Silicone grease is available as a replacement part: part number G 000 405 A2 Electronic parts catalogue.]
16. Moisten new seals (B) lightly with coolant (or apply a small quantity of silicone grease) and slip them onto coolant pipes (A).
17. Attach coolant pipes (A) to evaporator housing and press into connections (C) of heat exchanger (arrow).
18. ⚠ Risk of leaks at heat exchanger.Crushed O-rings and coolant pipes/clips that are not fitted straight or are not attached fully will lead to leaks. — Fit new coolant pipe clips (F) at connections (C) of heat exchanger, as shown (slide on as far as possible (arrow)). [Note: Do not re-use seals (B) and clips (D) after removal; renewing Electronic parts catalogueIf a replacement heat exchanger (C) has been fitted instead of the standard heat exchanger illustrated above, fit the coolant pipes as described for this version of the heat exchanger .]
19. Install remaining components at air conditioning unit.
20. Install air conditioning unit .

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