Dash removal for recirc flap work

[Randy Mueller]

TSB 879001
	* A/C - Insufficient Cooling
90audi07
Subject: Fresh air/recirculation servo mount, repairing Model(s):  5000 1984-1988 m.y. 100/200 From 1989 m.y.
Group: 87 
Number: 90-01 
Date: November 30, 1990 insufficient A/C cooling can be the result of a broken fresh air/recirculation servo mount caused by a torn, distorted, or shifted recirculation air flap seal.
A misaligned seal exposes seal adhesive, and causes the recirculation flap to stick. The added force required to open the flap causes the servo mount to break.
Use the following procedure to repair a broken or cracked fresh air/recirculation servo mount.Parts required
Description         Part No.             Quantity
Bracket             200 271 200          1
Screw, (4.2 X 13) 
self-tapping        N 013 966.12           2
Seal                433 271 263 A          1
CAUTIONPart numbers are for reference only. Always check with your Parts Department for latest parts information.
    
^ remove glove compartment 
^ remove glove compartment liner, if equipped     
^ remove passenger side lower shelf     
^ remove screws (arrows) from recirculation air flap 
^ disconnect spring and remove flap 
^ inspect flap seal for distortion or rips and replace if damaged, Part No. 433 271 263 A 
^ thoroughly clean and remove any adhesive from surface of flap 
^ lubricate seal surface with silicone or petroleum jelly 
^ unfasten water tray in plenum and lift tray partially up 
^ reaching through plenum, disconnect fresh air/recirculation servo from fresh air flap 
^ remove vacuum hose and remove fresh air/ recirculation servo 
^ remove broken servo mount from servo     
^ remove (cut) any remaining pieces of broken servo mount from housing 
^ install bracket 1, Part No. 200 271 200 onto housing in same location as old mount     
CAUTION
DO NOT over-tighten screws or permanent damage to the housing will result.
^ install self-tapping screws, Part No. N 013 966.12 or equivalent through holes in bracket (arrows) and fasten to housing     
Note
A 1/4 inch drive air or electric powered ratchet with a hex shank phillips bit makes installing these screws easier.
^ inspect end of fresh air/recirculation servo (arrow) for cracks, replace servo if damaged 
^ check servo diaphragm for leaks using hand vacuum pump US 8026 
^ diaphragm must hold vacuum If NO 
^ replace vacuum servo     
^ install vacuum servo to new bracket and iock in place by turning servo 900 (1/4 turn) 
^ connect vacuum hose to servo 
^ connect end of vacuum servo to fresh air flap 
^ re-fasten water tray in plenum 
^ install recirculation air flap 
^ seal and flap must be clean and free of seal adhesive 
^ check A/C system for proper operation 
^ fresh air/recirculation flaps must move (open and close) freely 
^ install passenger side lower shelf 
^    install glove compartment liner (if necessary) and glove compartment
Suggested Repair Time Labor operation:
Quality 8760311           Diagnosis Repair        Check Install fresh  air/  recirculation 20 TU.      75 TU.    5 TU. servo mounting bracket



________________________________
 From: Kenneth <auditude at cox.net>
To: 200q20v at audifans.com 
Sent: Thursday, June 6, 2013 12:02 PM
Subject: Re: Re: Dash removal for recirc flap work
 

Randy Mueller <quikqtr at yahoo.com>
> 
> Recirc Flap Mounting Repair Information:?
> Refer to TSB 879001
> when the Twist Lock mounting point (Plastic) breaks, there is a metal repair bracket (if still available?) PN 200 271 200 Plus a pair of self drilling/self tapping screws PN 013 966.12 (or 1/4 Hex Head screws available locally.
> 
> As for the Upper Return Spring Plastic Support that also breaks:
> I snip off the broken plastic support rod, pre-bend a piece of coat hanger into an "L" shape, Clamp it into a small Vise Grip Type Pliers, Heat the long end with a Butane or Propane Torch & Pierce it through one side of the plastic to come through where the original rod was, Heat Coat Hanger again & continue on through apposing side, Let cool & bend protruding end to lock it into place = Fixed...

Thanks, Randy.

I have the repair kit consisting of the metal bracket, spring, and maybe screws.  Anyone know where can I find a copy of the TSB to see what it reads?

Cheers,

Kenneth
_______________________________________________
200q20v mailing list    http://www.audifans.com/mailman/listinfo/200q20v