AC Programmer Manual Conversion or Vacuum Test Jumper

[Kneale Brownson]

You can't send graphics to the list, but you COULD send to interested 
individuals who ask purtypleeze, eh?


At 09:26 PM 08/21/2001 -0500, Matthew Caprio wrote:

>Yeah, I did, but the email with the photo got bounced from the list, so I
>sent it again sans photo.  Maybe I will save it at a lower res to get it
>just under the 40k limit and try again.
>
>Thanks for the feedback.
>Matt
>
>----- Original Message -----
>From: "Kneale Brownson" <knotnook at traverse.com>
>To: "Matthew Caprio" <caprio at flash.net>; "Quattro List"
><quattro at audifans.com>
>Sent: Tuesday, August 21, 2001 7:04 PM
>Subject: Re: AC Programmer Manual Conversion or Vacuum Test Jumper
>
>
> > Great report, Matthew.  Did you take any photos of the parts involved?
> >
> > At 06:18 PM 08/21/2001 -0500, Matthew Caprio wrote:
> >
> > >AC Programmer Manual Conversion or Vacuum Test Jumper
> > >
> > >Keywords:
> > >AC, programmer, solenoid valve, solenoid switch, vacuum switch, vents,
> > >flaps, automatic climate control.
> > >
> > >Applies to:
> > >86-88 5000 (and maybe more models and years)
> > >
> > >Background:
> > >The solenoid vacuum valves in Audi AC Programmers control the flow of
> > >vacuum to the AC vent actuators.  These solenoid valves have a tendency
>to
> > >become clogged or contaminated by oil.  Bypassing these solenoid valves
> > >can be useful as a diagnostic tool (to determine if the problem is lack
>of
> > >vacuum, failed signals, or clogged valves), or as a long term solution to
> > >convert the programmer to manual operation.
> > >
> > >Fix:
> > >A vacuum line jumper can be made from parts inside the programmer to
>route
> > >the vacuum input source directly to the vacuum acutators, bypassing the
> > >solenoid valves and all their electronics.  This jumper can be left
>inside
> > >the existing programmer, or can be made with parts from a junked
> > >programmer as a stand alone unit.
> > >
> > >How to make it:
> > >The jumper consists of 2 parts and some vacuum hose.  The parts are: 1.)
> > >the connector block from the AC programmer where the 6 port vacuum
> > >connection plugs in.  2.) the vacuum splitter block from the AC
>programmer
> > >where the 1 vacuum input is split into 4 lines that normally feed the 4
> > >solenoid valves.
> > >
> > >The ports on the connector block are numbered 1-6.  The ports on the
> > >splitter block are numbered 1-6.  Run 4 lines from the connector block
> > >ports 1,2,3,4 to the vacuum splitter block ports 3,4,5,6 (the order is
>not
> > >important).  Run 1 line from the connector block port 5 to the splitter
> > >block 2.  Cap off splitter block port 1 with the red rubber cap that
> > >should already be on there.
> > >
> > >Secure all hoses in place with some sort of silicone or glue (nothing
>that
> > >will be sucked in there and clog up anything).
> > >
> > >Plug this into the car's clear colored vacuum harness connector with the
> > >colorful tubes.  You are ready to run.
> > >
> > >This arrangement forces the following conditions:
> > >-recirc door open (no outside air flowing into cabin)
> > >-heater valve closed (no hot coolant flowing into heater core for heat)
> > >-all air routed away from defrost
> > >-all air redirected fully through dash vents at the driver
> > >
> > >Notes:
> > >This arrangement is best for summer AC mode.
> > >All other normal programmer arrangements (defrost, bilevel, etc) can be
> > >made manually with this jumper by disconnecting (AND CAPPING) the proper
> > >line from the splitter block to the connector block.  Both ends must be
> > >capped to prevent vacuum leaks and contamination of the vacuum
> > >actuators.  Create your own exciting custom settings!  The following
>table
> > >indicates what does what:
> > >
> > >Block Port Number - Harness Line Color - Function
> > >1 - red - shuts recirc door AND closes hot flow to heater core (with
> > >vacuum applied)
> > >2 - yellow - reroutes air from footwell (default) to half center vents
> > >bilevel (with vac)
> > >3 - green - reroutes air from footwell (default) to full center vents
> > >(with vacuum applied)
> > >4 - blue - reroutes air from defrost (default) to footwell (with vacuum
> > >applied)
> > >5 - black - input vacuum source
> > >6 - no connection - no function
> > >
> > >note that port 1 eventually splits to perform 2 functions- closing heater
> > >valve and closing recirc door flap.
> > >
> > >Other notes:
> > >The splitter block also contains a check valve which prevents air from
> > >flowing in the wrong direction.  Test this check valve before you make
>the
> > >jumper to ensure you have a reliable one.  To test, supply a vacuum (or
> > >suck with your mouth) on a hose to port 2 on the splitter block.  You
> > >should be able to suck, but not blow if the check valve is working
>properly.
> > >
> > >Testing the system with the jumper:
> > >If the jumper is properly made and installed, and your system directs air
> > >as indicated above, then you know that 1.) you have adequate vacuum
>coming
> > >from your black hose and the "egg crate" accumulator.  2.) that your
> > >actuators are working.  3.) there are no vacuum leaks in your colored
> > >vacuum hoses going to your actuators.  Any problems that may exist are
> > >either in 1.) AC head (generating the commands), 2.) the connections
> > >between the head and the programmer, 3.) the programmer itself or a
> > >solenoid valve.
> > >
> > >FYI: a commonly reported problem on these cars is that the return spring
> > >breaks on the recirc door to leave it in recirc even with the heat on
> > >(acting like the vacuum is applied to port 1, but opening the heater
> > >valve).  Or, the bracket which supports the return spring cracks.
>Another
> > >one is that the hose to the recirc door sometimes falls off.  Oh yeah,
> > >also there may be a spurious / weak voltage source to the programmer that
> > >sometimes is not enough to actuate the solenoids-- this is real difficult
> > >one to diagnose, but that's how I learned all of the above in the
> > >process.  I'm sure there are more, since this system does NOT age well,
> > >but I haven't heard them all.
> > >
> > >Good luck, and I hope the list can benefit from this hard learned info.
> > >Matthew Caprio
> > >Austin, TX
> > >88 5ksQ
> >