Re: Type 44 Fresh air flap repair experiences?

[Peter Golledge <petergg@dimensional.com>]

Peter Schulz wrote:
> 
> Folks:
> 
> Perused the archives late last night to find out how to repair the
> fresh air flap under behind/the glovebox.
> 
> The wagon definitely shows signs of a malfunctioning flap
> (windows fog up quickly for no apparent reason, I hear a pressurized
> air sound (possibly the hose cam off the vacuum actuator)).

In my experience (5K and 200TQ) the spring on the fresh air flap
has been the culprit.  Worth cleaning/checking anyhow as there
is usually a lot of crap in the fresh air intake.

> Does anyone have either pictures of the flap and how to access
> it, or detaile dinstructions?  My archive search, using "air flap"
> turned up alot of references, but no real instructions.  I also
> looked at Scott Mockry's site, which also ahowed a drawing of
> the flap, but no detailed instructions.

The flap can be accessed from the footwell if you first remove the
shelf under the glove box.  The shelf comes out after remove a couple 
philips head screws.  To shed some light on the matter I find it
is best to open the hood and the black plastic cover sitting between the
top of the firewall and the windscreen.  You have to remove at least the
passenger side wiper from memory to get the black plastic cover off.

Once you have the cover off check for leaves blocking the fresh air
intake,
clean/vacuum out the mess.  You should be able to fire up the engine,
set the climate temp to 'LO' and verify that the flap closes, I believe
the flap should open if the climate temp is raised.  All of the
permutations of the climate system are still a mystery to me I am sure
one of the list regulars should be able to put me straight if my memory
is faulty (which is frequently is).

If the flap is not operating you should be able to verify that the 
'assisting' spring is still intact by looking straight up under/behind
the glove box from the footwell.  This is best achieved whilst lying on 
your back with you head in the footwell, Yoga is probably not a bad
option for
those wishing to work on an Audi at times.  There should be a short
(~1.25") spring attached to the center of the flap which is used to
'assist' the
vacuum motor, frequently this spring (or its mount on the door!) fails.
A simple ~50 cent replacement from the local hardware will work just
fine as long as the length and "strength" are reasonably close.

If it is _not_ the spring, well I can't help you there, both of mine
have been broken spring problems.  Getting the new spring hooked up in
inside can require quite a bit of dexterity with a pair of long nose
pliers.

> (By detail, I mean the type of detail that is generally used
> when describing how to replace the timing belt, bomb, etc.)

The above is not that detailed, but give it a try.

> Do I have to remove the glovebox? I took a look around the passenger
> footwell, and could not see any obvious access point.
> 
> And yes, I will write up an FAQ on this when I finish the repair.

Cheers
--  
Peter Golledge

89 200TQ,  79 Porsche 930,  89 SAAB 900i