Complete Air Conditioner Unit, Removing and Installing

Complete Air Conditioner Unit, Removing And Installing

- Discharge refrigerant circuit.
- Remove dust and pollen filter and its bracket.
- Disconnect battery cables and remove battery.


NOTE:
- Obtain radio code before disconnecting battery.
- On vehicles with power seats, move the seats back as far as possible before disconnecting the battery.


- Release pressure in coolant system by opening cap on coolant expansion tank.







- Clamp off and disconnect both coolant hoses leading to heater core in air conditioner unit (e.g. using VAG 3094)


NOTE:







- The coolant hoses must be re-installed in the correct positions:
-- Coolant hose -A- supply from cylinder head.
-- Coolant hose -B- return to water pump.
- Bleed cooling circuit







- Place container beneath connection -A- and carefully blow out coolant from heater core (using compressed air) via connection -B-.
- Remove grommet -C-.
- Remove refrigerant line
- Remove refrigerant lines and secure them (e.g. with cable tie) so they are not in the way during installation procedure.







- Seal off refrigerant lines -B- and open connections -A- on evaporator.
- Remove grommet -C-.
- Remove storage compartment on driver's side, center console and instrument panel fascia.







- Remove instrument panel cross member -A-.


NOTE: The instrument panel cross member is fastened to the window cross member with an additional screw.


- Disconnect all electrical harness connectors for wiring between body and air conditioner unit -B-.


NOTE: Before disconnecting, mark the connectors for the wiring to the various positioning motors so that they do not become interchanged when reconnecting.







- Remove air conditioner unit -B-.


NOTE:
- Starting September 1998, there was a running change in production from the version "1" air conditioner to the version "2" air conditioner.
- From model year 2002 air conditioner version "3" are installed


Notes for installation:
- Before installing, check all gaskets and seals on the air conditioner unit for damage and replace if necessary.
- After assembling, all cable ties which were removed in order to take out the air conditioner must be reinstalled in their original positions.
- Replace both O-rings for the refrigerant lines.
- Make sure refrigerant lines are not under stress when installed.
- Make sure that the condensation drainage duct and condensation drain valve are properly seated.