Air Conditioner Unit, Removing and Installing
Air Conditioner Unit, Removing And Installing
Special tools and equipment
- Hose clamps 3093 or 3094
- Compressed air gun, standard
- V.A.G 1274 hand pump with adapters
CAUTION: On vehicles equipped with Audi Telematics by OnStar, switch-off the emergency (backup) battery for the Telematic/Telephone Control Module prior to disconnecting the vehicle battery. Switch-on the emergency (back-up) battery after reconnecting the vehicle battery.
Removing
- Remove plenum cover.
- Discharge A/C refrigerant system
- Disconnect battery and remove.
NOTE:
- Obtain radio code before disconnecting battery.
- On vehicles with power seats, move the seats back as far as possible before disconnecting the battery.
- Take a note of the length and assignment of bolts during removal.
- All cable ties opened or cut during air conditioner removal must be reinstalled at the same locations during installation.
- Release pressure in coolant system by opening cap on coolant expansion tank.
- Mark allocation of the coolant hoses -A- and -B-.
- Clamp off and disconnect both coolant hoses leading to heater core in air conditioner unit (e.g. using V.A.G 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 under connection -A-.
- Place a piece of hose on connection -B-and carefully blow out coolant from heater core with compressed air.
- Remove grommet -C-.
- Remove refrigerant lines from evaporator and secure (e.g. with cable tie) so they do not interfere during installation.
- Remove grommet -E-.
NOTE:
- Seal all open connections.
- To seal off all open connections on evaporator, sealing caps from a replacement evaporator can be used (preventing dirt and moisture from entering the system).
- Protect driver and passenger seat using seat cover.
- Remove glove compartment, driver's side storage compartment, center console and instrument panel:
- Remove instrument panel:
NOTE: To prevent the instrument panel shell from damage, instrument panel should be placed on a clean work bench which is covered with clean cardboard.
- Remove brace -A- for central tube (passenger side on center tunnel)
- Remove accelerator pedal module.
Vehicles with knee bolster
- Remove right support (located above clutch pedal).
All vehicles
- Remove bolts -A- and -B-between brace -C-and the air conditioner.
- Remove brace -C-for central tube (driver's side on center tunnel).
- Remove front footwell vent
- Remove bolt for brake pedal mounting bracket (and clutch pedal) from central tube.
- Loosen hex nuts -A- for central tube left side and unscrew approx. 15 mm.
- Remove hex nuts -B-for central tube on right side
- Remove connecting bolts between central tube and the windshield cross member (in passenger compartment).
- Remove connecting bolts between central tube and the plenum chamber (between electronic box and windshield cross member in plenum chamber).
- Pull central tube carefully back, until cross member touches the hex nuts on the left side and still rests on the threaded bolt on the right side.
- Remove intermediate piece for defrost channel -A- and center air ducts for instrument panel -B-.
- Remove evaporator drain from air conditioner unit
- Loosen securing ties of wiring harness on air conditioner unit.
- Remove passenger lower A-pillar trim and cut wire harness cable ties and move wire harness out of the way.
- Disconnect all electrical connection between wiring harness and the electrical components of the A/C system.
NOTE: The wiring harness "air conditioner" is removed together with the air conditioner unit.
- Remove bolts -A-.
- Remove air conditioner unit -A- toward passenger side.
NOTE:
- When removing air conditioner unit, make sure the two coolant lines of the heater core do not get caught or bend on plenum chamber or sound insulation mat.
- Observe wiring harness, individual wiring connection may get damaged when pulling on harness.
Installing
Installation is reverse of removal, noting the following:
NOTE:
- Before installing, check all gaskets and seals on the air conditioner unit for damage and replace if necessary.
- Make sure coolant hoses to heater core are secured.
- Connect coolant hoses properly to heater core. Observe markings:
A - Supply hose from cylinder head
B - Return hose to water pump
- Install removed components, except storage compartment driver's side, in reverse order.
- Bleed coolant circuit:
NOTE: The heater core must additionally be bled, due to the allocation of the coolant lines to the heater core. Proceed as follows:
- Bleed coolant circuit.
- Switch ignition off.
- Carefully open coolant reservoir cap (observe safety precautions when opening the cap)
- Loosen clamp on coolant hose -B-.
- Pull hose -B-until the hole in the coolant hose is no longer sealed with the pipe.
- Increase pressure in coolant circuit e.g. using V.A.G 1274 hand pump.
- Bleed heater core via coolant hose -B-until coolant exits bubble free.
- Push coolant hose -B-on heater core pipe and tighten with clamp.
- Add coolant if necessary.
- Check coolant circuit for leaks, pay particular attention between coolant hoses and heater core.
- Install driver's side storage compartment and other removed components.
- Install refrigerant lines from evaporator.
- Check evaporator drain hose for correct seating
- Evacuate refrigerant circuit and recharge again
NOTE:
- When installing the instrument panel, make sure that the intermediate piece for the defroster fits properly on the air conditioning unit and the defrost vent does not pinch the intermediate piece.
- After installing the instrument panel, check the vent direction and air distribution of flowing air coming from the defrost vent to windshield.