Audi Workshop Service and Repair Manuals

Special tools, testers and auxiliary equipment required

• ◆ Hose clamps 3093 or 3094
• ◆ Commercially available compressed air gun

Removing

Notes:

• ◆ On removal, note the bolt lengths and assignment for re-installation.
• ◆ All cable ties which are released or cut open when the air conditioner is removed must be replaced in the same position when installing.

• ‒ Drain the refrigerant circuit

=> Air conditioner - with refrigerant R134a

• ‒ Cover the driver's and passenger's seat with protective covers.
• ‒ Remove the dust and pollen filter .
• ‒ Start the final diagnosis in vehicles with an air-flow flap .
• ‒ → Wait until the air-flow flap -A- has moved to the "closed" position.

• ‒ Terminate the final control diagnosis with a closed air-flow flap.
• ‒ Switch the ignition on.
• ‒ In vehicles with electrically adjustable seats, move them back as far as possible before disconnecting the battery.
• ‒ Observe or obtain radio code on vehicles with coded radio.
• ‒ Disconnect earthing strap at battery with ignition switched off.
• ‒ Remove the battery.
• ‒ Open the cover of the coolant expansion tank

• ‒ → Mark the layout of the coolant hoses -A- and -B-.
• ‒ Pinch off the coolant hoses to the heat exchanger with hose clamps V.A.G 3094 and detach the hoses.
• ‒ Detach the vacuum pipe to the engine and secure to the water pipes in the heat exchanger.
• ‒ Place a container under the connection for hose -A-.

• ‒ → Use the compressed air pistol to blow the coolant carefully out of the heat exchanger through the coolant hose -B-.
• ‒ Remove the grommet -C-.

• ‒ → Remove bolt -A-.
• ‒ Remove the refrigerant lines to the evaporator => Page 87-141 and secure them (e.g. with a cable tie), so they do not get in the way during installation.

Notes:

• ◆ Close the open pipe connections.
• ◆ Cap -C-, an evaporator spare part, for example, is suitable for sealing the open connections on the evaporator. It is also used as a guide during assembly.

• ‒ → Remove the grommet -D-.
• ‒ Detach the connector from the air conditioner low pressure switch -F73 and secure the lines and connector to the connection point.
• ‒ Remove the glove box, the shelf on the driver's side and the centre console:

=> General Body Assembly, Interior; Repair group 68; Storage compartments/covers; Removing and installing glove box

=> General Body Assembly, Interior; Repair group 70; Dash panel

• ‒ → Loosen the bolt -1- for attaching the pedal cluster to the cross piece for the dash panel:

=> Running gear, front-wheel drive and four-wheel drive; Repair group 46; Removing and installing pedal cluster

• ‒ Loosen the bolt -5- on the steering box/steering column -4-.
• ‒ After removing the steering column from the steering box, secure the steering column -4- with wire -3- at hole -2- to prevent it coming apart.

• ‒ Remove the E-box in the plenum chamber and detach the connector in the connector point and between the dash panel and the vehicle:

=> Electrical System; Repair group 97; Fitting locations for control units and electrical components

• ‒ Remove the footwell vents => Page 87-69.

• ‒ → Remove the dash panel with the dash panel and air conditioner cross piece:

=> General Body Assembly, Interior; Repair group 70; Dash panel

Note:

To ensure that the outer surface of the dash panel is not damaged, the dash panel may only be placed on a clean work bench which should be covered with clean cardboard, for example.

• ‒ Separate all the electrical connections between the dash panel and air conditioner at the connectors.

• ‒ → Loosen all the bolts between the dash panel and the air conditioner.
• ‒ Remove the air conditioner from the dash panel.

Installing

Installation is carried out in the reverse order; note the following:

Note:

Check all the seals on the air conditioner for damage, replace damaged seals.

• ‒ When installing the dash panel, ensure that the vacuum hose and connector to the -F73 are inserted through the openings in the back wall of the plenum chamber with the refrigerant pipes and the evaporator flange respectively.
• ‒ Install the refrigerant lines to the evaporator => Page 87-141.

• ‒ → Connect the coolant hoses to the heat exchanger correctly. Note the markings:

•     A -    Return hose to the water pump (with vent hole)
•     B -    Inlet hose from the cylinder head

• ‒ After the installation of the dash panel, check that the grommet -C- is seated correctly.

• ‒ Check that the condensation drain hoses are seated correctly => Page 87-52.
• ‒ Bleed the coolant circuit:

=> Relevant Workshop Manual Engine, Mechanical Components; Repair group 19

• ‒ Evacuate refrigerant circuit and refill:

=> Air conditioner - with refrigerant R134a