Audi Workshop Service and Repair Manuals

Removing –  Remove plenum chamber cover. –  Drain refrigerant circuit → Air conditioner with refrigerant R134a. –  Disconnect and remove battery -A- → Electrical system; Rep. Gr.27.   Note t  If necessary, obtain radio anti-theft code before disconnecting battery -A-. t  On vehicles with electrically adjustable seats, move seats to rearmost position before disconnecting battery -A-. t  On removal, note down bolt lengths and assignment for re-installation. t  All cable ties and other wiring harness fasteners released or cut open on removing air conditioner unit are to be re-attached in same position on installation. –  Dissipate pressure in coolant circuit by opening cap at coolant expansion tank. → Engine, mechanics; Rep. Gr.19

–  Mark positions of coolant hoses -A- and -B-. –  Pinch off both coolant hoses to heat exchanger of air conditioner unit (e.g. using hose clamps up to Ø 25 mm -3094-) and detach hoses.   Note t  Make sure coolant hoses are correctly connected: t  - Coolant hose -A- supply from cylinder head t  - Coolant hose -B- return to water pump t  - Bleeding coolant circuit → Engine, mechanics; Rep. Gr. 19

–  Place vessel beneath connection -A-. –  Attach section of tubing to connection -B- and use a compressed-air gun to carefully blow the coolant out of the heat exchanger (into the vessel). –  Remove socket -C-. –  Detach refrigerant pipes to evaporator → Chapter and secure them (e.g. with cable tie) such that they do not impede installation.

–  Remove socket -E-.   Note t  Seal open pipe connections. t  A cap from a replacement evaporator, for example, is suitable for sealing the open connections at the evaporator. –  Place protective covers over driver's and front passenger's seats. –  Remove glove box, driver's storage compartment, centre console and dash panel → General body repairs, interior; Rep. Gr. 70; Dash panel   Note So as not to damage the dash panel fascia, the dash panel is only to be placed on a clean workbench covered, for example, with clean cardboard.

–  Remove support -A- for dash panel cross member (on passenger's side at transmission tunnel). → General body repairs, interior; Rep. Gr.68 –  Remove accelerator pedal module → Fuel system; Rep. Gr.20.

–  Remove bolts -A- and -B- between support -C- and air conditioner unit. –  Remove support -C- for dash panel cross member (on driver's side at transmission tunnel) → General body repairs, interior; Rep. Gr.68. –  Remove front footwell vent → Chapter. –  Detach mounting bracket for brake pedal (and clutch pedal) from dash panel cross member. → Brake system; Rep. Gr.46

–  Unfasten hexagon nuts -A- for dash panel cross member on left and screw out by approx. 15 mm. → General body repairs, interior; Rep. Gr.70 –  Remove hexagon nuts -B- for dash panel cross member on right → General body repairs, interior; Rep. Gr.70. –  Remove connecting bolts between dash panel cross member and windscreen cross member (in passenger compartment) as well as connecting bolts between dash panel cross member and plenum chamber (between electronics box and windscreen cross member in plenum chamber). → General body repairs, interior; Rep. Gr.70 –  Carefully pull dash panel cross member to rear until it makes contact with nuts on left and is still resting on stud on right.

–  Remove intermediate piece for defroster duct -A- and air duct to centre dash panel vents -B-. –  Detach condensate drain from air conditioner unit → Chapter. –  Detach fasteners of vehicle wiring harness (with cable ties) at air conditioner unit. –  On vehicles with electric supplementary heater (vehicles with diesel engine only), unplug connectors from auxiliary heater element -Z35- → Chapter. –  Unplug all connectors between vehicle wiring harness and electrical components at air conditioner unit.   Note The “air conditioner” wiring harness is removed with the air conditioner unit.

–  Remove bolts -A-.

–  Take out air conditioner unit -A- towards passenger's side.   Note t  On removing air conditioner unit, pay attention to both coolant pipes to heat exchanger to ensure that they do not catch on opening to plenum chamber or on noise insulation mat and become bent. t  Pay attention to wiring harness. Pulling too firmly could damage individual wires.