Removing and installing air conditioner - vehicles from Model Year 1997 — AUDI

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.
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.
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.
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
87-179
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-.
Remove the glove box, the shelf on the driver's side, the centre console and the dash panel:

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

=> General Body Assembly, Interior; Repair group 68; Storage compartments/covers; Removing and installing driver's storage compartment
General Body Assembly, Interior
Storage compartments/covers
Removing and installing driver's storage compartment

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

Remove the dash panel support -A-.
Detach the dash panel support -B- from the vehicle.

Note:

The upper fastening bolt on the air conditioner cannot be removed.

Remove the footwell vents => Page
87-69
.

Screw out the bolts -A-.
Separate all the electrical connections between the vehicle and the air conditioner at the connectors.

Screw out the bolts -A-.
Remove the air conditioner towards the passenger's side.

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.

Install the refrigerant lines to the evaporator => Page
87-179
.

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