Heating and A/C unit, removing and installing: Removing

WARNING: This page does not describe the selected car, but rather 17 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Remove plenum chamber cover.
Discharge refrigerant circuit → Discharge refrigerant circuit .
Disconnect and remove Battery A →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

NOTE:

If necessary, obtain radio anti-theft code before disconnecting Battery A.
On vehicles with electrically adjustable seats, move seats to rearmost position before disconnecting Battery A.
On removal, note down bolt lengths and assignment for reinstallation.
All cable ties and other wiring harness fasteners released or cut open on removing air conditioner are to be reinstalled in same position on installation.

Dissipate pressure in coolant circuit by opening cap at coolant reservoir. →
- 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

CAUTION:

On vehicles equipped with Audi Telematics by OnStar, switch-off the emergency (back-up) 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 →
- 91 - COMMUNICATION
- 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER for COMMUNICATION, CABRIOLET

Fig 1: Identifying Coolant Hoses

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark positions of coolant hoses - A - and - B -.
Pinch off both coolant hoses to heater core of air conditioner (e.g. using Hose Clamps Up To 25mm Dia. 3094) and remove hoses.

NOTE:

Make sure coolant hoses are correctly connected:
- Coolant hose - A - supply from cylinder head
- Coolant hose - B - return to water pump
- Bleeding coolant circuit →
- 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Fig 2: Identifying Connections & Grommet

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place container beneath connection - A -.
Install section of tubing to connection - B - and use a compressed-air gun to carefully blow the coolant out of the heater core (into the container).
Remove grommet - C -.
Remove refrigerant lines to evaporator → Refrigerant lines on evaporator flange, removing and installing and secure them (e.g. with cable tie) such that they do not impede installation.

Fig 3: Refrigerant Lines On Evaporator Flange, Removing/Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove grommet - E -.

NOTE:

Seal open line connections.
A cap from a replacement evaporator, for example, is suitable for sealing the open connections at the evaporator.

Place protective covers over drivers and front passengers seats.
Remove glove compartment, drivers storage compartment, center console and instrument panel →
- 70 - INTERIOR TRIM
- 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET

NOTE:

So as not to damage the instrument panel fascia, the instrument panel is only to be placed on a clean workbench covered with clean cardboard.

Fig 4: Removing Support For Instrument Panel Cross Member

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove brace - A - for instrument panel cross member (on passengers side at transmission tunnel). →
- 68 - INTERIOR EQUIPMENT
- 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET
Remove accelerator pedal module → 20 - FUEL SUPPLY SYSTEM .

Fig 5: Removing Bolts Between Support And Air Conditioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - A - and - B - between support - C - and air conditioner.
Remove support - C - for instrument panel cross member (on drivers side at transmission tunnel) →
- 68 - INTERIOR EQUIPMENT
- 68 - INTERIOR EQUIPMENT for BODY INTERIOR - CABRIOLET
.
Remove front footwell vent → Footwell vents front, removing and installing .
Remove mounting bracket for brake pedal (and clutch pedal) from instrument panel cross member. → 46 - BRAKES - MECHANICAL COMPONENTS

Fig 6: Defroster Outlet Vent Intermediate Piece For Front Windshield, Removing/Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen hex nuts - A - for instrument panel cross member on left and screw out by approx. 15 mm. →
- 70 - INTERIOR TRIM
- 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
Remove hex nuts - B - for instrument panel cross member on right →
- 70 - INTERIOR TRIM
- 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
.
Remove connecting bolts between instrument panel cross member and windshield cross member (in passenger compartment) as well as connecting bolts between instrument panel cross member and plenum chamber (between electronics box and windshield cross member in plenum chamber). →
- 70 - INTERIOR TRIM
- 70 - INTERIOR TRIM for BODY INTERIOR - CABRIOLET
Carefully pull instrument panel cross member to rear until it makes contact with nuts on left and is still resting on stud on right.

Fig 7: Removing Intermediate Piece For Defroster Channel And Air Guide To Center Instrument Panel Vents

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove intermediate piece for defroster channel - A - and air guide to center instrument panel vents - B -.
Remove evaporator from air conditioner → Evaporator housing drain, removing and installing .
Remove fasteners of vehicle wiring harness (with cable ties) at air conditioner.
Disconnect all connectors between vehicle wiring harness and electrical components at air conditioner.

NOTE:

The "air conditioner" wiring harness is removed with the air conditioner.

Fig 8: Removing Air Conditioner Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - A -.

Fig 9: Take Out Air Conditioner Towards Passengers Side

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Take out air conditioner - A - towards passengers side.

NOTE:

When removing air conditioner, pay attention to both coolant lines to heater core to ensure that they do not catch on opening to plenum chamber or on noise insulation mat and become bent.
Pay attention to wiring harness. Pulling too firmly could damage individual wires.