Note. Before disconnecting battery, obtain anti-theft radio security code if necessary. On vehicles with electrically adjustable seats, move the seats back as far as possible before disconnecting the battery. Refer to Removal and Installation . When removing bolts, take note of the length and assignment of bolts for re-installation. All cable ties opened or cut during removal of heating A/C unit must be reinstalled at the same locations during installation. Depending on vehicle equipment and on engine, heat insulation has been applied to coolant hoses, these must not be damaged and must be re-applied after installing.

Evacuate the refrigerant circuit. Refer to EVACUATING REFRIGERANT CIRCUIT and refer to DRAINING REFRIGERANT CIRCUIT .

Switch off ignition.

Protect driver and front passenger seats using seat covers.

Disconnect battery, refer to REMOVAL AND INSTALLATION .

Release pressure in cooling circuit by opening the cap on coolant expansion tank, refer to [For engine(s) CBRA] General Information , or refer to [For engine(s) BPY] General Information , or refer to [For engine(s) CCTA, CBFA] General Information , or refer to [For engine(s) CBEA] General Information .

Remove the components that hinder access to the mounting bolts for refrigerant lines -A- on expansion valve and to coolant hoses to heater core in engine compartment.

Scheme 98

Note. Depending on engine and version of vehicle, it may be necessary to loosen or to remove the following components (top engine cover, pressurized air pipe to throttle valve part and depending on engine the intake manifold, etc.). Refer to [For engine(s) CBRA] Removal and Installation or refer to [For engine(s) BPY] Removal and Installation or refer to [For engine(s) CCTA, CBFA] Removal and Installation or refer to [For engine(s), CBEA] Removal and Installation . Depending on the engine (for example, on certain 2.0L diesel engines and depending on the exhaust system) it may be necessary to remove the plenum chamber cover and the front wall of the plenum chamber -A- in order to be able to remove the heat shield and to remove the refrigerant lines from the expansion valve and the coolant hoses from the heat exchanger. Refer to Removal and Installation . The heat shield -B- is available in different versions. For version 1, sheet metal nuts -A- must be removed and heat shield -B- disengaged from vehicle. On version 2, clamping washers -A- and clamp -C- must be removed and heat shield -B- disengaged from vehicle. After disconnecting coolant hoses, remove heat shield -B- completely. For the sake of clarity, the illustrations show the heat shield -B- with the engine removed.

Loosen the heat shield -B- from the front of the plenum chamber and from the bulkhead and move it to the side, or remove it completely.

Slide a thermal protective cover -D- and -E- as far back as possible until it is possible to installed the 3093 -F- onto the coolant hoses -A- and -B-.

Scheme 99

Mark arrangement of coolant hoses -A- and -B-.

Scheme 100

Note. The heater core is designed for a specific coolant flow direction, therefore coolant hoses must be connected on the proper sides (coolant hose -A- supply from cylinder head, coolant hose -B- return to coolant pump). The coolant hose arrangement is the same in both vehicles without and with A/C, this illustration shows a vehicle with A/C. Bleed the coolant circuit. Refer to [For engine(s) CCTA, CBFA] General Information .

If necessary, clamp off vent hose (from upper connection -A- to coolant expansion tank).

Cover the area beneath connections for coolant hoses -A- and -B-, for example, with a paper towel.

Clamp off coolant hoses to heater core of heating A/C unit (e.g. using 3093) and remove them.

Connect one section of hose -A- on to upper connection.

Scheme 101

Hold a container -B- under the lower connection -C-.

Using a compressed air gun, carefully blow coolant out of heater core (into container -B-).

Disconnect refrigerant lines from expansion valve, refer to REFRIGERANT LINES, DISCONNECTING FROM EXPANSION VALVE and secure (e.g. with cable tie) so they do not interfere during installation.

Note. Seal open line connections (against dirt and moisture penetration). Uses the caps from the replacement evaporator to seal off the open connections on the expansion valve or on the evaporator.

Remove the glove compartment, the driver side storage compartment, the center console and the instrument panel. Refer to Removal and Installation .

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 the gas pedal module. Refer to ACCELERATOR PEDAL MODULE WITH THROTTLE POSITION SENSORS .

Remove the left and right vents -C-.

Scheme 102

Fold back the carpet on the driver and front passenger sides so that the vents for the rear footwells can be removed -A- and -B-. Refer to Removal and Installation .

Remove both rear footwell vents -A- and -B-.

Remove fresh air blower. Refer to FRESH AIR BLOWER AND CONTROL MODULE, AUTOMATICALLY REGULATED A/C SYSTEM

Vehicles with manually regulated A/C system: remove A/C Control Module -J301- (do not remove base plate for controls), refer to HEATER AND A/C SYSTEM CONTROLS .

Remove the instrument panel and the instrument panel cross-member. Refer to Removal and Installation .

Remove Data Bus On Board Diagnostic Interface -J533- (secured to bracket -A- in area of steering column). Refer to [For engine(s) CBRA, BPY, CCTA, CBFA] Removal and Installation .

Remove bolts -B- and release bracket -A- from A/C unit (bracket remains on wiring harness secured to vehicle).

Remove both bolts -A- on bracket for wiring harness -B-.

Scheme 103

Disconnect the connector -C-.

Remove condensation drain from A/C unit, refer to CONDENSATE DRAIN HOSE .

Loosen securing ties of wiring harness on A/C unit.

On vehicles with an electric auxiliary heater (on vehicles with Diesel engine), disconnect wire connections to voltage supply for the Auxiliary Heater Heating Element -Z35-. Refer to AUXILIARY HEATER HEATING ELEMENT WITH CONTROL MODULE .

Disconnect all electrical connections between vehicle wiring harness and the A/C unit electrical components on connectors.

Note. The wiring harness air conditioner is removed together with the A/C unit.

Carefully pull right side of A/C unit slightly toward rear (far enough that bolt -B- on right bracket -A- can be loosened).

Scheme 104

Note. Only pull carefully on A/C unit so that bracket -A- does not break. To loosen bolt -B-, reach between A/C unit and floor mat on right wheel housing (to make this possible, fresh air blower has been removed earlier).

Remove bolts -B- and release bracket -A- from A/C unit (bracket remains on wiring harness secured to vehicle).

Disengage both flanges for coolant pipes to heater core -A- and for expansion valve (to evaporator) -B- from pass-throughs of grommet -C-.

Scheme 105

Note. When removing A/C unit, make sure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or noise insulation mat. Observe wiring harness, individual electrical wiring connections may get damaged when pulling on harness.

Remove A/C unit -A- towards passenger side.

Scheme 106

Installation

Installation is reverse of removal, noting the following

Two technicians are needed to install the heater and A/C unit.

Note. Before installing, check all gaskets and seals on the A/C unit for damage and replace if necessary. Check securing of coolant pipes to heat exchanger.

Insert molded seal -A- (working from passenger compartment) into bulkhead -B-, make sure that reinforcement -C- (wire bracket) is positioned correctly in molded seal -A-.

Scheme 107

Ask a colleague for assistance to install the heating and A/C unit.

Have the second mechanic (working from engine compartment) guide both flanges for coolant pipes to heater core -A- and for expansion valve (to evaporator) -B- through pass-throughs of grommet -C- when inserting heating and A/C unit.

Note. When installing A/C unit, make sure the two coolant pipes of the heater core do not get caught and bent or damaged on plenum chamber or noise insulation mat. Observe wiring harness, individual electrical wiring connections may get damaged when pulling on harness.

Connect condensation water drain to connection on A/C unit and check condensation water drain for correct seating, refer to CONDENSATE DRAIN HOSE .

Reinstall removed components in reverse order of removal except driver storage compartment.

Note. When installing the instrument panel, make sure that the defrost intermediate piece its properly on A/C unit and the defrost vent does not pinch the intermediate piece. After installing the instrument panel, check the output direction and distribution of the air flow from the defroster vent to the windshield.

Connect coolant hoses properly to heater core. Observe markings

A - Supply hose from cylinder head

B - Return to the coolant pump

Connect refrigerant lines to expansion valve, refer to REFRIGERANT LINES, DISCONNECTING FROM EXPANSION VALVE .

Check installation position of coolant hoses to heater cores (they must not contact components which grow hot) and position and state of heat protection insulation applied to coolant hoses if necessary (not installed on all engine types).

Bleed cooling circuit, refer to [For engine(s) CBRA] General Information or refer to [For engine(s) BPY] General Information or refer to [For engine(s) CCTA, CBFA] General Information or refer to [For engine(s) CBEA] General Information .

Check coolant circuit for leaks, pay particular attention to the connection between coolant hoses and heater core, refer to LEAK DETECTION .

Check grommet -C- in bulkhead for proper seating.

Seal flange for coolant pipes to heater core -A- and for expansion valve (to evaporator) -B- at pass-through of grommet -C- with silicon adhesive sealant if necessary (to prevent water from penetrating).

Evacuate and recharge refrigerant circuit. Refer to CHARGING REFRIGERANT CIRCUIT and refer to DRAINING REFRIGERANT CIRCUIT .

Reinstall driver side storage compartment and remaining removed components.

If necessary, check the A/C system using Vehicle Diagnosis, Testing and Information System VAS 5051 under "Guided Fault Finding".

Check the air vent direction on vehicles with a manual climate control system. as depending on switch position, the flexible shaft rotates twice for one switch rotation via set of gears on heating A/C unit and on heating A/C unit controls. Refer to HEATER AND A/C SYSTEM CONTROL BASE PLATE .

Operate the A/C system after filling the refrigerant circuit, refer to A/C SYSTEM, OPERATING AFTER FILLING REFRIGERANT CIRCUIT .

Note. Note the information regarding operating the A/C system after filling, refer to CHARGING REFRIGERANT .

HEATING AND A/C UNIT Audi A3 8P рестайлинг 2