Preparing to remove the front radiator
1. Move the front seats as far back as possible and turn off the ignition.
2. Open the expansion tank to relieve coolant pressure.
3. Remove the wiper assembly (see Chapter 11).
4. Remove the right and left parts of the front wall of the air intake chamber (A and B in the illustration). They are secured with bolts (C and D), and seals (E and F) are installed between them and the body.
12.4. Fastening the side parts of the front wall of the air intake chamber.
5. Remove the center part (And in the illustration) front wall of the air intake chamber (A and B in the illustration).
12.5. Fastening the central part of the front wall of the air intake chamber.
It is secured with bolts (B) and nuts (C), and a seal (D) is installed between it and the body. There is no need to completely remove the nuts. If there are any lines attached to the central part of the wall, separate them.
6. Mark the coolant hoses (A and B in the illustration), so as not to confuse them.
12.6. Connecting the coolant hoses to the climate control system housing.
Clamp the hoses and disconnect them. Remove the bushing (C) from the bulkhead and slide it into the passenger compartment.
7. Connect the hoses (A and B in the illustration) to the radiator ports, carefully apply compressed air (D) and blow the coolant out of the radiator into a container (C).
12.7. Blowing out the heater radiator.
8. Remove the lower left instrument panel trim (see Chapter 11).
9. Remove the gas pedal assembly (see Chapter 4).
10. Remove the brake light bulb together with its holder (do not separate the sensor from the holder), as described in Chapter 8.
11. Release the control unit holder and relay mounting block from the instrument panel beam, located to the left of the climate control system housing. Place the holder and mounting block so that they do not interfere with removal.
12. Remove the air duct leading to the driver's footwell.
13. Remove the left cover from the heater radiator. To do this, unscrew the bolts (A and B in the illustration).
12.13. Fastening the left radiator cover.
If there is not enough space to access bolt (B), carefully separate areas (E) from the cover and carefully push cover (D) away from the floor covering to the left. Release the cover (D) from the holders (C) on the coolant pipe bushings and separate it from the wiring harness secured to the upper side.
14. Remove the lower right instrument panel trim and main storage compartment (see Chapter 11).
15. Remove the air duct leading to the front passenger footwell.
16. Remove the right cover from the heater radiator. To do this, unscrew the bolt (And in the illustration), release the cover (B) from the holders (C) and separate it from the wiring harness secured to the top side.
12.16. Fastening the right radiator cover.
17. Separate the floor covering from the central tunnel on the left and right sides, and then carefully bend it back so that it is not damaged during removal and does not interfere with further work.
18. Protect the floor covering in the driver's footwell and on the center tunnel in the area under the radiator connections. Use a waterproof covering and absorbent paper for this.
Front heater radiator
Note: You will need an assistant to install the radiator.
19. Prepare for removal (see subsection above).
20. Remove the clips (And in the illustration) from the coolant lines (B and C), pull these coolant lines out of the heater core and set them aside so that they are out of the way.
12.20. Connecting the coolant lines to the heater radiator.
21. Remove the bolts (D in the illustration).
12.21. Removing the front heater radiator.
Unscrew the retaining pins (A) from the holders (B), pull them out of the lower air duct (C) and out of the air conditioning system housing. Release the clips (E) of the lower air duct (C), fold it together with the radiator as far down as possible (F), and then pull the air duct together with the radiator as far back as possible. Remove the radiator together with the air duct (C) towards the driver's footwell.
22. Clean the front housing of the Climate System (D in the illustration) and the lower air duct (B).
12.22. Front radiator installation details.
Make sure the seals (C) on the radiator (A) are in place. They should be securely attached around the entire perimeter and should not be damaged. Insert the radiator into the correct position into the lower air duct, and then install them together onto the air conditioning system housing. At the same time, make sure that the locking tabs fit into the grooves correctly.
23. Insert the retaining pins (And in illustration 12.21) and insert them into the holders (B). Install the bolts (D).
24. Wet the new O-rings (1 in illustration 12.20) in the coolant and install them into the ports (F) of the radiator. Insert two coolant pipes (B and C) into the radiator ports and secure them (A). Check that the clamps (A) are positioned correctly.
25. Install the right and left radiator caps, as well as the remaining removed parts located in the passenger compartment (except for the lower left instrument panel trim).
26. Install the bushing into the opening in the bulkhead (See illustration 12.6) and check its position on the coolant pipe flange (from the passenger compartment). Connect the coolant supply hose (A), fill the expansion tank and loosen the clamp installed on the hose (A) so that the coolant slowly fills the radiator and begins to flow out of its second port, and then connect the hose (B). Note: If the coolant does not flow out of the hose (A), create pressure on the filler neck of the expansion tank. Filling the radiator this way simplifies the next bleeding of the cooling system.
27. Install the removed parts located in the engine compartment. Make sure the coolant line connections are tight. Pay particular attention to the connections between the coolant pipes and the heater core. Pressure test the cooling system (see section 4 of Chapter 1).
28. Install the lower left instrument panel trim and the remaining removed parts.
29. Bleed the cooling system (see Section 2).
30. After installation, clear the fault memory of the front climate control module and apply the basic settings.
Rear radiator
31. Turn off the ignition.
32. Open the expansion tank to relieve coolant pressure.
33. Bring the rear housing of the climate control system to the service position (see Section 11).
34. Remove activators "V239" and "V240" (13 and 9 in Illustration 8.1d) rear left and right air flow intensity control flaps. Remove the bolts (And in the illustration) and remove the top cover (B).
12.34. Removing the top cover.
35. Mark the coolant hoses (A and B in the illustration), so as not to confuse them.
12.35. Connecting the coolant hoses to the rear radiator.
Clamp the coolant hoses and release the radiator (C) from the climate control system housing.
36. Take measures to collect the leaking coolant and disconnect the coolant hoses from the rear radiator.
37. Clean the rear housing of the air conditioning system and make sure that the foam seals are securely bonded to the radiator (And in the illustration).
12.37. Rear radiator seals.
38. Insert the rear radiator into the climate control system housing and connect the coolant hose (In the illustration 12.35). Fill the expansion tank and loosen the clamp on the hose (B) so that the coolant slowly fills the radiator and begins to flow out of its second port, then connect the hose (A).
Note: If coolant does not flow out of hose (B), apply pressure to the filler neck of the expansion tank. Filling the radiator this way simplifies the next bleeding of the cooling system.
39. Install the remaining removed parts and bleed the cooling system (see Section 2).
[The original material is located on the website «AudiManual.ru»]