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Re: 1999 Audi A4 Climate Control Removal/Installation
You have to remove the trim panel around the stereo/climate control to expose the screws that hold it in place. Once you do that, and the screws are removed, it pulls straight out and unplugs. No need to disconnect the battery and no tricks to it once it slides out.
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first unhook the battery! then unbolt the cables from the back of the starter! be sure to mark them with masking tape, or something you can use to identify what wire goes where! then unbolt the starter bolts from the starter, and remove it! reverse this to put new starter back in!
Before removing the stereo or any other electrical component, it is vital that you first disconnect the grounding cable from the Neon's battery. The grounding cable connects the battery to the frame or chassis of the vehicle.
Use a Phillips-head screwdriver to loosen the grounding cable's camp from the negative battery lead. Make sure to rest the clamp away from the negative lead post until the removal is complete.
Remove the Dash Trim Panel
The dash trim panel that surrounds the Neon stereo needs to be removed to access the stereo. The panel contains, but is not connected to, the climate control knobs on the dashboard.
Grab the panel at the bottom corners and pry it from the dash. You will likely be able to remove the panel without the assistance of a trim pry tool, but if you are having difficulty removing the panel by hand, wrap a thin cloth around a trim panel removal tool or flat head screwdriver to remove the panel.
Once the lower edge of the panel is relieved from the panel, you can work your hands (or flat pry tool) around the perimeter to separate the remaining edges.
Since the panel is not connected to the climate control knobs, you will not need to disconnect the wiring to the knobs. The panel, once free, can be set aside until you replace the stereo.
Remove the Stereo
The Neon stereo deck is held into the stereo mounting bracket by 10 millimeter bolts on either side of the radio. Remove the bolts and store them in the ashtray for safe-keeping.
Pull the stereo from the dock. The unit will easily slide from the mounting bracket with an even pull from the left and right of the stereo. Pull the stereo far enough to reach the wiring on the rear of the radio.
The wiring to the stereo includes the antenna, the power supply and the speaker wires. There may also be patch cables connected if an amplifier is connected to your stereo system. Pull the cables from the stereo. The antenna and power supply are single cables. The speaker wires (and patch cables) will be grouped by wire binders. The plastic wire binders should be pulled as a unit. Do not pull the wires themselves.
Once the wiring has been disconnected from the stereo, the unit will be completely free from the Neon.
If you plan to operate the vehicle before installing a new stereo or re-installing the factory deck; reconnect the grounding cable to the negative battery lead. Otherwise, leave the cable away from the negative lead until all of your work is completed.
SECTION 412-04: Control Components
1998 Contour/Mystique Workshop Manual
REMOVAL AND INSTALLATION
Procedure revision date: 09/14/2001
Climate Control Assembly
Remove the radio chassis. For additional information, refer to Section 415-01.
Remover, Radio 415-001 (T87P-19061-A) Removal
NOTE: Make sure the audio unit key code is available before disconnecting the audio unit electrical connectors and note the audio unit station presets. Using the special tool, detach the audio unit.
Insert the Radio removal tool into the locating holes until they click into place.
Pull the tools gently to the left and right of the audio unit to release the locking tangs.
Pull the audio unit out of the instrument panel.
Remove the audio unit.
Disconnect the power electrical connector.
Disconnect the audioline/speaker electrical connector.
Disconnect the antenna cable.
NOTE: When installing the audio unit make sure the rear support engages on the carrier. To install, reverse the removal procedure.
Enter the audio unit keycode and re-program the pre-set audio unit stations
Remove the floor console. For additional information, refer to Section 501-12.
Floor Console - Vehicles with Automatic Transaxle
WARNING: Wait at least one minute after disconnecting the battery cables before removing the floor console. Failure to follow this instruction may increase the possibility of accidentally deploying the air bag(s) and may cause personal injury. Disconnect the battery ground cable.
Remove heater/evaporator case. Remove vacuum source line from heater core tube seal. Remove seal from heater core tubes. Remove heater core access cover screws. Remove access cover and seal from heater/evaporator case. Lift heater core and case seals out of heater/evaporator case. Installation If installing new heater core, transfer case seals to new core. Install heater core and seals into heater/evaporator case. Install heater core access cover on case. Install seal on heater core tubes. To complete installation, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.
HEATER/EVAPORATOR CASE Removal
Disconnect negative battery cable. Drain coolant from radiator. Gently pull instrument panel away from right side of dash panel.
Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect heater hoses from heater core. Plug heater core tubes or drain coolant by blowing coolant from heater core using low pressure compressed air. Disconnect vacuum supply hose from inside engine compartment.
Disconnect A/C lines from evaporator core. Plug A/C lines and evaporator core tubes. Remove instrument panel assembly brace to evaporator case bracket screw. Remove assembly brace.
Remove floor register and rear floor duct from bottom of heater/evaporator case. Remove nuts securing heater/evaporator case to firewall. Remove 2 screws securing support brackets to cowl top panel. Carefully pull heater/evaporator case away from firewall. Remove heater/evaporator case.
To install, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.
INSTRUMENT PANEL Removal & Installation
Position front wheels in straight-ahead position. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section. Disconnect negative battery cable. Remove steering column trim shrouds.
Disconnect all electrical connections from steering column switches. Remove cover from under steering column. Remove 4 bolts and reinforcement from under steering column. Disconnect parking brake release control motor from parking brake and ignition switch connector.
Disengage insulator retainer. Remove insulator. Remove 4 nuts and reinforcement below steering column. Remove 4 nuts securing steering column to instrument panel and lower column to front seat. Disconnect PRNDL cable (A/T models).
Ensure ignition switch is locked to prevent steering column from turning. Remove 4 instrument cluster retaining screws. Disconnect speed control cable and vehicle speed sensor (if equipped). Disconnect electrical connectors and remove instrument cluster. At steering column opening, remove one bolt securing instrument panel to brace. Remove one instrument panel brace bolt (below radio area).
Remove sound insulator under glove box by removing 2 push nuts securing insulator to studs on climate control case. Remove glove box door and compartment. Remove air cleaner housing, battery and battery tray. Disconnect wires of main wire loom in engine compartment. Disengage rubber grommet from firewall. Feed wiring into passenger compartment through hole in firewall.
Remove right and left kick panels. Disconnect wires from instrument panel at right and left kick panel sides. Remove screws on left and right sides of instrument panel.
Pull up to unsnap right and left speaker opening covers. Remove speaker covers. Working through steering column and glove box openings, reach under instrument panel and disconnect electrical connectors, vacuum hoses, A/C-heater control panel cables, and radio antenna cable.
Support instrument panel. Remove 3 screws attaching top of instrument panel to cowl top. Disconnect remaining wires. Remove instrument panel. To install instrument panel, reverse removal procedure.
Pull the instrument panel console bezel forwards and disconnect the electrical connectors.
Detach the temperature and air distribution blend door Bowden cables from the climate control assembly.
Remove the climate control assembly.
Install or connect the following:
Climate control assemblyBowden cables to climate control assemblyClimate control assembly electrical connectorsInstrument panel console bezel and securely tighten the screwsAudio unitNegative battery cable
Make sure you have the anti-theft codes for the audio and the navigation system, and then write down the audio presets.
Disconnect the negative cable from the battery.
From under the hood, disconnect the heater valve cable from the heater valve. Turn the heater valve arm to the fully opened position.
When the engine is cool, drain the engine coolant from the radiator.
Disconnect the inlet heater hose and the outlet heater hose from the heater core.
Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines, the brake lines, and related parts.
Remove the dashboard.
Remove the evaporator.
Remove the mounting bolts and remove the heater unit.
Front heater unit
Remove the self-tapping screws and the clamp.
Carefully pull out the heater core so you don't bend the inlet and outlet pipes.
Front heater core
Using care, install the heater core to the heater unit and secure.
Using care, install the heater unit and tighten mounting nuts and bolts to 7 ft-lb (10 Nm).
Install the evaporator.
Install the dashboard.
Connect the inlet heater hose and the outlet heater hose to the heater core.
Connect the heater valve cable to the heater valve.
Refill the cooling system with engine coolant.
Adjust the heater valve cable.
Make sure that there is no coolant leakage.
Make sure that there is no air leakage.
Connect the negative battery cable.
Perform the power window control unit resetting procedure.
Enter the anti-theft codes for the audio and the navigation system, and then enter the audio presets.
RearTo Remove: NOTE: The rear blower motor, the rear heater core, the blower screen, the rear blower resistor (heating/air conditioning system) and the rear power transistor (climate control system), the rear air mix control motor (climate control system) , the rear mode control motor and the rear expansion valve can be replaced without removing the rear heater-A/C unit.
Remove the self-tapping screws and the clamp, and then remove the bolts and the rear evaporator lines with the rear expansion valve. If necessary, remove the rear expansion valve. Use a second wrench to hold the other fitting on the valve so the rear evaporator lines won't twist. Leave the first fitting loosely connected so you can use it to hold the valve while you loosen the second fitting.
Remove the rear heater hoses.
If necessary, remove the rear blower motor, the rear heater core, the blower screen, the rear blower resistor (heating/air conditioning system), the rear power transistor (climate control system), the rear air mix control motor and the rear mode control motor.
Remove the self-tapping screws and the lower housing.
Remove the self-tapping screws, and carefully separate the left upper housing from the right upper housing. Remove the rear heater core.
Rear evaporator assembly
Replace the rear heater core.
Attach the heater hoses.
Make sure no air is leaking from the left upper housing and the right upper housing fitting and from the upper housings and the lower housing fitting.
Before reassembly, make sure that the rear air mix control linkage and door move smoothly without binding.
Before reassembly, make sure that the rear mode control linkage and door move smoothly without binding.
Reassemble the housing.
After reassembly, make sure the rear air mix control motor runs smoothly.
After reassembly, make sure the rear mode control motor runs smoothly.
Refill the cooling system and make sure that there is no coolant leakage.
removed the panel below the radio, clips hold it in and you have to yank it out without damage. then there are two 8mm head bolts behind that panel facing up. they hold the whole frame for the audio and climate controls. then push on that frame with your fingers to pop out the whole panel that the radio and the climate controls are mounted to. then simply disconnect the harnesses and remove the climate controls(three screws and the dials pop off). now you can get to the four 8mm bolts that hold the audio unit in.
Disconnect starter cable and push-on connector from starter solenoid. CAUTION:
When disconnecting hard-shell connector at S terminal, grasp the
plastic shell and pull off. Do not pull on wire. Be careful to pull
straight off to prevent damage to the connector and S terminal. If any
part of the connection is damaged, replace the damaged components.
Remove upper bolt.
Remove lower bolt.
Remove the starter motor from the vehicle.
Position starter motor to engine and install upper and lower bolt finger-tight.
Tighten the upper bolt to 22-28 Nm (16-21 Lb-Ft) .
Tighten the lower bolt to 22-28 Nm (16-21 Lb-Ft) .
Connect connector on starter solenoid. Be careful to push straight on and make sure connector locks in position with a notable click or detent.
Install starter cable nut to terminal. Tighten to 11-13 Nm (91-122 Lb-In) .
Replace red safety cap.
Lower vehicle to floor.
Connect battery ground cable. NOTE: When the Powertrain Control Module (PCM)
is disconnected and reconnected, some abnormal drive symptoms may occur
while the powertrain control module relearns its adaptive strategy. The
vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
This solution has two basic assumptions. (1) Your fuse is fine and (2) the problem is a blown bulb and not a wiring issue. That having been said, you're going to have to CAREFULLY remove the audio/climate control trim panel. Use a trim stick (if you can find one) or a taped or cloth-covered thin flathead screwdriver and GENTLY but firmly, pry the trim to release the clips. There are six clips holding the trim panel. Two on the bottom, two on the sides just under the vents, and two at the top corners. Next you're going to have to remove the control assembly. There are 6 bolts holding it in place. Remove the bolts then pull out the assembly slightly so that you can disconnect the electrical connectors on the back of the unit. Do NOT pull the wires directly or you can cause serious damage. Only pull on the plastic connectors holding the wires. After all the connectors are unplugged, paying attention to where they come from so that you plug them back in correctly, the unit can be removed. Next you're going to have to remove the back cover of the unit. To do that, first remove the two side bolts from the mounting brackets on each side attached to the climate control assembly. Then remove the back cover by unscrewing the six screws along the sides of the back cover and the two recessed screws at the top. Once the back cover is removed, you should see a light blue plastic piece with a screwdriver slot in the middle of it. That's your bulb. Take out the old bulb, put in your new one and reverse everything you just did to put it all back together again. If you've done everything right, your unit should be illuminated once again. Good luck.