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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!
What you will need:-
1.Phillips Screw Driver
2.Depending on what stereo system you have, stereo removal keys.
REMOVAL AND INSTALLATION
Climate Control Assembly/heater control unit/
Removal 1. Standard preparatory measures
Make a note of the radio keycode.
Make a note of the preset radio stations. CAUTION: Disconnect the battery negative lead. 2. Remove the radio. 3. Note:The control unit for the heating/air conditioning system, all operating knobs and the air distribution operating switch make up one assembly.
Remove the bezel/control unit.
1 Remove the screws on the top of the unit
2 Unclip the clips either side of the unit
Pull the bezel/unit forwards.
Disconnect the plug. 4. Unclip the air distribution shaft. 5. Remove the heater/air conditioning module and the fan operating switch.
Installation 1. Refit the components in the reverse order. 2. Install the radio. 3. Connect the battery ground lead.
Enter the radio keycode.
Reprogramme the preset radio stations.
Reset the clock.
Carry out a road test to enable the PCM to collect data. 4. Check that the heater/air conditioning operates properly.
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.
Fig. After the negative battery cable is disconnected, remove the
wire terminals from the starter solenoid
Fig. Remove the lower starter mounting bolts...
Fig. ...followed by the upper bolt, then remove the starter
from the transaxle housing
Fig. Lower starter bolt locations-1994 2.0L, 2.0L ABA
Fig. Remove the upper starter bolts
Fig. Mark the location and length of each starter bolt
Fig. Remove the starter
Fig. Close up view of the starter drive gear
Fig. When the solenoid is energized the starter drive is pushed
out and meshes with the flywheel to crank the engine
Note the radio security code, and then disconnect the battery
Raise and safely support the front of the vehicle with jackstands.
If installed, remove the lower engine shield.
The engine must be supported on 1990-97 Passat models as the
starter mounting bolts also support the engine-to-transmission mounting
If necessary, label the small wires before disconnecting them.
On 1990-97 Passat models:
On Audi A4 and 1998-00 Passat models:
Release the number
electrical connector from the starter.
Then remove the nut for the large battery cable and remove the
Loosen then remove the clamp that secures the heat shield to the
Remove the fasteners securing the bracket at the front of the
starter and remove the bracket.
Remove the starter mounting bolts, while supporting the weight of
Pull the starter straight out from the transaxle.
On vehicles with a manual transaxle, there is a bushing where the
starter shaft fits into the bell housing. If the shaft or bushing is
worn or if the starter has been jamming, the bushing should be replaced.
There is a special bushing removal tool available but a small inside
bearing removal tool is usually sufficient.
Install the starter into the transaxle.
Tighten the related starter motor fasteners as follows:
Starter support bracket, M5 nut: 35 inch lbs. (4 Nm)
Starter support bracket, M8: 16 ft. lbs. (22Nm)
Battery cable to solenoid, M8 nut:10 ft. lbs. (13Nm)
hydraulic hose support bracket, M8: 84 inch lbs. (10Nm)
Starter mounting fasteners, M10: 44 ft. lbs. (60 Nm)
Starter mounting fasteners, M12: 48 ft. lbs. (65 Nm)
The balance of the installation is in reverse order of removal.
Be careful not to over tighten the battery cable connection. The
metal is soft and the threads will strip easily.
Lower the vehicle from the jackstands.
Connect the negative battery cable and enter the radio security
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.