HOW TO INSTALL AN HEATING CORE AN AUDI CABRIOLET 1996 CONVERTIBLE
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1996 Audi Cabriolet Question: HEAT CORE
Answer #1overbys from Overbys Inc, April 15, 2011, 09:55Master
Vehicles with audio coded antitheft system refer to Radio/Stereo, Service Precautions . See: Accessories and Optional Equipment\Radio/Stereo\Service Precautions
Disconnect battery cables and remove battery.
Discharge and recover A/C refrigerant. Refer to Heating and Air Conditioning, Service and Repair . See: Service and Repair Remove center vent/control panel.
Remove instrument panel.
Clamp heater hoses in engine compartment to prevent excessive coolant loss, then remove them from firewall. Cap hoses after removal.
Remove refrigerant lines from A/C evaporator.
Remove right side air plenum cover, outside air temperature sensor and mounting bolts; then remove air intake.
Remove two nuts from firewall. One is located directly next to the heater hose fitting, the other is located several inches directly below the first.
Remove vacuum hose from two-way valve.
Remove water drain hose from heater/evaporator housing.
Remove fuel injection control unit.
Remove heater/evaporator housing from vehicle, then separate housing and remove heater core Fig.18 .
Reverse procedure to install, noting the following:
If heater core does not lock firmly in place, secure with self tapping screws.
Check Bowden cables for kinks and ease of movement prior to reinstalling heater/evaporator assembly. Replace if necessary.
Torque A/C refrigerant lines to 12 ft. lbs . Ensure there is no tension on lines during reinstallation.
When installing instrument panel, push hose from defroster duct up and into blower nozzles. Ensure fit is secure.
Keeping side and bottom mounting screws loose, adjust gap between instrument panel and windshield to approximately 9/32 of an inch. Close front doors and ensure retaining tabs of trim panel fit behind edge of housing.
Adjust instrument panel height to match that of door trim panels, then torque panel mounting screws to 4 ft. lbs .
ps:labor guide gives close to 9 hours for this job