Audi Workshop Service and Repair Manuals

Checking, removing and installing fresh air intake Preparation –  Switch off the ignition. Vehicles with a high-voltage system (hybrid vehicles) For all work on vehicles with a high-voltage system, pay attention to the additional warnings for such vehicles → Chapter and → Electrical system; Rep. gr.93. As work in the vicinity of high-voltage system components is necessary for the following sequence of operations, perform „Visual inspection of high-voltage components and cables for damage“ → Chapter and heed the „General warnings for working on high-voltage system“ → Electrical system; Rep. gr.93   WARNING Danger from unexpected engine starting When performing general work on vehicles with a high-voltage system, switch off the ignition and remove the ignition key from the passenger compartment.   WARNING Working on vehicles with high-voltage wiring: l  Do not support yourself or tools on high-voltage wiring or associated components --> this can damage the insulation. l  High-voltage wiring must not be excessively bent or kinked --> this can damage the insulation. l  The round high-voltage connectors are colour-coded with an external coloured ring and are provided with mechanical coding or guide lugs. It is important to observe this coding when joining up the round high-voltage connectors, otherwise the connectors can be damaged.   DANGER! Risk of fatal injury if high-voltage components are damaged. Observe the following when working in the vicinity of high-voltage components or wiring: t  It is not permitted to use cutting or forming tools, other sharp-edged tools or heat sources such as welding, brazing, soldering, hot air or thermal bonding equipment. t  Before starting work, visually inspect the high-voltage components in the areas involved. t  Before working in the engine compartment, visually inspect the power electronics -JX1-, electric drive motor -V141-, air conditioner compressor -V470- and high-voltage wiring. t  Before working on the vehicle underbody, visually inspect the high-voltage wiring and covers. t  Before working on the rear section of the vehicle, visually inspect the high-voltage wiring and the electro-box with the maintenance connector for high-voltage system - TW -. t  Visually inspect all potential equalisation lines. Check the following when making the visual inspection: t  There must be no external damage on any component. t  The insulation of the high-voltage wiring and potential equalisation lines must not be damaged. t  There must be no unusual deformation of the high-voltage wiring. t  All high-voltage components must be identified by a red warning sticker.

–  Remove the rubber seal -A- and the plenum chamber cover -B- (different versions) → General body repairs, exterior; Rep. gr.50. t  After removing the plenum chamber cover -B-, visually inspect the high-voltage components -D- (in this case the power and control electronics for electric drive -JX1-) and the high-voltage cables -E- → Chapter and → Electrical system; Rep. gr.93 t  When working in the area of high-voltage components -D- and high-voltage cables -E- always make sure that these components are not damaged → Electrical system; Rep. gr.93. t  On completion of work and before fitting the plenum chamber cover -B-, visually inspect the high-voltage components -D- and the high-voltage cables -E- → Electrical system; Rep. gr.93.   Note If cleaning of the water drains involves removing the scuttle panel trim -C-, refer to → General body repairs, exterior; Rep. gr.50. Vehicles with no high-voltage system –  Remove the plenum chamber cover and / or scuttle panel trim (different versions) → General body repairs, exterior; Rep. gr.50.   Note

t  The following illustration shows the positions of the components on an Audi A5 Coupé. The layout may differ slightly on the Audi A5 Sportback, Audi A4, Audi Q5 etc. Unless otherwise indicated, the components are however to be removed, installed and checked in the same manner as described for the Audi A5 Coupé.

t  An additional cover with drip rail -B- may be fitted at the fresh air intake housing -A- depending on the vehicle model and the type of plenum chamber cover fitted → Electronic parts catalogue.

–  Remove the two wiper arms (only on vehicles on which the scuttle panel trim and the cover for the fresh air intake at the scuttle panel trim -A- form one component) → Electrical system; Rep. gr.92. –  Detach the rubber seal -B- on the left to the necessary extent → General body repairs, exterior; Rep. gr.50. –  Remove the cover for the fresh air intake at the scuttle panel trim -A- or the scuttle panel trim (different versions) → General body repairs, exterior; Rep. gr.50.   Note If necessary, carefully detach the scuttle panel trim from the fastener at the cross-member of the windscreen -C- → General body repairs, exterior; Rep. gr.50. All vehicles Checking –  Check the scuttle panel trim -A- for proper installation and damage → General body repairs, exterior; Rep. gr.50. –  Check the seals between the cover for the fresh air intake -A-, the scuttle panel trim and the cross-member of the windscreen -C- for damage and proper attachment. These seals stop water running between the windscreen cross-member and the scuttle panel trim into the intake housing of the air conditioning unit → General body repairs, exterior; Rep. gr.50. Removing and installing   Note

Depending on the version, a dust filter designed to stop the fresh air blower drawing in dust and sand may be fitted instead of the intake grille -A- for certain countries with a high dust level in the ambient air (e.g. for China) → Electronic parts catalogue. –  Preparatory work → Anchor.

–  If applicable, unplug the connector -B- from -G238- / -G657- (different layouts).   Note There are different versions of the fresh air intake housing -C- (with and without mount for -G238--A-, mount at front or on side). Pay attention to the correct version → Electronic parts catalogue.

–  If fitted, remove bolts -C- (tightening torque: 3 Nm) and detach cover with drip rail -B-.

–  Unscrew bolts -B- (tightening torque: 3 Nm). –  Detach the fresh air intake -C-. Install in reverse order, paying attention to the following:   Note t  Prior to installation, check the fresh air intake -C- and the bonded seal for damage. Replace the seal or fresh air intake -C- if damaged. t  On installation, make sure the fresh air intake -C- and the corresponding seals are correctly positioned. If the fresh air intake -C- is not installed properly, water could run via the sealing surface -D- into the intake housing of the air conditioning unit.

t  Before fitting the scuttle panel trim cover panel -A-, check the scuttle panel trim and the corresponding seals to the cover -A- (different versions) and windscreen cross-member -C- for damage. If the cover, scuttle panel trim or seal has not been installed properly or is damaged, water may run into the fresh air intake and thus into the intake housing of the air conditioning unit.