Fresh Air Intake
Fresh Air Intake
• Depending on the version, for some countries with high dust levels, a filter - C - is installed in the filter mount - B - instead of the fresh air intake grille - A -. The dust filter - C - prevents pollen and sand from getting sucked into the fresh air blower (V2). Refer to Electronic Parts Catalog (ETKA).
• Make sure when removing the dust filter - C - that contaminates do not fall into the A/C intake shroud.
• The dust filter - C - is held in the filter mount - B - with the retaining strap - D -.
• Note the replacement interval for the dust filter - C -.
• Clean the air intake shroud and the area around the dust filter - C - in the plenum chamber before installing a new filter.
• Pay attention to the air flow direction - arrows - when installing the dust filter - C -.
Preparatory work
- Turn off the ignition.
With high voltage systems (hybrid vehicles)
Read and follow all of the supplemental warnings for all work performed on vehicles with the high voltage system.
If it is necessary for the following procedure to perform work in the vicinity of high voltage components, perform a visual inspection of the high voltage components and cables for damages, refer to => [ Visual Inspection of High-Voltage Components and Cables for Damage ] Visual Inspection of High-Voltage Components and Cables For Damage and always follow the warnings when working on the high voltage system.
Risk of unintended engine start
The ignition must be turned off and the ignition key must remain outside of the vehicle when working on vehicles with a high voltage system.
How to handle high voltage cable:
• Do not stand on or place tools on high voltage cables and their components as it may damage the cable insulation.
• Never bend or kink high voltage cables forcefully as it may damage the cable insulation.
• Color-code the round high voltage connector with an external color ring and code them mechanically using the guide- or code tabs. Always make certain that the coding matches when connecting the round connector in order to avoid mechanically damaging the high voltage connector.
There is a risk of electrocution from damaged high voltage components
Observe the following when working around high voltage components and high voltage wires:
• Never work around high voltage components and cables with cutting, deformed, or sharp edged tools, or heat sources such as welding or soldering tools, heated air, and thermal glue.
• Inspect the high voltage components visually before beginning.
• Perform a visual inspection of the electric drive power and control electronics (JX1) , the electro-drive drive motor (V141) , the A/C compressor (V470) and the high voltage lines when working in the engine compartment.
• Perform a visual inspection of the high voltage lines and the cover when working on the underbody.
• Perform a visual inspection of the high voltage lines and the Electrobox with the high voltage system maintenance connector (TW) when working in the luggage compartment.
• Perform a visual inspection on all of the potential equalization cables.
Observe the following items when performing the visual inspection:
• The components do not display any signs of external damage.
• The high voltage cable insulation and the potential equalization cables are not damaged.
• The high voltage cables do not display any abnormal deformations.
• Every high voltage component is marked with a red warning label.
- Remove the rubber seal - A - and the plenum chamber cover - B - (there are different versions).
• Inspect the high voltage components - D - (the electric drive power and control electronics (JX1) ) and the high voltage cables - E - after removing the plenum chamber cover - B -. Refer to => [ Visual Inspection of High-Voltage Components and Cables for Damage ] Visual Inspection of High-Voltage Components and Cables For Damage
• Be careful not to damage any high voltage components - D - or the high voltage cables - E -.
• Inspect the high voltage components - D - and high voltage cables - E - after completing the work procedure and before installing the plenum chamber cover - B -.
• Remove the cowl panel - C - if it is necessary to clean the water drains.
For vehicles without a high voltage system
- Remove the plenum chamber cover and/or the cowl panel (there are different versions).
• The following illustrations show the location of the components on an Audi A5 Coupe; an Audi A5 Sportback, Audi A4, Audi Q5 etc., the location of the components varies slightly. The description of the components is not different; removing, installing and checking is performed in the same way as on the Audi A5 Coupe.
• The fresh air intake shaft - A - may have an additional cover with a rain water drain channel - B - depending on the vehicle version and the plenum chamber cover installed. Refer to the Parts Catalog.
- Remove both windshield wiper arms (only on vehicles where the cowl and the fresh air intake cover on the cowl - A - are one piece).
- Pull the left rubber seal - B - as far as necessary
- Remove the fresh air intake cover on the wind cowl - A - or the wind cowl (different styles).
• Loosen the cowl panel trim from the windshield crossmember - C -.
All vehicles
Checking
- Check the cowl - A - for proper installation and damage.
- Check the seals between the fresh air intake cover- A -, the cowl and the windshield cross member - C - for damage and proper fit. This seals prevent water from entering between window cross member and cover and running into A/C unit air intake shroud.
Removing and Installing
• Depending on the version, for some countries with high dust levels (for example China), a dust filter installed instead of intake air grille - A -, which prevents dust and sand from entering the fresh air blower. Refer to Electronic Parts Catalog (ETKA).
- Perform the preparatory work.
- Disconnect the connector - B - from the air quality sensor (G238) / humidity sensor in fresh air intake duct (G657) (there are different locations).
• There are different versions of the air intake shroud for the fresh air intake - C - (with and without a mount for the for the air quality sensor / humidity sensor in fresh air intake duct - A -, in the front or on the side). Refer to the Parts Catalog.
- Remove the screws - C - (tightening specification: 3 Nm) and cover with the water channel - B -.
- Remove the screws - B -.
- Remove the fresh air intake - C -.
Installation is done is reverse order, observe the following:
• Pay attention to the tightening sequence for the nuts - B - when installing them.
- Tighten the nuts - B - lightly by hand in the following sequence.
• Tighten the inner lying nut - B - (in the right illustration).
• Tighten the outer lying nut - B - (top left in the illustration).
• Tighten the outer lying nut - B - (bottom left in the illustration).
- Tighten the nuts - B - which correspond to the tightening sequence at the top (tightening specification: 3.5 Nm).
• Check for damage prior to installing the fresh air intake - C - and the bonded seal; if there is damage, replace the seal or fresh air intake - C -. Refer to the Parts Catalog.
• When installing, make sure the fresh air intake - C - and seal are seated correctly; if the fresh air intake - C - is not installed correctly, water can seep into the A/C unit intake shroud through the sealing surface - D -.
• Prior to installing the cowl cover - A - (there are different versions), check the cowl and the seals for the cover - A - and the window cross member - C - for damage; if the cover, the cowl or the seal are damaged, water can seep into the fresh air intake and also into the A/C intake shroud.