Removing and installing air-intake box: Audi A6/A7 C7

🧭 Before you start

Move the passenger seat back, remove the glove box, footwell vent and any cooling duct, then the cover, blower connector and noise insulation. Mark and unplug the motor connectors, remove brackets and bolts, and release the retainer tab to lower the box. Clean and inspect seal and chamfer, refit gently, secure the extra bolt via the pollen filter slot, then clear event memory and run basic setting.

Fits: Audi A6/A7 C7 (4G, 2011–2018); platform code 4X

• Renewed: if necessary

Don't miss

• Mark the control motor connectors before unplugging; mixed-up flap motors give wrong air distribution.
• Do not force the box onto the housing; deformed tabs cause whistling leaks at the joint.
• Check the foam seal and chamfer; damaged sealing surfaces cause noise when the system runs.
• Use the correct bolt at the extra attachment point; an oversize bolt damages the mounting.
• Route the harness clear of moving control motor levers, then run basic setting.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Observe general notes .
2. Move front right seat to rearmost position.
3. Switch off ignition.
4. Remove glove box General body repairs, interior68Shelves / trim panels; Removing and installing glove box.
5. Remove footwell vent (front passenger side) .

6. On vehicles with the "“deluxe”" air conditioner version, remove the air duct for glove compartment cooling .
7. Use a screwdriver (1) to unfasten the quick-release fastener (2).
8. Disengage cover (3) at bracket (4) and detach.
9. Unplug electrical connector (C) at fresh air blower (B).
10. Release bracket (A) and detach noise insulation cover (B).
11. Mark the connectors (A, B) and control motors.
12. Unplug electrical connectors and move clear wiring harness (C) at air-intake box (D).
13. Remove bolts (A and B).
14. Detach bracket (C).
15. Unplug the connector (A) at the evaporator output temperature sender G263(B).
16. Remove bolt (A).
17. Slide home a screwdriver in the guide at the top of the air intake box and release the retainer tab (B)(top arrow). At the same time pull the air intake box (E) downwards on the right and disengage at the air distribution housing (D)(bottom arrows). [Note: If the air intake box cannot be released, the air distribution housing and air intake box have been secured with a bolt at attachment point (C) alongside the retainer tab.]
18. Remove the dust and pollen filter .
19. Remove bolt (A) at attachment point (C) via installation slot for dust and pollen filter (E).
20. Check the evaporator (A), air duct housing (B) and air intake box (C) for contamination and clean if necessary.
21. Check foam seal (D) attached to air-intake box for damage and renew if necessary.
22. Check the contact surface/chamfer (E) at the air distribution housing for damage. [Note: If the foam seal or the contact surface/chamfer is damaged, air may escape at this point and cause noise when the air conditioner is in operation.If the air distribution housing and air intake box have not been properly assembled, air may escape at the joint and cause noise when the air conditioner is in operation.If the contact surface/chamfer is damaged, fill the damaged area with silicone adhesive sealant for example Electronic parts catalogue.]
23. Insert lower lugs of air-intake box (E) in mounting on air distribution housing (D) and swivel upwards. [Note: If the retainer tab (B) does not engage instantly, pull the air intake box to the rear in the area of the upper retainer tab and at the same time press the right side forwards and upwards.]
24. ⚠ Leakage at joints.When assembling the air-intake box and the air conditioning unit, proceed carefully and do not exert much pressure.If force was applied on assembling the air intake box and air conditioning unit, the tabs of the air intake box may be permanently deformed and whistling noise may occur during air conditioner operation on account of minor leaks at the joints. — Fit the bolt through the mounting slot for the dust and pollen filter at the air distribution box and tighten.
25. Remove the air intake box again.
26. Remove the dust and pollen filter .
27. At attachment point (D) make a ∅ 4 mm hole.
28. Re-install the air intake box.
29. Screw in the bolt (A) at the attachment point (C) by way of the mounting slot for the dust and pollen filter (E). [Note: Pay attention to the correct version of the bolt (A) on account of the risk of damage to the attachment point (C) if the bolt is too large Electronic parts catalogue.]
30. Route the wiring harness such that it cannot come into contact with moving components (e.g. control motor lever).
31. Read out event memory and delete any entries displayed.
32. Perform basic setting.
33. Perform final control diagnosis.

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