Removing and installing air intake box of heater and air conditioning unit — AUDI

🧭 Before you start

Fits: Audi A5 (8T, 2007–2016), Audi Q5 (8R, 2008–2017), Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015); platform code 83

• Special tools named: VAS 5051
• Renewed: seal

Don't miss

• Air duct from air duct (B) to dash panel vent (right-side) is secured with two bolts; to remove air duct, only unscrew bolt screwed into dash panel cross member from below (only this bolt is accessible).
• To avoid interchanging them with other identical connectors, mark connector to air flow flap control motor V71(E) and connector (F) to air recirculation flap control motor V113 and unplug them from control motors.
• When routing the wiring, make sure it is routed at the control motors so that it cannot come into contact with moving parts of the control motors.

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. Switch on ignition.
2. Set air outflow direction on air conditioner operating and display unit (Climatronic control unit J255) to "“DEF”" (to windscreen).
3. Move front passenger's seat to rearmost position.
4. Switch off ignition.
5. Remove glove box General body repairs, interior68Shelves / trim panels; Removing and installing glove box.

6. Remove right footwell vent (front passenger's side) .
7. Remove threaded fasteners (A) and detach insulating mat (B).
8. Remove bolts (A).
9. Loosen air duct to dash panel vent (right-side) from dash panel cross member (do not remove); different versions General body repairs, interior70Central tube for dash panel. [Note: Air duct from air duct (B) to dash panel vent (right-side) is secured with two bolts; to remove air duct, only unscrew bolt screwed into dash panel cross member from below (only this bolt is accessible).]
10. Remove air duct (B) to right dash panel vent (passenger's side).
11. Remove A-pillar trim (bottom) (C) and bracket (B)General body repairs, interior70Passenger compartment trim panels; Removing and installing A-pillar trim.
12. Unplug connector (A) from fresh air blower control unit J126.
13. If fitted, remove control unit for headlight range control J431(1) (or control unit for cornering light and headlight range control J745) and corresponding retaining frame Electrical system94Automatic headlight range control; Removing and installing headlight range control unit.
14. Remove fresh air blower V2. [Note: The air intake box of the air conditioning unit can also be removed and installed with the fresh air blower V2 installed; however, since there is little room it is easier to remove the V2 first (this will give you more room when removing and installing the air intake box).]
15. Unfasten wiring (A) from attachment points at air intake box.
16. Use e.g. a screwdriver (D) (lift slightly and pull in direction of arrow) to release fastener (C) (between air conditioning unit and the air intake box (B)).
17. After releasing fastener (C), pull air intake box (B) downwards on right side (in direction of arrow).
18. To avoid interchanging them with other identical connectors, mark connector to air flow flap control motor V71(E) and connector (F) to air recirculation flap control motor V113 and unplug them from control motors.
19. Unfasten upper lug of air conditioning unit (E) from mounting of air intake box (D).
20. Unfasten the two lower mounting points between air conditioning unit (B) and air intake box (A).
21. Remove air intake box.
22. Check evaporator (A) and air duct in air conditioning unit to evaporator (B) for dirt and clean if necessary.
23. Check dust and pollen filter and air duct in air intake box to air conditioning unit (C) for dirt and clean if necessary.
24. Check all-round groove at air conditioning unit (D) and all-round chamfer at air intake box (E) for damage. [Note: If the groove or chamfer is damaged, fill the damaged area with e.g. silicone adhesive sealant D176 001 A3 Electronic parts catalogue; otherwise air could emerge at this point when the air conditioner is being operated, leading to noise.]
25. Before inserting air intake box (C), check seal at fresh-air intake duct (A) for damage. Renew seal if damaged.
26. Check position of fastener. Air intake box (C) and air conditioning unit (D) can only be assembled if catch (B) is in position shown.
27. Plug in connectors to air flow flap control motor V71(E) and air recirculation flap control motor V113(F) according to marks made previously.
28. Insert the two lower lugs of air intake box (A) in mounting points of air conditioning unit (B).
29. Lift air intake box on right side until upper lug of air conditioning unit (C) is positioned in mounting of air intake box (D) and then press the two components together. [Note: If the catch (E) has slipped forwards during installation, the two components cannot be assembled.During assembly, make sure that no other components are trapped and that the chamfer at the air intake box is inserted all round in the groove of the air conditioning unit.]
30. ⚠ When assembling the air intake box and the air conditioning unit, proceed carefully and do not exert much pressure.If you apply pressure while connecting the air intake box with the air conditioning unit, the bottom tabs on the air intake box (A) might be deformed.Deformed tabs on the air intake box (A) can lead to whistling noises during the operation of the air conditioner due to small leaks at the connection points. — Slide catch (C) in direction opposite to arrow (this engages air conditioning unit with air intake box (B)).
31. Insert wiring (A) into attachment points at air intake box. [Note: When routing the wiring, make sure it is routed at the control motors so that it cannot come into contact with moving parts of the control motors.]
32. Re-install all parts removed in reverse order.
33. Switch on ignition.
34. Perform basic setting and final control diagnosis for air conditioner Vehicle diagnostic, testing and information system VAS 5051 ("Guided Fault Finding"). [Note: The control motors on this vehicle are equipped with an electronic feature which enables a new control motor to learn its position at the air conditioning unit during basic setting; only then can it be activated by the air conditioner operating and display unit (Climatronic control unit J255); currently all control motors are identical Vehicle diagnostic, testing and information system VAS 5051 ("Guided Fault Finding").While you are performing the basic setting, the control motors are assigned and adapted in accordance with the series connection of the wiring. If the sequence is not as specified, the control motors will not be adapted properly and the flaps will not be controlled correctly (overview of air conditioner control motors).In cases of doubt as to whether the two control motors (air flow flap control motor V71 and air recirculation flap control motor V113) have been connected properly to the wiring, you can check the activation via the "“air conditioner final control diagnosis”" function. The air recirculation flap (F) is visible when the glove box is removed Vehicle diagnostic, testing and information system VAS 5051 ("Guided Fault Finding").]
35. Interrogate event memory of operating and display unit (Climatronic control unit J255) and erase any faults displayed Vehicle diagnostic, testing and information system VAS 5051 ("Guided Fault Finding").

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