Jehnert 45180 User manual

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Installation Instructions Product-Ident: 45180
doorboards include speakers, Audi A3 8P Sportback
Technical Details:
Car Features: 4-doors, electrical window controls
Model/Year: 8PA (09.2004)
Setup-Advice: To reach the best performance, the setup of the
radio (Bass, Loudness etc.) should be null or
neutral.
recommended amplifier power: from 2x 100 - 200 Watt / 2 Ohm
Parts list:
1x Doorboards (right+left) Audi A3 8P Sportback, covered
1x grills (right+left) Audi a3 8p sportback , cover: acoustic fabric
2x XE 26 - Neodymium-Tweeter ø 26mm
(1")
incl. mounting device, Hex nut M4, washer ø 12mm
2x XM 110 - High-End-midrange driver, ø 100mm
(4"),
incl. adapter ring
4x XM 165 - Low midrange driver, power woofer ø 165mm
(6,5")
1x 3-way frequency crossover (right+left) Audi A3 -sportback - part-no. 45180
1x Hardware bag, Audi A3 -sportback - part-no. 45180/41180
2x flat head srew M4 x 40
2x flat head srew M4 x 50
2x flat head srew M4 x 60
16x hex nut M4
6x spax screw 4,5 x 80
4x Velcro strip à 2,5 cm (reserve)
12x washer 12mm
12x washer 20mm
Garantee:
We grant a manufacturers guarantee of 2 years starting from the date of purchase of the doorboard or sound system from the dealer. Within this
guarantee period to our choice we either repair or replace free of charge all defects due to material or workmanship. Exempt from this guarantee
are damages due to improper use, wear and tear or damages which have to be led back on wear or interventions by third parties. The guarantee
does not cover subsequent damages or such defects that only insignificantly impair the value or the usability of the doorboard/sound system. The
guarantee does not cover damages due to external influences. Doorboards with additional or wrong assembly drill holes cannot be returned. These
are damages to the doorboard which cannot be repaired again.

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Installation Instructions Product-Ident: 45180
1 Disassembly of the door card
1.1 Roll down window completely.
1.2 Unclip the grill above the doorhandle and remover the screw underneath (A).
1.3 Unscrew screws B + C1-C2.
1.4 Unclip the lower and lateral edges of the door lining and remove the door card upwards.
1.5 Remove the Bowden pull wire out of the door latch lever.
1.6 Unplug central-switch.
1.7 Car door: disconnect the original loudspeaker plugs and dismount the original woofer (will not be used any more)
2 Tweeter installation A-pillar - original mount - without mounting device
2.1 Dismount the original speaker grill of the A-pillar and the original tweeter. Unplug the connecting cables. (No more need of the
original connecting cable and tweeter).
2.2 Remove the tweeter out of the catch:
---> bayonet catch: turn to the right and pull out of the holding device - by means of the screw.
(no more need of the catch)
2.3 Adapt the JEHNERT-tweeter cable with the speaker cable (1,5 - 4 qmm), lead the cable up to
where the crossover is installed in the car door.
In order to avoid vibration noise insulate all cables with insulating tape e.g.
2.4 Adjust the JEHNERT-tweeter in the original cut-out and affix with hot melt adhesive or silicone on the backside.
2.5 Reinstall the A-pillar.

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Installation Instructions Product-Ident: 45180
3 Handling of door card: Doorboard alignment
3.1 Place the door card on a plane surface.
3.2 Dismount the loudspeakers attached to the doorboard for transport protection --> retain the screws for later assembly.
3.3 Place the doorboard without speakers on the door card and align it:
Only precise alignment of the doorboards with the door card warrants optimal fit!
Reference points for alignment:
3.4 Reference point 1-3 on the notches of the door card:
Adjust the noses of the doorboard with the notches of the doorcard.
3.5 Controll reference point:
The lower edge of the doorboard is parallel with the lower edge of the door card.
4 Handling of door card
4.1 Use the doorboard as template in order to mark fastening points and cut-outs:
Precisely align the doorboard with the fixing points of the door card.
4.2 In order to align planely please start with the cut-out of the midrange speaker.
Mark the midrange cut-out acc. to figure. For a plane alignment of the doorboards please consider the overlapping
midrange position on the backside of the doorboard. Mark the cut-out accordingly and cut it out.

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Example
Example
Example
Example
Installation Instructions Product-Ident: 45180
5 Marking fastening points
5.1 Mark the fixing points 1-5_ premounted in the doorboard:
Pressing the doorboard onto the door card leaves a visible impression of the screws - the fastening positions of the
door card.
Marking of the pre-drilled fastening points 5-10:
Use a thin awl to set the marks on the door card.
6 Handling of door card cut-outs
The cut out behind the speakers are providing the required full volume of the car door:
6.1 Mark the cut outs for the woofers on the door card. Enlarge them approx. 1cm (= approx. outer diameter of the
woofers).
6.2 For a plane alignment of the doorboard also mark the overlapping tray for the cut-out.
IMPORTANT! Check all cut-outs marked:
The fastenings of the doorboard must have to be screwed with the door card!
The fastenings of the door card must not be removed!
6.3 Remove the doorboard again and cut out the positions marked on the door card. Use a compass saw.
ATTENTION!!! Please observe the wiring harness in the car door.
6.4 Drill the bore holes for the M4-screws according to the marks set before - use a 4mm drill and
enlarge to 7-8mm (not for Spax-screws).

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Example
Installation Instructions Product-Ident: 45180
7 Fastening doorboard
7.1 Screw in the screws supplied with. Affix the doorboard to the door card.
Screw all screws only hand-tight . Secure all M4-screws with washers and nuts.
TIP: Treat the screw thread with a liquid for screw-in type fuse. (Speaker vibrations may loosen the screws after
some time).
7.2 Check again for precise fit and tighten the screws.
All cutting edges of the doorboard must fit to the door card snugly all around without gap!

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Example
Installation Instructions Product-Ident: 45180
8 Adaptation amplifier - crossover circuit / Insulation of the car doors
8.1 Insulation of the car doors - Important tips against vibration-noise (see attached installation recommendation)
8.2 Adaptation amplifier - crossover circuit:
Lead 1x speaker cable (1,5 - 4 qmm) from amplifier to the crossover circuit:
mount of crossover circuit: car door / behind the door card
9 Insulation of the back side of the door card
In order to avoid vibration noise insulate all cables with insulation tape e.g.
9.1 Insulate the backside of the door card e.g. with self-adhesive vibration suppressing insulation
fleece – see attached installation recommendation.
ATTENTION / danger ! No insulation behind the side-airbags!
IMPORTANT:
No insulation material behind loudspeaker, door latch lever and fastening points of the
door card!

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Installation Instructions Product-Ident: 45180
10 Installation of crossover circuit + speaker connection
10.1 Precable crossovers - see wiring diagram.
10.2 Install crossover – without housing; covered with foamed material - in the hollow space between door card and car door (see
fig.) and ensure precise fit.
*Important:
Protect the sheet bar against humidity and observe that the sheet bar does not touch any metal parts – danger of short
circuit!
10.3 Connect all speakers to the crossover circuit according to the wiring diagram.
10.4 Insert woofer and midrange.
10.5 Notice: You should check the polarity of all woofers after having connected them
to the crossover circuit with a 9 volt battery
(input cable on the side of the amplifier):
pole of the crossover circuit input +to +of a 9 Volt battery
pole of the crossover circuit input -to -of a 9 Volt battery
All woofers must move uniformly!
Wrong polarity of a woofer can totally equalize the bass sound!

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Installation Instructions Product-Ident: 45180
11 Installation of the door card onto the car doors
11.1 Check up length of the screws and bolts:
In order to prevent damages of mechanic parts of the car doors, please check once again the length of all bolts and screws on the
back side of the door card! No touch with any mechanic parts of the car doors!
(please shorten if necessary)
11.2 Put the door card into the upper sealing of the car door.
11.3 Fit the door card in contrary order of succession.
There is an open part (see fig.) in the doorboard above the second woofer for the fastening screw B
Final inspection after installation of the door card:
Please check all functions of the operating elements such as seat adjustment, opening of the glove box, window winder
etc.
12 Installation of the doorboard grills
12.1 Carefully press grill with Velcro fasteners onto the doorboards:
IMPORTANT: The Velcro fasteners stick very strongly!
Therefore only press the grills to the doorboard at the end of the installation of the doorboard and the soundsystem!
12.2 Further tips see attached installation recommendation.

Insulation of the door lining
Attention / Danger !!!
No insulation behind
the side-airbags ( g. “B”)
☞Important:
No insulation material behind
- loudspeaker
- door latch lever
- drill ahole for the installation clip ( g. A)
Important tip:
the use of woofer in the door lining may cause vibrations which lead to annoying rattle noises in the car door
!
fi g.: example of a car door
Preventive measurements against vibration noise:
• use our self-adhesive insulation fl eece (art.no.: 27000) or a foam material for
the backside of the door lining (see fi g. above) or
• stabilize the backside of the door lining by means of a special material
(Glass Fibre Filler or stiffening material)
important: keep the cut-outs for the door-airbags and speakers open
• affi x the *backside of the inner door metal with self-adhesive asphalt mats (see fi g. * )
• by knocking on the car door, vibrations caused by mechanic parts (e.g. Bowden pull wire etc. )
and wiring harness may be found out. Cover these parts with foamed material, felt or
something like that
• cut off overlapping cable tie (rattle noise)
• adhere felt or foamed material under the original wiring harness
front side of
inner door metal
door metal outside
= back side of the
inner door metal
moisture protection foil
fi g.: example of a car door

Installation of the speaker’s grill
Precisely align and carefully press grill into the Velcro fasteners.
The Velcro fastener makes a crackling sound when it is closed correctly.
Our Tip:
If the panel cannot be pressed on completely at some points. . .
Cause: the special form at these points and the resulting differences inmaterial cross section of the grill.
Solution: the distance can be levelled out with spacers 3 under the Velcro disc.
(Spacers included with the screw kit)
6. Removing the grills:
The Velcro fasteners stick together very strongly! The grills can be removed anytime by carefully lifting them off.
Please, avoid any way of forceful yanking at the grills. It could break!
☞
Self-help and fault diagnosis
The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the follow-
ing measures are not effective, please call us. Info-Hotline Tel. [phone]
What can it be if ... possible cause/ solution
..it doesn’t sound right · wrong polarity on the subwoofers (see „speaker connection“)
· crosover circuit attached wrong (see „wiring diagram speaker connection“)
· door lining and moisture protection foil not cut out
(see. „installation of teh door lining“ and „installation of the speakers grill“)
    ·ampilierdoesn’thaveenoughpower(see.„technicaldetails“)
    ·amplierconnection
...it doesn’t t correctly · door panel customization (see „handling of the door lining“)
· installation of the panels on the door lining
.....grills do not hold observe notes (see „installation of the speakers grill“)
vibrations observe notes (see „insulation of the door lining“)
②self-adhesive Velcro-strip
①Velcro fastener
③Washer M4 ø 20 as spacer