Audi A4. Body repair manual - part 5
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
Gap dimensions, tailgate
Letter
Actual gap dimension (mm)
Parrallelism (mm)
-A-
4.0 +1
0.5
-B-
5.0 +1
1
-C-
4.0 +1
0.5
-D-
3.4 +1
0.5
-E-
3.4 +1
0.5
-F-
5.0+1
-G-
1.0
-H-
2.5
0.1
-I-
3.3
0.1
-J-
3.3
0.2
-K-
3.0
0.4
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
Tailgate lock, removing and installing
1 - Tailgate lock
- To remove, swing out hinge arm -3- from
operating rod -4- and unhook operating
rod from tailgate lock.
- Remove hex bolts -2- and tailgate lock.
2 - Hex nut
8 Nm (71 in. lb)
3 - Hinge arm
Must be swung over operating rod -4-
4 - Operating rod
- To remove, first disengage from lock
system -6-.
5 - Hex nut
8 Nm (71 in. lb)
6 - Lock system
Removing page 55-43
7 - Tailgate lock actuator
Removing page 55-44
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
Tailgate lock system, removing and
installing
- Remove tailgate trim.
Repair Manual, Body-Interior, Repair Group 70
- Disengage lock system at plug for vacuum line -1- and remove from
lock actuator -2-.
- Unclip operating rod -3-.
- Disengage locating hooks on release handle and remove page 55-
47 .
- Remove hex bolts (arrow) and remove lock system from tailgate.
Hex bolt tightening torque: 8 Nm (71 in. lb)
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
Lock actuator, removing and installing
- Push out clamping pins (arrow) and remove lock actuator -1- from lock
-2-.
- Clamping pins must be snapped into expanding clips again during
installation.
- Pry out using screwdriver if necessary.
Note:
Illustration shows component after removal.
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
Grip piece, removing and installing
1 - Hex nut
8 Nm (71 in. lb)
2 - Bracket
- To remove, remove hex bolts -1- and
bolts -3-.
Note:
Part was discontinued shortly following series
launch.
3 - Hex bolt
8 Nm (71 in. lb)
4 - Tailgate
Removing and installing page 55-32
5 - Lock mechanism
- To remove, remove hex bolts -1-.
- Disengage locating hooks on release
handle ( Fig. 1 ) and remove.
- Remove lock mechanism.
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
6 - Grip piece
- Before removal, remove tailgate trim.
Repair Manual, Body-Interior, Repair Group 70
- To remove, remove hex nuts -1- and
bolts -3-.
- Pull grip piece slightly out of tailgate and
disconnect harness connectors for
license plate lights.
- To install, insert grip piece into tailgate
holes.
- Thread bracket -2- at lock mechanism
and attach to grip piece using external
securing screws.
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
Fig. 1
Removing and installing lock unit
- Using screwdriver, press in and disengage securing hooks (arrow) on
inside of tailgate.
- Pull release handle -1- down and out of lock system -2- under grip
piece.
Tailgate (Avant), ([micro] m.y. 1999 VIN 8D XA 200 000)
Tailgate striker, removing and installing
- Before removing striker, mark its position using
soft pencil.
- To remove, unscrew hex nuts -2- and remove striker -1-.
- Position new striker according to markings and tighten hex nuts finger-
tight.
- Close tailgate until lock engages and tailgate is in flush position.
- Open tailgate and tighten hex nuts to 8 Nm (71 in. lb).
- Check for flushness and shutting comfort; adjust if necessary.
Tailgate (Avant) (m.y. 1999 VIN 8D XA 200 001 [micro])
Tailgate (Avant) (m.y. 1999 VIN
8D XA 200 001
)
Grip piece, removing and installing
1 - Hex bolt
8 Nm
2 - Hex nut
8 Nm
3 - Tailgate
4 - Seal
Tailgate (Avant) (m.y. 1999 VIN 8D XA 200 001 [micro])
5 - Grip piece
Removing:
- Before removing, remove tailgate trim.
Repair Manual, Body-Interior, Repair Group 70
- Disconnect electrical harness connector
for license plate lights and switch for rear
lid release.
- Remove hex bolts -1- and hex nuts -3-.
- Locking system is removed via interior of
luggage compartment.
- Pull grip piece out of rear lid.
Installing:
- Install grip piece on rear lid via rear lid
bore holes.
- First tighten both hex nuts -2- to 8 Nm.
- Then secure locking system using hex
bolts -1- and tighten bolts to 8 Nm.
6 - Microswitch for rear lid release
Removing page 55-26
Tailgate (Avant) (m.y. 1999 VIN 8D XA 200 001 [micro])
Tailgate lock, removing and installing
1 - Lock actuator for rear lid
Before removing, first disengage operating
rod -2- from rear lid lock Fig. 1
Remove Torx bolts -9- and take out
actuator
2 - Operating rod
Unclip and clip in rear lid lock Fig. 1
3 - Cap
To remove, unclip from rear lid lock and
remove page 55-54 .
4 - Tailgate lock
Removing:
- Disengage operating rod -2- and
connecting rod -6- from rear lid lock.
- Remove hex nuts -4- and take out rear
lid lock.
Locking system is removed from rear lid via
interior of luggage compartment.
- Pull grip piece out of rear lid.
Tailgate (Avant) (m.y. 1999 VIN 8D XA 200 001 [micro])
Installing:
- First tighten both hex nuts -2- to 8 Nm.
- Then secure locking system using hex
bolts -1- and tighten bolts to 8 Nm.
5 - Hex nut
8 Nm
6 - Operating rod
Unclip and clip in rear lid lock Fig. 1
7 - Hex nut
8 Nm
8 - Lock mechanism
Removing page 55-55
9 - Torx screw
2.5 Nm
Tailgate (Avant) (m.y. 1999 VIN 8D XA 200 001 [micro])
Fig. 1
Disengaging and engaging operating and connecting rods
- Swing hinge arm -6- in direction of arrow -A- and pull out connecting
rod -4-.
- Swing hinge arm -3- in direction of arrow -B- and pull out connecting
rod -5-.
- To remove rear lid lock -1- remove hex nuts -2-.