Audi A4. Body repair manual - part 2
Body, front
Front fender (VIN 8D XA 200 001 and
S4), assembly overview
1 - Combination bolt
4.5 Nm
2 - Threaded rivet
The threaded rivet is inserted with VAG
1618 A.
3 - Combination bolts (2x)
7.5 Nm
4 - Phillips-head screw
4.5 Nm
5 - Phillips-head screw
Only installed for S4.
4.5 Nm
Body, front
6 - Snap-on nut
Only installed for S4.
7 - Fender
Drill additional hole at bottom for S4 fender
Fig. 2 .
Removing:
- Remove bumper page 63-5 .
- Remove wheelhousing liner page 66-
31 .
- Remove headlights
Repair Manual, Electrical Equipment, Repair
Group 94, headlights, headlights, removing and
installing.
- Disconnect harness connector for side
turn-signal.
- Remove end plate Fig. 1 .
- Remove bolts -1-; -3-; -4- (bolt -5- only
for S4) -8-; -9- and -14-.
Body, front
8 - Metal bolt
7.5 Nm
9 - Metal bolt
7.5 Nm
10 - Bracket
11 - Metal bolt
7.5 Nm
12 - Metal bolt
7.5 Nm
13 - Bracket
14 - Combination bolt
10 Nm
15 - Combination bolt
7.5 Nm
Body, front
Fig. 1
Removing and installing end plate
- Remove front wheel.
- Remove wheelhousing liner page 66-31 .
- Remove bolt -2- (2x).
Tightening torque: 2.5 Nm
- Remove end plate -3- from fender -4-.
- Expanding clip -1- (2x).
Body, front
Fig. 2
Drilling hole for S4 fender
Note:
For part replacement, drill hole before painting.
- Drill 7 mm diameter hole in fender. Dimension -a- = 22mm and -b- =
8mm.
- Restore corrosion protection at edges of hole.
Fig. 3
Lower fender mount (S4)
- Slide speed nuts -4- onto door sill from bottom.
- Speed nuts -5- only for S4
- Secure fender -1- at bottom using reinforcing bracket -2- and bolts -3-.
Body, front
Noise insulation panel, assembly overview
1 - Quick-release screw
Remove only this quick release screw for
service position
Three pieces
2 Nm (18 in. lb)
2 - Front noise insulation
3 - Quick release screw
Three pieces
If rear noise insulation panel is also - 4 -
being installed, then longer quick-release
screws must be used
2 Nm (18 in. lb)
4 - Rear noise insulation panel
Only installed for certain engine types
Installed over noise insulation panel -2-
5 - Quick-release screw
Two pieces
2 Nm (18 in. lb)
Body, front
6 - Mounting for noise insulation panel
Position -9- must face left side of vehicle
7 - Bolt
Two pieces
7.5 Nm (66 in. lb)
8 - Plate nut
Two pieces
9 - Plate nut
Three pieces
10 - Clamping pin
Two pieces
11 - Wheelhousing liner
12 - Bumper
13 - Lock carrier with attachments
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Rear lid ( m.y. 1999 VIN 8D XA
200 000)
Rear lid and rear lid lock, removing,
installing and adjusting
1 - Stop buffer (2x)
Adjusting:
- Loosen bolt -11- and detach stop buffer.
- Tighten bolt -11- finger-tight (it must still
be possible to move stop buffer).
- Carefully close rear lid until lid is flush
with rear side panels.
- Carefully open rear lid -3-.
- Pull stop buffer -1- out two catches (1
mm preload) and tighten bolt -2- to 6 Nm
0.5 Nm (53 in. lb
4 in. lb).
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
2 - Rear lid
Removing:
- Remove warning triangle and holder
page 55-21 .
- Remove rear lid lining.
- Disconnect and unclip electrical wiring
harness connectors.
- Unclip vacuum line for central locking
system.
Second person is needed to remove lid
- Remove nuts for rear lid hinges page
55-16 .
Installing:
- Install in reverse order of removal.
Adjusting:
- Use rear lid hinges to center and adjust
height of rear lid
page 55-17 .
- Adjust stop buffers -1-.
- Adjust striker plate -5-.
- Center lid according to panel gap
dimensions page 55-20 .
3 - Rear lid lock
- Unclip operating rod -9-.
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
4 - Locking cylinder
- Remove warning triangle and holder
page 55-21 .
- Remove rear lid lining.
- Disconnect vacuum line for central
locking system.
- Disconnect harness connectors.
- Unclip operating rod -9-.
- Remove bolts -7-.
5 - Striker plate
- Unscrew nuts -6-.
Adjusting:
- Tighten nuts -6- finger-tight (it must still
be possible to move striker plate).
- Carefully close rear lid until lid is flush
with rear side panels.
- Carefully open lid and tighten nuts -6-.
6 - Hex nut
8 Nm (71 in. lb)
7 - Hex nut
8 Nm (71 in. lb)
8 - Hex nut
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
9 - Operating rod
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
10 - Retaining clip
11 - Hex bolt
6 Nm (53 in. lb)