Audi A4. Body repair manual - part 3
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Rear lid hinge, removing and installing
Rear lid hinge cover
- Insert wiring and tubing for central locking system -4- into lower recess
of cable guide at cover -1-.
- From below, attach cover -3- for rear lid hinge between gas-filled strut -
5- and hinge lever, and clip onto hinge lever -2- at top so it engages
audibly.
Removing and installing rear lid hinge
- Loosen nuts -1- at top on left and right.
Tightening torque: 21 Nm (15 ft lb)
- Remove nuts -2- at bottom on left and right.
Tightening torque: 21 Nm (15 ft lb)
- Prop up or secure lid in open position.
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
- Remove bolts -5- (2x).
Tightening torque: 21 Nm (15 ft lb)
- Lift lid slightly and remove hinge -4-.
Note:
For easier adjustment of the rear lid hinge, use graduations -3- and -8-
marked on the hinge and the rear lid.
Removing and installing gas-filled strut
- Using screwdriver, push back retaining springs -7- slightly at both ends
of gas-filled strut and clip or unclip gas-filled strut as desired.
Note:
When removing or installing the gas-filled strut, push back the opened
rear lid slightly beyond its normal position, being careful not to damage
components.
Installing
- Clip in gas-filled strut at bottom first, then at top.
- Install with tube end of strut at rear lid.
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Releasing gas from strut
- Clamp gas-filled strut in vice area -x-.
Dimension -x- = 50 mm (2 in.)
- Using saw, cut into cylindrical part of strut at point within first third of
cylinder's length (measured from piston rod end of cylinder).
WARNING!
Clamp only in the area shown; otherwise there is a risk of an
accident!
Note:
Always wear eye protection when performing this procedure. Cover the
sawing area with a clean rag to contain any escaping fluid.
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Rear lid seal, installing
The butt joint -A- of the rear lid seal must be aligned with the ball socket of
left hinge.
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Removing and installing handle mechanism
for rear lid
- Remove bolts -1- (2x).
Tightening torque: 2.5 Nm (22 in. lb)
- Attachment point -A-; remove nuts (2x) for lock cylinder on inside of lid.
Tightening torque: 6 Nm (53 in. lb)
- Pull handle mechanism -3- out enough that harness connectors for
both license plate lights can be disconnected.
- Remove handle mechanism.
- Install nuts -2- (2x) using special tool VAG1618A.
Panel gap dimensions
-a-
3.0 mm
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Removing and installing holder for warning
triangle
- Remove warning triangle.
- Remove bolts -2- (2x).
Tightening torque: 2 Nm
1 - Holder
3 - Expanding clips (2x)
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Rear lid lock actuator, removing and
installing
Removing
- Remove lock cylinder page 55-14 .
- Push out retaining pins -3- (2x).
- Push tab -4- back and disconnect.
- Remove rear lid lock actuator -1-.
Installing
- Set lock cylinders in "open" position.
- Slide ridged plate -1- to left.
First ridge on plate -1- must snap into first groove on grooved segment
-2-.
Rear lid ([micro] m.y. 1999 VIN 8D XA 200 000)
Rear lid microswitch, removing
- Remove lock cylinder page 55-14 .
- Disengage microswitch -1- in direction of arrow and carefully push out
using screwdriver.
Notes:
The lock cylinder cannot be adjusted for compatibility with other locks
using standard tools.
In order to maintain single key capability, the lock cylinder must be
ordered according to the lock number.
Rear lid (m.y. 1999 VIN 8D XA 200 001 [micro])
Rear lid (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
Rear lid (m.y. 1999 VIN 8D XA 200 001 [micro])
5 - Grip piece
Removing:
- Before removal, 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 from rear lid via
interior of luggage compartment
- Pull grip piece out of rear lid.
Installing:
- First tighten both hex nuts -2- to 8 Nm.
- Then secure locking system using hex
bolts -1- and tighten bolts to 8 Nm.
- Re-connect electrical connection.
Rear lid (m.y. 1999 VIN 8D XA 200 001 [micro])
Rear lid microswitch, removing and
installing
1 - Grip piece
2 - License plate lights
3 - Sealing washer
4 - Rear lid microswitch
- Disconnect electrical connectors.
- Remove grip piece.
- Release locking mechanism (arrow) and
remove microswitch.
5 - Seal
Adhesion surface must be free of dust and
grease
Self adhesive; remove protective foil before
application and press seal on in center
Rear lid (m.y. 1999 VIN 8D XA 200 001 [micro])
Tailgate lock, removing and installing
1 - Rear lid lock actuator
Before removing, first disengage operating
rod -2- from rear lid lock Fig. 6
- Disconnect electrical harness connector.
- Remove Torx bolts -8-.
2 - Operating rod
Disengage and engage in rear lid lock
Fig. 6
3 - Tailgate lock
Removing:
- Disengage operating rod -2- and
connecting rode -5- from rear lid lock.
- Disconnect electrical harness connector.
- Remove hex nuts -4- and take out rear
lid lock.
Rear lid (m.y. 1999 VIN 8D XA 200 001 [micro])
4 - Hex nut
8 Nm
5 - Operating rod
Unclip and clip in rear lid lock Fig. 6
6 - Hex nut
8 Nm
7 - Lock mechanism
Removing page 55-30
8 - Torx screw
2.5 Nm