Audi A8 1994 Operating instructions

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Body repairs
Audi A8 1994 ➤
Edition 10.1998
Service
Service Department. Technical Information

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A004DKI0120

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Type plate and vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Body - Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Foam-filled cavities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Floor group, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Floor group, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Floor group, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.5 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.6 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1 Wing mounting flange - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Front wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Front longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Closure plate for strut holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Longitudinal member front section - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Roof - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 A-pillar trim - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Outer B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Inner B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Inner side member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8 Top part of cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Rear cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Audi A8 1994 ➤
Body repairs - Edition 10.1998
Contents i

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1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Rear cross panel/side panel - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 Luggage compartment floor/side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Rear longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5 Side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6 Rain channel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Audi A8 1994 ➤
Body repairs - Edition 10.1998
ii Contents

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00 – Technical data
1 Vehicle identification data
1.1 Type plate and vehicle identification
number
The type plate -A- is located on the lock carrier at the front right.
Vehicles for certain export countries have no type plate.
The vehicle identification number -B- (chassis number) is stam‐
ped on the rear bulkhead in the engine compartment. Detach the
seal in the area of the marking.
1.2 Vehicle data sticker
The vehicle data sticker is located in the spare wheel well at the
rear of the vehicle.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
1. Vehicle identification data 1

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with respect to the correctness of information in this document. Copyright by AUDI AG.
2 Body - Bonded joints
2.1 Body - centre
• The following body areas are bonded
– Roof to roof frame
– Inner roof frame to outer roof frame
Audi A8 1994 ➤
Body repairs - Edition 10.1998
2 Rep. Gr.00 - Technical data

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2.2 Body - rear
– Rear wheel housing liner to rear wheel housing
Audi A8 1994 ➤
Body repairs - Edition 10.1998
2. Body - Bonded joints 3

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3 Foam-filled cavities
The following areas of the body are foam-filled for acoustic rea‐
sons:
a = A-pillar
b = Inner B-pillar
c = Outer side panel
d = D-pillar
Use foam D-000-111-A 2.
Alternatively, use can also be made of a 2-component foam which
does not absorb moisture.
a = Foam-filling hole
Audi A8 1994 ➤
Body repairs - Edition 10.1998
4 Rep. Gr.00 - Technical data

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A = A-pillar
B = Inner B-pillar
C = Outer side panel
An aluminium wire mesh is inserted at the bottom to stop the foam
running through.
D = D-pillar
Prior to foam filling, spray the pillar with wax from inside to stop
the surface being damaged during the foam filling process.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
3. Foam-filled cavities 5

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4 Corrosion protection
The following body areas are flooded with hot wax:
A = Outer side member.
B = Front and rear doors.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
6 Rep. Gr.00 - Technical data

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Bonnet
A = Front frame.
B = Front frame reinforcement.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
4. Corrosion protection 7

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5 Body dimensions
5.1 Floor group, front
Distance between front attachment points of front axle
Distance between rear attachment points of front axle
Distance between front attachment points of front axle
Diagonal distance between attachment points of front axle
Audi A8 1994 ➤
Body repairs - Edition 10.1998
8 Rep. Gr.00 - Technical data

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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5.2 Floor group, centre
Distance between rear attachment points of front axle and rear
axle mounting
Diagonal distance between rear attachment points of front axle
and rear axle mounting
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 9

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5.3 Floor group, rear
Distance between front attachment points of rear axle
Distance between rear attachment points of rear axle
Distance between attachment points of rear axle
Diagonal distance between attachment points of rear axle
Audi A8 1994 ➤
Body repairs - Edition 10.1998
10 Rep. Gr.00 - Technical data

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Distance between production mountings
Distance between rear longitudinal members
Distance between rear axle rear attachment point and rear lon‐
gitudinal member
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 11

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5.4 Body - front
Distance between front longitudinal members
Audi A8 1994 ➤
Body repairs - Edition 10.1998
12 Rep. Gr.00 - Technical data

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Distance between wing panel mountings
Distance between front attachment points of strut holder
Distance between rear attachment points of strut holder
Distance between front hinge attachment points
Diagonal distance between hinge attachment points and wing
panel mounting
Diagonal distance between attachment points of strut holder
Distance between front hinge attachment points and wing panel
mounting
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 13

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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5.5 Body - centre
5.5.1 Front door opening
Height of door opening
Distance between A-pillars
Distance between B-pillars
Distance between A-pillar and B-pillar
Audi A8 1994 ➤
Body repairs - Edition 10.1998
14 Rep. Gr.00 - Technical data

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5.5.2 Rear door opening
Distance between C-pillars
Distance between B-pillar and C-pillar
Height of door opening
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 15

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5.6 Body - rear
Distance between side panels (top)
Distance between side panels (bottom)
Distance between rear cross panel flange and window cross
member flange
Audi A8 1994 ➤
Body repairs - Edition 10.1998
16 Rep. Gr.00 - Technical data