Audi A8 User manual

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Body Repairs
Audi A8 2003 ➤
Edition 05.2011
Service
Service Department. Technical Information

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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 © 2011 Audi AG, Ingolstadt A004EKI0120

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Moulded foam inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair methods for bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Floor group, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Floor group, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Floor group, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Wing mounting flange - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Wing mounting flange - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Front wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Front longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5 Longitudinal member (front section) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Roof - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Roof side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Roof side member - Renewal (long version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5 Outer B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
Contents i

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5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7 Inner B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1 Rear cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 Rear cross member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Rear longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.3 Rear wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5 Spare wheel well - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
ii Contents

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00 – Technical data
1 Vehicle identification data
1.1 Vehicle identification number
The vehicle identification number appears in the windscreen on
the driver's side, on the vehicle data sticker and is stamped on
the suspension turret (right-side).
1.2 Type plate
The type plate is located on the passenger-side door pillar. Ve‐
hicles for certain export countries have no type plate.
1.3 Vehicle data sticker
The vehicle data sticker is located in the spare wheel well under
the luggage compartment floor (left-side in direction of travel).
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
1. Vehicle identification data 1

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with respect to the correctness of information in this document. Copyright by AUDI AG.
2 Moulded foam inserts
Various body cavities of the Audi A8 2003 are fitted with moulded
foam inserts.
The foam inserts reduce the noise transmitted to the interior when
driving.
These pre-moulded parts are fitted during body manufacture and
subsequently increase their volume in the paint shop drying oven
at approx. 180 °C after priming.
Caution
The replacement foam inserts expand only after reaching
about 180°C. For this reason, an additional filler foam is used
when performing repairs.
Filler foam required for repairs: D 506 KD1 A3.
As the required temperatures cannot be achieved under normal
workshop conditions, proceed as follows:
Remove residue of foam material on vehicle.
Restore paint coating; apply two coats (wet on wet) of glass/paint
primer D 009 200 02 if necessary, flash-off time approx.10 mi‐
nutes.
Requirement
Before continuing with this procedure, ensure that the replace‐
ment panel is ready for installation, i.e. cut to shape, matched up
to the vehicle, corrosion protection applied.
Renewing moulded foam insert
Fix moulded foam insert to vehicle.
Apply filler foam -D 506 KD1 A3- to replacement part.
Secure new part in position. Gently press in new part in vicinity of
moulded foam insert until it makes contact, and then weld into
place.
The foam hardens within 25 minutes.
Do not weld (SG) within 15 mm of the foam insert (on either side).
After painting the vehicle the repaired area must be cavity-sealed.
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
2 Rep. gr.00 - Technical data

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3 Repair methods for bonded joints
3.1 Body - rear
– Light mounting to outer side panel. 5x solid rivets.
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
3. Repair methods for bonded joints 3

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4 Body dimensions
4.1 Floor group, front
a - 836 ± 2 mm
Distance between front attach‐
ment points of front suspen‐
sion
b - 1067 ± 2 mm
Diagonal distance between at‐
tachment points of front sus‐
pension
c - 762 ± 2 mm
Distance between rear attach‐
ment points of front suspen‐
sion
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
4 Rep. gr.00 - Technical data

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4.2 Floor group, centre
a - 1818 ± 2 mm
Distance between rear attach‐
ment points of front suspen‐
sion and rear axle mounting
b - 2245 ± 2 mm
Diagonal distance between
rear attachment points of front
axle and rear axle mounting
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
4. Body dimensions 5

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4.3 Floor group, rear
a - 1444 ± 2 mm
Distance between front attach‐
ment points of rear suspension
b - 1078 ± 2 mm
Distance between rear attach‐
ment points of rear suspension
c - 1599 ± 2 mm
Diagonal distance between at‐
tachment points of rear sus‐
pension
d - 1032 ± 2 mm
Distance between attachment
points of rear suspension
e - 1014 ± 2 mm
Distance between rear attach‐
ment points of rear suspension
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
6 Rep. gr.00 - Technical data

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4.4 Body - front
a - 1026 ± 2 mm
Distance between front longi‐
tudinal members
b - 894 ± 2 mm
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
4. Body dimensions 7

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
c - 1428 ± 2 mm
Distance between wing panel
mountings
e - 848 ± 2 mm
Distance between attachment
points of suspension strut
mountings
f - 1510 ± 2 mm
Distance between front hinge
mountings
d - 1726 ± 2 mm
Diagonal distance between
hinge mountings and wing
panel mountings
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
8 Rep. gr.00 - Technical data

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4.5 Body - centre
4.5.1 Front door opening
a - 929 ± 2 mm
Height of door opening
b - 1552 ± 2 mm
Distance between A-pillars
c - 1124 ± 2 mm
Distance between A-pillar and
B-pillar
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
4. Body dimensions 9

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4.5.2 Rear door opening
a - 964 ± 2 mm
Height of door opening
b - 917 ± 2 mm
Distance between B-pillar and
C-pillar
c - 1506 ± 2 mm
Distance between C-pillars
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
10 Rep. gr.00 - Technical data

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4.6 Body - rear
a - 1096 ± 2 mm
b - 914 ± 2 mm
Distance between rear longitu‐
dinal members
c - 1259 ± 2 mm
Distance between side panels
(top)
d - 603 ± 2 mm
Distance between rear cross
panel flange and window cross
member flange
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
4. Body dimensions 11

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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5 Body panel gaps/shut lines
5.1 Body - front
N - 0.0 mm
A - 1.0 mm
D - 2.0 mm
F - 3.0 mm
J - 4.5 mm
K - 5.0 mm
Use special tool 3371 for adjusting or checking.
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
12 Rep. gr.00 - Technical data

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5.2 Body - centre
N - 0.0 mm
D - 2.0 mm
E - 2.5 mm
F - 3.0 mm
G - 3.5 mm
H - 4.0 mm
J - 4.5 mm
K - 5.0 mm
M - 6.0 mm
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
5. Body panel gaps/shut lines 13

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5.3 Body - rear
D - 2.0 mm
E - 2.5 mm
F - 3.0 mm
G - 3.5 mm
H - 4.0 mm
K - 5.0 mm
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
14 Rep. gr.00 - Technical data

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6 Straightening jig
Alignment bracket set -VAS 6181- (also suitable for quattro ver‐
sions)
Note
♦ The item numbers in the illustrations are identical with the end numbers on the alignment bracket mountings.
♦ The item numbers of the alignment bracket mountings marked with a circle are for checking the body with
mechanical units installed.
♦ The required basic set size is given for the alignment bracket mountings.
♦ The following illustrations show the right side of the vehicle.
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
6. Straightening jig 15

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 - MZ 260 and TV 400
4 - MZ 260
6 - MZ 602
12 - Mounting for bar
6 - MZ 602 and alignment
bracket mounting -8-
10 - Bolts for suspension strut
mounting
11 - Bolt for suspension strut
mounting
14 - Bar in place of steering
box
15 - Mounting for steering
16 - MZ 140
20 - Bracket without MZ, and
front production mounting -21-
22 - MZ 200 (quattro only)
24 - MZ 080
26 - MZ 200
28 - MZ 602 and alignment
bracket mounting 29
30 - MZ 260
32 - MZ 142 and TV 400
Audi A8 2003 ➤
Body Repairs - Edition 05.2011
16 Rep. gr.00 - Technical data