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Audi A8 D5 Body Repair Manual
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Audi A8 D5 Body Repair Manual

Audi A8 D5 Body Repair Manual

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Service
General InformationBody Repairs,
General Body Repairs
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
Edition 04.2018
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

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Summary of Contents for Audi A8 D5

  • Page 1 General Body Repairs 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 Edition 04.2018 with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 2 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 Technical information should always be available to the foremen and mechanics, because their with respect to the correctness of information in this document.

  • Page 3: Table Of Contents

    Symbols relating to rivets ..........permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Symbols relating to preparation .
  • Page 4 Corrosion protection ............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.

  • Page 5: Safety Precautions

    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.

  • Page 6: Battery, Power Supply

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Work on natural gas vehicles may only be performed by spe‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability cially trained staff.

  • Page 7: General Notes On Body Repairs

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not joint are described in the relevant Body Repairs workshop man‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ual.

  • Page 8: Moulded Foam Inserts

    ♦ Do not weld (SG) within 40 mm of foam insert (on either side). 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.

  • Page 9: Explanation Of Symbols

    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.

  • Page 10: Symbols Relating To Rivets

    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.

  • Page 11: Symbols Relating To Preparation

    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.

  • Page 12: Symbols Relating To Corrosion Protection

    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.

  • Page 13: Vehicle Body Construction Features

    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.

  • Page 14: Assessing Damage

    ♦ Examine the engine/gearbox/axle/exhaust system mountings 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 for damage. with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 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.
  • Page 16 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.

  • Page 17: Measuring Procedures / Damage Diagnosis

    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.

  • Page 18: Overview Of Materials Used

    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.
  • Page 19 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.

  • Page 20: Contact Corrosion

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not patible. 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.
  • Page 21 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not to form bundles which are weaved together. 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.
  • Page 22 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not suffer internal damage. After the load has been relieved, spring‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability back is possible for the component. In such cases, proper as‐...

  • Page 23: Passive Safety

    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 Points to check: with respect to the correctness of information in this document.
  • Page 24 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 ing lock) will prevent the belt tensioner (mechanical triggering) with respect to the correctness of information in this document.
  • Page 25 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not triggered. 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.

  • Page 26: Notes On Disposal

    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.

  • Page 27: Thermal Joining Techniques

    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 For body repair work, access to the welding points may vary; a with respect to the correctness of information in this document.

  • Page 28: Shielded Arc Plug Welding (Sg Plug Welding)

    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 Equipment with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 29: Sg Continuous Seams And Stitch Weld Seams

    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.

  • Page 30: Mig Soldering/Brazing

    Only equipment which is listed as approved in the workshop 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 equipment catalogue may be used.

  • Page 31: Aluminium Welding

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Aluminium welding 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.

  • Page 32: Laser Welding

    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.

  • Page 33: Laser Soldering/Brazing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not MAG welding MAG welding permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability MIG soldering/braz‐ MAG welding with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 34: Replacement Joining Techniques In Repair Work (Aluminium)

    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.

  • Page 35: Cold Joining Techniques

    – Use brush to apply thin coat of aluminium primer and allow to 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.
  • Page 36 Only work on adhesives in well ventilated areas. ♦ 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. It is essential to pay attention to warnings provided by manu‐...

  • Page 37: Rivets

    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.
  • Page 38 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.
  • Page 39 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.
  • Page 40 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 7.2.4 Kerb-Konus rivets 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. Coated stainless steel Kerb-Konus rivets are used.

  • Page 41: Overview Of Riveting Attachments (Pairs Of Tools)

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Note 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.

  • Page 42: Overview Of Rivets And Tools

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Overview of rivets and tools 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.
  • Page 43 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.
  • Page 44 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.
  • Page 45 4 x 12 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 Solid with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 46 907.162 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 rivet with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 47 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.
  • Page 48 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 1.5 – 3.5 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.

  • Page 49: Overview Of Rivets Used For Repair Measures

    To be used 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 measures with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 50: Flow-Drill Screws (Fds)

    Creating an FDS joint (upper panel with‐ 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 out pre-drilled holes) with respect to the correctness of information in this document.
  • Page 51 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 The repair kit can be used to mark the holes on new parts where with respect to the correctness of information in this document.

  • Page 52: Clinching

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Set riveting tool to material thickness for all operations. 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.

  • Page 53: Separating Techniques In Body Welding; Areas Of Application

    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.

  • Page 54: Milling

    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.

  • Page 55: Surface Repairs

    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.

  • Page 56: Dent Removal Procedures For Aluminium Panels

    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 Temperature monitoring during heating with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 57: Bonded Joints With Aluminium

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Processing metal and aluminium filler has numerous benefits: 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.

  • Page 58: Processing Unleaded Tin

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Only approved filler materials must be used. Lead-free and lea‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ded body solder are not approved.

  • Page 59: Performing Straightening Work On Body Structure

    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 10.2 Separating cuts with respect to the correctness of information in this document.

  • Page 60: Corrosion Protection

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Contact corrosion can occur if unsuitable fasteners (bolts, nuts, permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability washers etc.) are used.
  • Page 61 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 ♦ Functional components such as brake systems and ex‐...

  • Page 62: Plastic Repairs

    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 check carefully whether the repair is feasible and economical (i.e.

  • Page 63: Repairing Scratches

    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.

  • Page 64: Repairing Cracks And Tears (Up To A Length Of 100 Mm)

    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.

  • Page 65: Repairing Holes (Up To 30 Mm Diameter)

    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.
  • Page 66 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.

  • Page 67: Plastic Repairs (Glass Fibre Materials)

    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.
  • Page 68 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.
  • Page 69 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.

  • Page 70: Glass Repairs

    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.
  • Page 71 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.

  • Page 72: Thread Repairs

    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.