Service

Body Repairs
Audi A4 2015 ➤
Audi A4 China 2016 ➤
Edition 06.2021

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.

Service Department. Technical Information

 Service
Repair Group overview for Body Repairs

Repair Group
00 - General, Technical Data
50 - Body Front
51 - Body Center, Chassis, Roof
53 - Body Rear

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.

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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2021 Audi AG, Ingolstadt D4B805CB264

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Contents

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Training/Personnel Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Procedures Requiring System to be De-Energized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Safety Precautions when Working on the High-Voltage System . . . . . . . . . . . . . . . . . . . . 5
2.4 Safety Precautions when Working near High-Voltage Components . . . . . . . . . . . . . . . . . . 6
2.5 Safety Precautions when Working on Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 7
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Notes for Working with Fine, Aluminum and Steel Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Line Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Adhesive Surfaces for Adhesive Tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Secured Threaded Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Identification Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Impact Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3.8 Generalpermitted
Information . . . .by. AUDI
unless authorised . . . AG.
. . .AUDI
. . .AG . .does
. . .not
. .guarantee
. . . . . .[Link]
. . . .any
. .liability
.................... 10
3.9 Molded Foam Part
with respect to the. correctness
. . . . . . .[Link]
. . . . . . in. this
. . .document.
. . . . . Copyright
. . . . . .by. AUDI
. . . AG.
...................... 11
3.10 Flow Drill Bolt Connections, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.11 Flattening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.12 Surface Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.13 Contoured Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Removal Method on Multi Material Body Repair Station . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Vehicle Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Type Plate/VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Vehicle Data Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Galvanized Body Parts and High and Higher-Strength Body Panels . . . . . . . . . . . . . . . . . . 19
6.1 Ultra High-Strength Hot Formed Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Aluminum Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 Surface Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.5 Filler Foam Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.6 Contoured Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.7 Laser Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.8 Seat Belt Fastener Threads, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Overview of Rivet Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8 Rivets and Tools Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.1 Rivet Overview in Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Thread Repair for M6 Pop Rivet Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9 Body Structural Adhesive D 180 004 M2, Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.1 Adhesive Surfaces, Preparing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10 Pneumatic Edge Milling Unit VAS882 005, Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.2 Operation/Changing the Milling Cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.3 Clinch Flanges, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.4 Curved/Flat Surface Panels, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.5 Outer Edges, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.6 Roof, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.7 Round Head Milling Cutter for Disconnecting Laser Weld Seams . . . . . . . . . . . . . . . . . . . . 75

Contents i
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

10.8 Aluminum Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

11 Body Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
12 Front Body, Sedan and Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
12.1 Center Body, Sedan and Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
12.2 Front Floor Assembly, Sedan and Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12.3 Rear Floor Assembly, Sedan and Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12.4 Rear Body, Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
12.5 Rear Body, Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
13 Bonded Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
13.1 Bonded Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
13.2 Spot-Welded Bonded Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
13.3 Bonded Joints, Checking and Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
13.4 Repair Methods for Partial Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
14 Protected
Tools . . . . Copying
by copyright. . . . . . for
. .private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in. part
. . .[Link]. whole,
. . . .is. not
........................... 91
14.1 permitted
Straightening Rack . . . . . . . . . . . . . . . . . . . . . . .
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.
. . . . . . ........................... 94

50 - Body Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 Impact Absorber Mount, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3 Longitudinal Member for Upper Wheel Housing, Replacing Partial Section . . . . . . . . . . . . 100
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4 Front Longitudinal Member, Replacing Partial Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5 Upper Wheel Housing Longitudinal Member, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6 Front Longitudinal Member with Suspension Strut Tower, Replacing . . . . . . . . . . . . . . . . 122
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7 Front Longitudinal Member, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
8 Upper Footwell Crossmember, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
9 Threads on Subframe Fastener, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
10 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

51 - Body Center, Chassis, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2 Permitted Separation Cuts on Entire Sidewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3 Roof, Replacing, Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.3 Vehicles with Sliding/Tilting Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4 Vehicles with Sliding/Tilting Sunroof, Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

ii Contents
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
5 Roof, Replacing (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
6 Front Roof Crossmember, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
7 Roof Pillar, Replacing, Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
8 Rear Roof Crossmember, Replacing, Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
9 Rear Roof Crossmember, Replacing, Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
10 Roof Pillar, Replacing, Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
11 Outer A-Pillar, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
12 Inner A-Pillar, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
13 Upper Inner A-Pillar, Replacing, Partial Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
13.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
14 Outer B-Pillar, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
14.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
15 Inner B-Pillar, Replacing, Partial Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
15.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
15.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
16 Front Seat Crossmember, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
16.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
16.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
17 RearbySeat
Protected Crossmember,
copyright. Copying for private Replacing . . . . in. .part
or commercial purposes, . .or. in. whole,
. . . . is. not
........................... 302
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
17.1 Tools
with respect. to
. the
. . correctness
. . . . . . .of. information
. . . . . . in. .this
. .document.
. . . . . .Copyright
. . . . .by. .AUDI . . .AG.
............................ 302
17.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
18 Outer Side Sill, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
18.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
18.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
19 Inner Side Sill, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
19.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
19.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
20 Center Tunnel, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
20.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
20.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
21 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

53 - Body Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Contents iii
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

2 Permitted Separation Cuts on Entire Sidewall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3 Cross Panel, Replacing, Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
4 Cross Panel, Replacing, Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
5 Lock Carrier, Replacing, Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
6 Lock Carrier, Replacing, Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
7 Tail Lamp Assembly Mount, Replacing, Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
8 Tail Lamp Assembly Mount, Replacing, Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
9 Rear Longitudinal Member, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 Side Panel, Replacing, Sedan permitted . . . . .unless
. . . .authorised
. . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG
. .does
. . .not. .guarantee
. . . . . or. .accept
. . . any
. . .liability
. 377
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
with respect to the correctness of information in this document. Copyright by AUDI AG.

10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

11 Side Panel, Replacing (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
12 C-Pillar Reinforcement, Replacing, Sedan and Avant are Identical . . . . . . . . . . . . . . . . . . 396
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
13 Rear Wheel Housing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
13.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
14 Inner Rear Wheel Housing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
14.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
15 Luggage Compartment Floor, Replacing, Only Vehicles with Natural Gas-Powered
Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
15.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
15.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
16 Spare Tire Well, Replacing, Sedan and Avant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
16.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
16.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
17 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
18 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

iv Contents
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

00 – General, Technical Data

1 Training/Personnel Qualification
(Edition 06.2021)
⇒ 1.1 , page 1

1.1 Qualification
To be able to perform a perfect and process-safe repair of
the mixed material body in the workshop, the following training
modules are required.
1. Volkswagen Adhesive Technician VB-121
2. Expert module
3. Recommendation: steel welding technology training ABA 111
P.2
Or similar qualification

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.

1. Training/Personnel Qualification 1
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

2 Safety Precautions
⇒ P2.1 recautions”, page 2
⇒ R2.2 equiring System to be De-Energized”, page 4
⇒ P2.3 recautions when Working on the High-Voltage System”,
page 5
⇒ P2.4 recautions when Working near High-Voltage Compo‐
nents”, page 6
⇒ P2.5 recautions when Working on Cooling System”, page 6
⇒ P2.6 recautions during Road Test with Testing Equipment”,
page 7

2.1 Safety Precautions

Follow all country-specific regulations regarding accident pre‐
vention and safety on the workplace.
Welding and sanding must always be carried out with Ventila‐
tion System.

WARNING
Risk of explosion due to dust concentration and aluminum
and steel when sanding and separating.
Death or serious bodily injury by explosion.
– Check and clean the exhaust extraction system before be‐
ginning work on the functions.
– Extract accumulating sanding dust with the respective per‐
mitted vacuum cleaner for the material.
– Always separate the dust from different materials (sepa‐
rate aluminum steel and carbon fiber-reinforced polymer
(CFRP)).
– Keep the work station free of aluminum and steel dust.
Remove the dust accumulation.
– Do not blow out the accumulated with compressed air.
– Never weld and sand in the same room at the same time.
– To prevent external sparks, if possible use only air driven
sanding and removal devices.
– Empty the extraction system after using.
– Prevent water and moisture when separating and sanding.

⇒ f3.1 or Working with Fine, Aluminum and Steel Dust”, page

8 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
Risk due to hazardous gases.
with respect to the correctness of information in this document. Copyright by AUDI AG.

Sparks are created when welding and separating. If the sparks

touch foamed areas within the body hazardous gases will be
created.
– Do not perform welding or separating with spark producing
devices or tools in the near of foamed areas.

2 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– The natural gas tank must be checked for damage if com‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

ponents in the rear side or rear area are removed due to

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

damage, such as the bumper cover, rear lid, underbody

trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. Death or serious bodily injury by explosion.
– Electrically and manually lock the natural gas fuel tank.

CAUTION
Risk of injury due to flying metal shavings
Irritation and injury to skin and eyes possible
– Wear protective eyewear.
– Wear safety gloves

CAUTION
Health risk due to dusts possible.
Irreversible deposit of dust particles in the lungs. Breathing
impairments possible from sanding and separating work.
– Wear a dust mask.
– Use proper extraction.
– No cutting procedures on carbon fiber-reinforced polymer
(CFRP) materials.

Galvanized Body Parts

CAUTION
When welding zinc-coated sheet steel panels, toxic zinc oxide
develops in the welding emissions.
– Perform the procedures with extraction.

2. Safety Precautions 3
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

CAUTION
If welding, soldering or cutting with spark-producing tools in
foamed areas hazardous gases are produced.
– Never weld, solder or separate within 15 mm of molded
foam parts.
– Perform the procedures with extraction.

Welding and sanding must always be performed with an evacu‐

ation system.
Never weld and sand in any area at the same time.
Clean the work area regularly depending on the amount of dust.
Accumulated dust must not be blown away with compressed
air.
The evacuation system must be cleaned regularly.
Follow all country-specific regulations regarding accident pre‐
vention and safety in the workplace.
Bonded Joints, Detaching
Body bonded joints can be detached by applying heat. The
adhesives used in the vehicle construction and the repair are
destroyed at temperatures 180 – 200°C.

Note

♦ Wear protective gloves and eyewear.

♦ Avoid direct contact of the adhesives with the skin.
♦ Avoid inhaling solvent vapors.
♦ Only process adhesives in well-ventilated areas.
♦ Always note the hazard information from the manufacturer.
♦ Also note the accident prevention regulations applicable in
the respective country.
♦ Note the corresponding safety data sheets for the adhesive.
♦ Use suitable extraction.

2.2 Procedures Requiring System to be

De-Energized
De-energizing and re-energizing takes place exclusively via the
Guided Fault Finding or the Guided Function , using the
Vehicle Diagnostic Tester.
Before any welding, sanding and separating works near the
high-voltage components the vehicle must be de-energized by
a »High-Voltage Technician- HVT« or a »High-Voltage Expert -
HVE«.
Before any body work with the straightening rack the vehi‐
cle must be de-energized by a »High-Voltage Technician -
HVT« oder »High-Voltage Expert -Protected
HVE«.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
Procedures after de-energizing may with
only be to
respect performed by
the correctness of information in this document. Copyright by AUDI AG.
a »Technician Trained in Electrical Systems«.
Procedures, on which the de-energizing or an extra de-ener‐
gizing procedure must be performed are listed in the repair

4 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

manual. Refer to ⇒ Motor; Rep. Gr. 00; High-Voltage System

Danger Classification.

2.3 Safety Precautions when Working on

the High-Voltage System

WARNING

High voltage is extremely dangerous.

The high-voltage system is under high voltage. Electrocution
can cause severe bodily or fatal injury.

– When working on the high-voltage system, the high-voltage

system must be de-energized.
– In some cases the high-voltage system must also be de-
energized when the work procedures do not directly affect
the high-voltage system.
– Note the work procedures that require the system to be de-
energized. Refer to ⇒ Rep. Gr. 00; High-Voltage System
Danger Classification.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energize the high-voltage system.

WARNING

High voltage is extremely dangerous.

The high-voltage system is under high voltage. Electrocution
can cause severe bodily or fatal injury.

– When working on the high-voltage system, the high-voltage

system must be de-energized.
– In some cases the high-voltage system must also be de-
energized when the work procedures do not directly affect
the high-voltage system.
– Note the work procedures that require the system to be de-
energized. Refer to ⇒ Rep. Gr. 00; High-Voltage System
Danger Classification.
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energize the high-voltage system.
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.

WARNING

There is a risk of fatal injury due to electric and magnetic

fields
The high voltage system emits electric and magnetic fields.
Fatal or serious bodily injuries are possible if active implants
(for example, pacemaker, insulin pumps) start malfunction‐
ing.

– Individuals with active implants cannot perform any proce‐

dures on high-voltage systems.

2. Safety Precautions 5
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

WARNING

Risk of damaging the high-voltage cables.

Misuse can damage the insulation of high-voltage cables or
high-voltage connectors.

– Never support on the high-voltage cables and the high-volt‐

age connectors.
– Never support tools on the high-voltage cables and the high-
voltage connectors.
– Never sharply bend or kink the high-voltage cables.
– Pay attention to the coding when connecting the high-volt‐
age connectors.

2.4 Safety Precautions when Working near

High-Voltage Components
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
WARNING with respect to the correctness of information in this document. Copyright by AUDI AG.

High voltage is extremely dangerous.

The high-voltage system is under high voltage. Electrocution
by direct contact or electric arc can cause fatal or serious
personal injury if high-voltage components and high-voltage
cables are damaged.

– Perform a visual inspection of the high-voltage components

and the high-voltage cables.
– Never use cutting, shaping, or sharp-edged tools near high-
voltage components and high-voltage cables.
– Never weld, solder, use thermal bonding or hot air near high-
voltage components and high-voltage cables.

2.5 Safety Precautions when Working on

Cooling System

WARNING

Risk of scalding due to hot coolant

The cooling system is under pressure when the engine is
warm. There is a risk of scalding due to hot steam and hot
coolant.

– Wear safety gloves.

– Wear protective eyewear.
– Reduce the pressure by covering the coolant expansion tank
cap with a cloth and carefully opening it.

6 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

WARNING

Risk of injury due to an activated parking heater and A/C

The parking heater and A/C can switch on unintentionally on
electric and hybrid vehicles with an activated parking heater
and A/C. Bodyparts can be pinched or pulled by self-actuat‐
ing radiator fans.

– Deactivate the parking heater and A/C.

2.6 Safety Precautions during Road

permittedTest
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with Testing Equipment with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

There is a risk of injury due to unsecured testing equipment.

If the front passenger airbag activates during an accident un‐
secured testing equipment becomes a dangerous projectile.

– Secure testing equipment on the rear seat.

or
– Have a second person operate testing equipment on the
rear seat.

2. Safety Precautions 7
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

3 Repair Information
⇒ f3.1 or Working with Fine, Aluminum and Steel Dust”, page
8
⇒ R3.2 outing and Securing”, page 9
⇒ C3.3 orrosion”, page 9
⇒ S3.4 urfaces for Adhesive Tape”, page 9
⇒ T3.5 hreaded Connections”, page 10
⇒ P3.6 lates”, page 10
⇒ W3.7 renches”, page 10
⇒ F3.9 oam Part”, page 11
⇒ D3.10 rill Bolt Connections, Servicing”, page
Protected by 12 Copying for private or commercial purposes, in part or in whole, is not
copyright.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ 3.11 , page 13 with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ T3.12 reatment”, page 14

⇒ S3.13 urface”, page 14

3.1 Notes for Working with Fine, Aluminum

and Steel Dust
Separation of aluminum and steel dust
All emissions of the new lightweight materials fall under the
hazardous materials ordinance (national regulations). These re‐
quire, independently from all repair quality related guidelines
by the vehicle manufacturer, a risk analysis by the company
performing the repair.
The employers may permit work with hazardous substances on‐
ly after, a risk assessment has been performed and the required
safeguard measures have taken place.
This means in the specific case, each repairing workshop is
legally obligated to create such risk assessment, before the
procedures are started or continued.
Fine Aluminum Dust

Physical:
♦ Aluminum dust is combustible and depending on the particle
size and concentration, explosive
Chemical:
♦ Aluminum dust and water produce a combustible/explosive
hydrogen gas
♦ Aluminum dust + ferric oxide (rust) react under heat with
each other (exothermic redox reduction)
♦ Aluminum dust + ferric oxide + strong ignition sources can
at a mixture ratio of 1:3 cause a thermal reaction. This metal
fire burns at a temperature of up to 2400 °C (4352 °F) and
cannot be extinguished with water.
♦ Aluminum dust is a hazardous material and must be properly
extracted according to the local regulations.
Fine Steel Dust

8 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Physical:
♦ Steel particles can be statically charged and even cold can
become an ignition source for the aluminum dust.
♦ Flying sparks from steel processing provides the perfect igni‐
tion source for aluminum dust.
♦ When performing a sandwich cut through steel and alumi‐
num the explosive aluminum dust and also the ignition
source emerge at the same time.
Chemical:
♦ Aluminum dust + ferric oxide (rust) react under heat with
each other (exothermic redox reduction)
♦ Aluminum dust + ferric oxide + strong ignition sources can
at a mixture ratio of 1:3 cause a thermal reaction. This metal
fire burns at a temperature of up to 2400 °C and cannot be
extinguished with water.

3.2 Line Routing and Securing

If loosening or removing and installing hydraulic lines, pneumat‐
ic lines or wires, draw sketches or take pictures. This will ensure
their original installation.

3.3 Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating
may be installed.
Furthermore,
Protected onlyforrubber/plastic
by copyright. Copying private or commercialparts and
purposes, adhesive
in part or in whole,made
is not of
electrically
permitted non-conductive
unless authorised by AUDI AG. AUDI materials are used.
AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
If there is any concern whether parts can be reused, then new
parts must be used according to the Electronic Parts Catalog
(ETKA).
Note:

NOTICE
Contact corrosion damage is not covered under warranty.
– Only use original replacement parts. They have been
checked and are compatible with aluminum.
– Accessories must be approved by Audi AG.

3.4 Adhesive Surfaces for Adhesive Tape

♦ The vehicle must be at room temperature before installing,
for example self-adhesive covers, door seals, etc. with adhe‐
sive tape.
♦ The adhesive surfaces on the body must be free of dust and
grease.
♦ Clean the adhesive surfaces using Cleaning Solution -D 009
401 04-.
♦ After installing, press on the covers with adhesive tape using
a roller.
♦ After installing, pull on the components by hand to check for
a secure fit.

3. Repair Information 9
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

3.5 Secured Threaded Connections

Installed bolts that are »microencapsulated« must be replaced,
and the threaded holes must be cleaned with a suitable thread
tap.

3.6 Identification Plates

When replacing vehicle components, the existing identification
plates on the old parts that indicate the replacement part num‐
ber (refer to Parts Catalog), must be applied to the new part
according to the specifications.

3.7 Impact Wrenches

Removing bolts and nuts is generally allowed using an impact
wrench. Procedures within an open high-voltage battery is ex‐
cluded from this. Generally no impact wrench is permitted for
these procedures.
If the following requirements are met, using an impact wrench
to screw in bolts and nuts is permitted during repair procedures.
Electric and compressed air impact wrenches are generally in‐
tended here.
Requirements:
• Bolts with locking fluid or self-locking nuts must only be
screwed in at low speeds.
• Use a suitable impact wrench with an adjustable speed and
torque range.
• Use suitable screwdriver bits near delicate surfaces, for ex‐
ample, use plastic-coated bits on aluminum rims.
• Note the Natural Gas Fuel Systems - General Information
repair manual when working in a natural gas fuel system
area.
Application:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Position the bolts or nuts by hand.
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.
• Only screw in the bolts or nuts with an impact wrench until
the head of the bolt or nut contacts the surface and then
continue to turn using a torque wrench.
• Clean the threaded pins before removing the bolt or nut.

3.8 General Information

⇒ I3.8.1 nformation”, page 11
Only select labor operations are described in this repair manual.
The following applies for labor operations that are not descri‐
bed: Separate the original joint and re-create it with the replace‐
ment part. Repairs using methods that differ from the original
manufacturing process are described.
If sub-parts are delivered, fit them and butt weld them using a
gas-shielded arc continuous weld seam.
Follow the information in the Body Collision General Information
repair manual.
Welding and sanding must always be performed with an evacu‐
ation system.

10 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Never weld and sand in any area at the same time.

Clean the work area regularly depending on the amount of dust.
Accumulated dust must not be blown away with compressed
air.
The evacuation system must be cleaned regularly.
At the same time pay attention to the corresponding country-
specific legislation.

3.8.1 General Information

Only use tools and materials for aluminum repairs.
Always only use new bolts.
Make sure there is enough work space for evacuating.
When sanding aluminum components check that steel inserting
elements are present in the sanding area.
When welding on the aluminum components the battery and all
control modules must be disconnected.
Temperature control while welding is absolutely required, so
that the carbon fiber reinforced polymer (CFRP) sections are
not warmed over 90 °C and damaged.

3.9 Molded Foam Part

On the Audi R8 MY 2015, various body cavities are equipped
with molded foam parts.
The molded foam parts reduce the transfer of driving noises in
the vehicle interior.
The molded parts are installed in the body shell assembly and
increase in volume after priming in the paint drying-oven from
approximately 180 °C.

Note

♦ Expanded foam inserts expand only after reaching 180 °C.

Because of this, filler foam is used for repairs.
♦ The Filler Foam -D 506 KD1 A3- is required for this repair.

Since this temperature is not reached under workshop condi‐

tions, proceed as follows:
Prerequisite
Before performing these steps, the replacement sheet metal
must be prepared for installation, for example, cut, fitted and
corrosion protection applied.
Molded Foam Part, Replacing
Secure the molded foam part on the vehicle.
Apply the Filler Foam -D 506 KD1 A3- to the molded foam part.
Secure new part by gently pressing the new part in the area of
the filler foam piece until it makes contact and weld it in.
The foam hardens within 25 minutes.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Do not gas-shield weld within 15 mm of foam
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.
After painting the vehicle, apply protective material in the cavi‐
ties near the repair area.

3. Repair Information 11
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Since this temperature is not reached under workshop condi‐

tions, proceed as follows:
Recreate paint structure, if necessary coat twice wet-on-wet
with glass/paint primer D 009 200 02 - drying time: approxi‐
mately 10 minutes.

3.10 Flow Drill Bolt Connections, Servicing

Note

Flow-drill bolts have been introduced on the Audi R8 that can

be replaced using the FD Bolt Socket -VAS852 007A-.

The repair concept for the pure aluminum body components

is the same as the repair procedures used on previous Audi
aluminum vehicles.
Flow Drill Bolts
Using the FDS Bolt Socket Set -VAS852 007- tool, allows the
best use of the threaded connection during repairs.

3.10.1 Flow Drill Bolt Socket Alternative

For the Audi R8, 12 mm Flow - Drill Bolts -WHT.006.547- are
used. Use a 12 mm socket for this and if necessary grid off the
bevel, this is the only way to allow the best use of the threaded
connection during repairs.

3.10.2 Original Position

Loosening the flow drill bolts
– If the flow drill bolt head is accessible, use the FDS Bolt
Socket Set -VAS852 007-.
– If the flow drill bolt head is covered with underbody protec‐
tion or similar seal, use the FDS Bolt Socket Set -VAS852
007-.

3.10.3 Upper Component is Pre-Punched as

Replacement Part
– Loosen the flow drill bolt threaded connection with FDS Bolt
Socket Set -VAS852 007-.
– Remove the upper section.
– Apply the Body Structural Adhesive to the entire area using
the Compressed Air Glue Gun. Refer to ⇒ S9 tructural Adhe‐
sive D 180 004 M2, Application”, page 35 .
– Position the new part and tighten using the FDS Bolt Socket
Set -VAS852 007- and new bolts to 5 Nm.

3.10.4 Upper Section is not Pre-Punched as a

Replacement Part
– Loosen the flow drill bolt threaded connection with FDS Bolt
Socket Set -VAS852Protected
007-. 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
– Remove the upper section.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Install the Flow Drill Bolt Repair Set -VAS6631- in the exist‐
ing flow drill bolt threads.
– Position the new part.

12 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Label the holes in the new part by hitting it lightly with a

plastic hammer.

Note

Allow for the flow drill bolt repair set offset: only make a superfi‐
cial mark if possible.

– Remove the upper section.

– Drill the upper section 7 mm diameter holes.
– Apply the Body Structural Adhesive to the entire area using
the Compressed Air Glue Gun. Refer to ⇒ S9 tructural Adhe‐
sive D 180 004 M2, Application”, page 35 .
– Position the new part and tighten using the FDS Bolt Socket
Set -VAS852 007- and new bolts to 5 Nm.

3.10.5 Upper and Lower Sections, Replacing

– Loosen the flow drill bolt threaded connection with FDS Bolt
Socket Set -VAS852 007-.
– Remove both sections.
– Make 4 mm holes using both sections at the same distance
as with the original joint.
– Remove the new parts.
– Expand the 4 mm holes in the upper section to 7 mm.
– Apply the Body Structural Adhesive to the entire area using
the Compressed Air Glue Gun. Refer to ⇒ S9 tructural Adhe‐
sive D 180 004 M2, Application”, page 35 .
– Position the new parts and tighten using the FDS Bolt Sock‐
et Set -VAS852 007- and new bolts to 5 Nm.

3.10.6 Flow Drill Socket Repair Set VAS6631

The repair set serves as a means of marking the holes on the
new parts where the flow drill bolt threaded connections are
used. Using the Flow Drill Socket Repair Set VAS6631 it is
possible to transfer the hole positions for the flow drill bolts to
the Audi aluminum vehicles if a repair is required. First loosen
the old flow drill bolts by using the socket. Then the damaged
panel is removed. Now the flow drill Protected
bolt repair set isCopying
by copyright. installed in or commercial purposes, in part or in whole, is not
for private
the existing holes in the aluminum panel that
permitted was
unless not replaced.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Do this using the Flow Drill Screw Repair Set - Ring Wrench
with respect to the correctness of information in this document. Copyright by AUDI AG.

VAS6631/1. The new aluminum panel is aligned to the vehicle

and attached with crimping pliers. Using light hammer strokes
(rubber hammer), the holes from the existing panel will be trans‐
ferred onto the replacement part with assistance from the flow
drill bolt repair set. The replacement part that now contains the
marks is removed again. Holes are drilled at the transferred
marks. It is then possible to secure the flow drill bolt threaded
connections of the new part to the body using the socket

3.11 Flattening
The risk of material expansion is greater with aluminum than
with steel.
Sharp-edged and hard flattening hammers (for example steel
hammers) should not be used and should be replaced with
plastic, wood or aluminum hammers.

3. Repair Information 13
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Any direct flattening procedures, meaning the aluminum panel

lies directly between the counterhold and the flattening ham‐
mer, should be reduced.
Flattening procedures on aluminum panels begins, contrary to
steel panels, in the center of the dent.
An aluminum panel should be pressed more often than beaten.
The counterhold tool should be handled loosely when smooth‐
ing. Smoothing too forcefully can cause the material to expand.
For this reason, a counterhold tool made of hard wood should
be used.
If material expansions do occur, they can be corrected by
warming and pulling.

Note

Heat maximum 150 °C.

Note

If a rip occurs during flattening, then that part must be replaced.

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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.
3.12 Surface Treatment
Only use stainless steel wire brushes.
Roughing blades must not be used due to smear effect.
Use sanding discs with P 80 through P 200 grit.
Only use sanding discs, drill bit, milling cutter and cutting discs
with Cleaning Block -DA 009 802-.
Clean surface with thinner.
Further surface treatment as with steel.

Note

Aluminum parts must be covered when sanding and welding

steel parts. Any steel shavings that contact aluminum must be
immediately removed or else contact corrosion can occur.

Note

♦ Use tools for either steel or aluminum.

♦ Recommendation: Aluminum Tool Set -VAG2010/2-

3.13 Contoured Surface

The contoured surface is a surface with the dimensional accura‐
cy of the edges and seams to the surface.
It is specified when:
♦ Any surfaces or parts that have been worked on, such as
removing dents, welding or spackling, must be dry sanded
with minimum P 80 grit sandpaper.

14 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ The vehicle paint shop technician must then re-create the

respective surface in a maximum of two steps.
For the contoured surface, the body filling materials
For vehicles made of steel
Two-Part Steel Scraper Set -DA 787 300 A2-
For vehicles made of aluminum
Two-part diamond-shaped scraper Aluminum Powder DA 004
200 A2 and Hardener DA 004 201 A1.
use body filler

Note

Leaded soldering tin may not be used since 01/01/2003.

Note

Audi AG has not approved any unleaded soldering tin proce‐

dure.

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.

3. Repair Information 15
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

4 Removal Method on Multi Material

Body Repair Station

Note

Empty the Ruwac NA35 Wet Collection for Explosive Materials

-VAS6572/1- and Ruwac NA35 Wet Collection for Explosive
Materials -VAS6572/2- before and after every operational use.

Betafoam Open-Celled Acoustic - Foam

This foam is not fire retardant or self-extinguishing. When oxy‐
gen is available for the foam, fire can result due to sparks or
other ignition sources.

Note

Never extract betafoam open-celled acoustic - foam using Ru‐

wac NA35 Wet Collection for Explosive Materials -VAS6572/1-
or Ruwac NA35 Wet Collection for Explosive Materials -
VAS6572/2-. 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

Fine Aluminum Dust

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

Fine aluminum dust is combustible and/or explosive. Technical

equipment must be handled so that no external ignition sources
can pass into the filter or the dust collection container. The sta‐
tionary "genuine" aluminum vacuum stations used through 2009
(Dansk Klimablock / Aeroweld or Nederman) do not offer the
technical equipment protection and also cannot be retrofitted.
All these suction devices and the aluminum vacuum devices
available on the market are without exception "ignition source
free". For this reason vehicles with steel parts and on which
flying sparks from the steel components cannot be completely
prevented must NOT be worked on in this area.
The Ruwac NA35 Wet Collection for Explosive Materials
VAS6572/1 (dust class M) from 2009 and the VAS6572/2 (dust
class H) have a 3-part protection against the intake of friction
sparks from the possible steel processing. This protection is
made of a 5 m long antistatic suction hose, the so-called spark
trap and a 5 m long flow calming section. This ensures that
also by unintentional sanding of steel components the glowing
sparks are cooled well below the ignition temperature of the alu‐
minum dust. The system has the German Technical Inspection
Agency certificate for considerably hotter and longer glowing
steel sparks.
A second risk is the static charging of metal particles due to
friction in the hoses and pipes during the suction process. This
static charge can function as an ignition source in the same
way as a glowing spark. To make sure that only the antistatic
so called "Ohm hoses" can be installed, the suction system
connection coupling and the hoses on the suction side have an
error safe Storz-C coupling.
The third risk is the suction device's possible impact as an
ignition source on the surrounding area. Because this suction
device is based on industrial vacuum cleaners it automatically
has all constructive features for the use in zone 22 and to
prevent a possible impact as an ignition source in the working
environment. For accident repairs the work procedures such
as cutting, grinding and welding automatically produce more
ignition sources than a suction device can.

16 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Fine Steel Dust

Steel sparks and dust are considered to be risk free. In multi
material mixed work stations the steel flying sparks present
the greatest risk potential for the fine aluminum dust! For this
reason and in compliance with the process separation, a steel
vacuum must always be provided which is also allocated to al‐
ways remain at the body work station. Generally only aluminum
vacuums are used because they have a tested spark trap, that
could be equal to the explosion protection device heat test,
while the vacuum sits next to the worker in the work area during
this procedure. The Ruwac NA35 Wet Collection for Explosive
Materials VAS6571/1 is based on the same basic machine as
the VAS6572/2, but without a 3-part spark trap. It is suitable for
use in zone 22. The filter is dust class "M" like those suitable for
the metal dust.

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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. Removal Method on Multi Material Body Repair Station 17

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

5 Vehicle Data
⇒ P5.1 late/VIN”, page 18
⇒ D5.2 ata Label”, page 18

5.1 Type Plate/VIN

The VIN can be found in the Infotainment, on the vehicle data
label and under the windshield on the driver side. In addition
the VIN is located on the right side in the engine compartment.
The type plate is located on the A-pillar on the right side of the
vehicle. Vehicles for certain export countries do not have a type
plate.

Note

♦ If the VIN is replaced in the event of a damage claim, servic‐

ing must be documented according to the legal regulations
applicable in that market.
♦ Please observe the country-specific legislation when replac‐
ing the VIN.
♦ If removed, stamp the VIN using the Numbering Stamps
-VAS6939- and the Stamp Set -VAS6940-.

5.2 Vehicle Data Label

The vehicle data label is located in the luggage compartment
under the luggage compartment floor cover.

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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.

18 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

6 Galvanized Body Parts and High

and Higher-Strength Body Panels
⇒ H6.1 igh-Strength Hot Formed Steel”, page 19
⇒ P6.2 anels”, page 20
⇒ C6.3 orrosion”, page 22
⇒ T6.4 reatment”, page 23
⇒ F6.5 oam Pieces”, page 23
⇒ S6.6 urface”, page 26
⇒ W6.7 elds”, page 26
⇒ B6.8 elt Fastener Threads, Servicing”, page 26

Note

Repairs may only be performed according to the manufactur‐

er specifications in the respective repair manual. High-strength
and hot-formed types of steel can only be repaired using mod‐
ern inverter technology, otherwise the passenger protection af‐
ter the repair will not be optimal. Body panels made from hard‐
ened steel are used in areas where there are extreme loads.
These lighter-weight body panels have a much higher strength
than conventional high-strength body 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

♦ For weight reasons, Audi uses soft steels, high-strength

steels, modern high-strength and ultra high-strength steels
and ultra high-strength hot-formed steels.
♦ Separating and butt welding these components is only per‐
mitted in the specified locations. There is a repair method
specified for this service.
♦ Spot welding is only permitted when using resistance spot
welders approved by Audi AG.

The body of this vehicle is in part manufactured from galvanized

steel panels.

6.1 Ultra High-Strength Hot Formed Steel

For weight reduction, the Audi A4 and Audi A4 Avant is made
from ultra high-strength hot-formed steel. Separating and butt
welding these components is only permitted in the specified
locations. In these areas a repair method is specified.
Spot welding is only permitted when using the specified inverter
point welders.
To illustrate the body more clearly, the outer side panel and the
roof are not shown.
Left/right upper outer A-pillar
Inner B-Pillar
Left/right inner side sill
Left/right outer bulkhead crossmember
Upper tunnel reinforcement

6. Galvanized Body Parts and High and Higher-Strength Body Panels 19

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

6.2 Aluminum Panels

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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.

20 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Color Aluminum
1 Green Aluminum panel
2 Blue Aluminum extrusion profile
3 Brown Aluminum cast profile

Suspension Strut Retainer

6. Galvanized Body Parts and High and Higher-Strength Body Panels 21

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

6.3 Contact Corrosion

Contact corrosion may occur if unsuitable connecting elements
(bolts, nuts, washers and etc.) are used.
For this reason, only fasteners with a special surface coating
may be installed.
In addition, rubber and plastic parts and adhesive are made of
non-conductive materials.
If there are doubts as to whether parts should be reinstalled,
install new parts.

Note

Note:

22 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Only use original replacement parts. They have been checked

and are compatible with aluminum.
Accessories must be approved by Audi AG!
Contact corrosion damage is not covered under warranty!

6.4 Surface Treatment

Only use stainless steel wire brushes.
Roughing blades must not be used due to smear effect.
Use sanding discs with P 80 through P 200 grit.
Only use sanding discs, drill bit, milling cutter and cutting discs
with Cleaning Block D 009 802.
Clean surface with thinner.
Further surface treatment as with steel.

Note

Aluminum parts must be covered when sanding and welding

steel parts. Any steel shavings that contact aluminum must be
immediately removed or else contact corrosion can occur.

Note

♦ Use tools for either steel or aluminum.

♦ Recommendation: Aluminum Tool Set -VAG2010/2-

6.5 Filler Foam Pieces

On the Audi A4 and Audi A4 Avant, various body cavities are
filled with molded foam parts.
The molded foam parts reduce the transfer of driving noises in
the vehicle interior.
The molded parts are installed in the body shell assembly and
increase in volume after priming in the paint drying-oven from
approximately 180 °C.

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. Galvanized Body Parts and High and Higher-Strength Body Panels 23

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Avant filler foam piece

24 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

♦ Replacement expanded foam inserts expand only after

reaching 180 °C. Because of this, filler foam is used for
repairs.
♦ Use filler foam D 506 KD 1 A3 for these services.

Since this temperature is not reached under workshop condi‐

tions, proceed as follows:
Remove any remaining foam from the vehicle.
Recreate paint structure, if necessary coat twice wet-on-wet
with Glass/Paint Primer D 009 200 02 - drying time approxi‐
mately 10 min.
Prerequisite
Before performing these steps, the replacement metal panel
must be prepared for installation, for example, cut, fitted, corro‐
sion protection measures performed.
Molded Foam Part, Replacing
Install the molded foam part on the vehicle.

6. Galvanized Body Parts and High and Higher-Strength Body Panels 25

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Apply Filler Foam -D 506 KD1 A3- on the replacement part.

Secure new part by gently pressing the new part in the area of
the filler foam piece until it makes contact and weld it in.
The foam hardens within 25 minutes.
Do not gas-shield weld within 15 mm of the filler foam.
After painting the vehicle, apply protective material in the cavi‐
ties near the repair area.

6.6 Contoured Surface

The contoured surface is a surface with the dimensional accura‐
cy of the edges and seams to the surface.
It is specified when:
♦ Any surfaces or parts that have been worked on, such as
removing dents, welding or spackling, must be dry sanded
with minimum P 80 grit sandpaper.
♦ The vehicle paint shop technician must then re-create the
respective surface in a maximum of two steps.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
For the contoured surface, the body filling permitted
materials 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.
For vehicles made of steel
Two-Part Steel Scraper Set -D 787 300 A2-
For vehicles made of aluminum
Two-part diamond-shaped scraper Aluminum Powder -D 004
200 A2- and Hardener -D 004 201 A1-.
Must be used.

Note

Leaded soldering tin may not be used since 01/01/2003.

Note

Audi AG has not approved any unleaded soldering tin proce‐

dure.

6.7 Laser Welds

Audi AG has introduced laser welding to vehicle manufacturer
with the Audi A4.
When laser welding, a high energy light beam is directed onto
the weld point via optical lenses or fiber optics.
During the welding process, the upper panel is melted through
and the lower panel is melted on the surface, thereby forming a
weld without using any additional materials.
When repairing, the laser weld seams are replaced by gas-
shielded arc weld seams or pop rivets.

6.8 Seat Belt Fastener Threads, Servicing

Refer to the adjustment description from the Belt Anchor Repair
Set -VAS6733- repair kit for the thread servicing procedure.

26 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Repair the threaded connection for the rear seat belt -A- and
the threaded connection for the front seat belt -B- with the
repair kit for the Belt Anchor Repair Set -VAS6733-.

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.

6.8.1 Thread Repair for M6 Pop Rivet Nut

The repair bolt WHT.006.778. can be installed as a replacement
if the self-tapping bolts WHT.002.612. are over-tightened or fail.
The drilling and installing of the pop rivet nuts are steps that
have been omitted.

6. Galvanized Body Parts and High and Higher-Strength Body Panels 27

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

7 Overview of Rivet Heads

Note

♦ This card serves only as a guide. Use the accompanying

Owner's Manual for the description of the procedure as well
as the areas of application.
♦ To increase the service life of the rivet head maker, use
commercially available cutting fluid.

D 1 + D 2 - 3.2 mm Diameter
Press - Punch Rivet
D 2 + D 3 - 3.2 mm Diameter
Press - Punch Rivet
D 2 + D 5 - 5 mm Diameter
Press - Punch Rivet
D 3 + D 5 - 5 mm Diameter
Press - Punch Rivet
D 4 + D 5 - 5 mm Diameter
Press - Punch Rivet
D 5 + D 12 - 8 mm Diame‐
ter Hole Punch - Welded Joint
Drill
D 6 + D 7 - 4.8 mm Diameter
Hole Stamp - Pop Rivet
D 8 + D 8 - Panel Reshaping
D 8 + D 9 - Pressure of 4 mm
- Solid Rivet
D 10 + D 11 - Hole Punch and
Stamp 4 mm Diameter - Solid
Rivet
D 13 + D 14 - 5.3 x 7.5 mm
Diameter Press - Punch Rivet
D 17 + D 17 - Panel Reshap‐
ing
D 15 + D 16 - 6.0 mm Diame‐
ter Hole Stamp - Solid Rivet
D 17 + D 17 - Pressure of 6.0
mm - Solid Rivet
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

S 1 + D 2 - 3.2 mm Diameter
with respect to the correctness of information in this document. Copyright by AUDI AG.

Press - Punch Rivet

S 2 + S 3 - 3.2 mm Diameter Positioner - Punch Rivet
S 4 + D 5 - 5.3 x 5.5 mm Diameter Press - Punch Rivet
S 5 + D 5 - 5.3 x 6.5 mm Diameter Press - Punch Rivet
S 6 + S 7 - 5.3 x 5.5 mm Diameter Positioner - Punch Rivet
S 6 + S 8 - 5.3 x 6.5 mm Diameter Positioner - Punch Rivet

28 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

8 Rivets and Tools Overview

Pop Rivet Pliers -VAG1753B-

Pop Rivet Pliers -VAG1765C-

Pop Rivet Nut Pliers -VAS5072A-

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.

Pneumatic Pop Riveter -VAG2003A-

8. Rivets and Tools Overview 29

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Pneumatic Rivet Gun -VAS6759-

Rechargeable Riveter -VAS5279A-

Rechargeable Riveter -VAS843 001-

Pneumatic-Hydraulic Riveter Set -VAS6790-
Compact Riveting Device -VAS6792-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Compact Riveting Device - Extension -VAS6792/2-
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.
FD Bolt Socket -VAS852007A-
Miracle Alurepair Plus-System -VAS852 001-
Rivet Part VA V V VA VA V V VA V V V
number G1 A A G1 G2 A A S8 A A A
size 765 S5 S5 75 00 S6 S 43 S S S
27 07 3B 3A 79 6 00 6 8 8
9 2 0 7 1 7 5 5
9 5 2 2
2/ 9 0 0
2 0 0
7 1
Punch 4D0 x x x
Rivet 803 217
N
3.35 x 5
mm
Punch 4D0 x x x
Rivet 803 217
Q
3.35 x 4
mm
Punch 4D0 x x x
Rivet 803 217
L
5.3 x 5
mm
Punch 4D0 x x x
Rivet 803 217
M
5.3 x
6.5 mm
Punch N 909 x x x
Rivet 261 02
5.3 x 6
mm
Punch N 911 x x x
Rivet 365 01
5.3 x
7.5 mm

30 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Rivet Part VA V V VA VA V V VA V V V
number G1 A A G1 G2 A A S8 A A A
size 765 S5 S5 75 00 S6 S 43 S S S
27 07 3B 3A 79 6 00 6 8 8
9 2 0 7 1 7 5 5
9 5 2 2
2/ 9 0 0
2 0 0
7 1
Punch N 911 x x x
Rivet 348 01
5 x 4.2
mm
Alumi‐ N 103 x x x
num 239 01
solid 4x8
rivet mm
Alumi‐ N 103 x x x
num 240 01
solid 4 x 12
rivet mm
Alumi‐ N 107 x x x
num 440 01
solid 6 x 10
rivet mm
Alumi‐ N 107 x
num 441 01
solid 6 x 12
rivet mm
Alumi‐ 4E0 809 x x x x
num 864 A
pop
rivet
with a
coun‐
ter‐
sunk
head
Alumi‐ 8Z0 809 x x x x
num 864
pop
rivet Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
with a permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
semi- with respect to the correctness of information in this document. Copyright by AUDI AG.
round
head
Flow WHT.00 x
Drill 3.873
Bolts M5 x 25
Flow WHT.00 x
Drill 6.547
Bolts M5 x 20
Flow WHT.00 x
Drill 7.052
Bolts M5 x 18
Threa N 907 x x x x x x
ded 163 01
rivet 14 mm
Threa N 907 x x x x x x
ded 162 01
rivet 10 mm

8. Rivets and Tools Overview 31

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Rivet Part VA V V VA VA V V VA V V V
number G1 A A G1 G2 A A S8 A A A
size 765 S5 S5 75 00 S6 S 43 S S S
27 07 3B 3A 79 6 00 6 8 8
9 2 0 7 1 7 5 5
9 5 2 2
2/ 9 0 0
2 0 0
7 1
Threa N 907 x x x x x x
ded 161 01
rivet 22 mm
Threa N 907 x x x x x x
ded 160 01
rivet 6 mm
Pop WHT x x x x x x
Rivet 005 413
A
6.5 mm
rivet
material
strength
: 5-9
mm
Pop WHT x x x x x x
Rivet 005.697
6.5 mm
rivet
material
strength
: 3 - 4.8
mm
Pop WHT x x x x x x
Rivet 911.527
.01
6.5 mm
rivet
material
strength
: 4.5 -
7.0 mm
Pop N 909 x x x x x x
Rivet 236 01
4.8 mm
rivet
material
strength
: 2.4 -
4.8 mm
Pop N.906.9 x x x x x x
Rivet 24.02
4.8 mm
rivet
material
strength Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
: 1.5 - permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
3.5 mm with respect to the correctness of information in this document. Copyright by AUDI AG.

Pop 4S0 843 x x x x x x

Rivet 658
Pop WHT VA
rivet 005 180 G1
screw 765
C/2

32 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Rivet Part VA V V VA VA V V VA V V V
number G1 A A G1 G2 A A S8 A A A
size 765 S5 S5 75 00 S6 S 43 S S S
27 07 3B 3A 79 6 00 6 8 8
9 2 0 7 1 7 5 5
9 5 2 2
2/ 9 0 0
2 0 0
7 1
Pop N.910.0 VA
rivet 11.01 G1
screw 765
C/4
Pop N.910.3 VA
Rivet 77.01 G1
Nut M10 765
Pop N.908.5 VA
Rivet 68.02 G1
Nut M8 765
Weld VAS852 x x
Studs 001/1
5 mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Weld VAS852 x AG. AUDI AG does
permitted unless authorised by AUDI x not guarantee or accept any liability
Studs 001/2 with respect to the correctness of information in this document. Copyright by AUDI AG.

4 mm

8.1 Rivet Overview in Repairs

⇒ S8.1.1 ide Accessible Rivets”, page 33
In production In repair To be used
Punch rivet, 3.3 Aluminum - Aluminum solid rivet: 4 mm
diameter Aluminum diameter
N.103.239.01
N.103.240.01
Punch rivet, 5.3 Aluminum - Aluminum solid rivet: 6 mm
diameter Aluminum diameter
N.107.440.01
N.107.441.01
Punch rivet, 3.3 Aluminum - Pop rivet: 4.8 mm diameter
diameter and Steel N.905.344.03
Friction elements rivet material strength: 1.5 -
3.5 mm
N.906.924.02
rivet material strength: 2.4 -
5.0 mm
Punch rivet, 5.3 Aluminum - Pop rivet: 6.5 mm
diameter and Steel WHT.005.413.A
if necessary Flow- rivet material strength: 3.35 -
drill bolts 5.35 mm
WHT.005.697
rivet material strength: 2.8 -
4.8 mm
N.911.527.01
rivet material strength: 4.5 -
7.0 mm
N.904.692.02
rivet material strength: 2.4 -
5.0 mm

8.1.1 One Side Accessible Rivets

– Remove the paint and oxide coating from the rivet head and
the connection point for the ground clamps.

8. Rivets and Tools Overview 33

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Bring the ground clamps as close as possible to the rivets.

– Weld on the Weld Studs -VAS852 001/1 or VAS852 001/2-
using the Miracle Alurepair Plus-System -VAS852 001-
specified by Audi AG.

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.

– Remove the Weld Studs -VAS852 001/1 or VAS852 001/2-

using Compact Riveting Device -VAS6792-.

8.2 Thread Repair for M6 Pop Rivet Nut

The repair bolt WHT.006.778. can be installed as a replace‐
ment if the self-tapping bolts WHT.002.605 or WHT.002.612.
are over-tightened or fail. The drilling and installing of the pop
rivet nuts are steps that have been omitted.

34 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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9 Body Structural Adhesive D 180 004

M2, Application
⇒ S9.1 urfaces, Preparing”, page 36

Bonded Joints, Detaching

Body bonded joints can be detached by applying heat. The
adhesives used in the vehicle construction and the repair are
destroyed at temperatures 180 – 200°C (356 to 392 °F).

Note

♦ Wear protective gloves and eyewear.

♦ Avoid direct contact of the adhesives with the skin.
♦ Avoid inhaling solvent vapors.
♦ Only process adhesives in well-ventilated areas.
♦ Always note the hazard information from the manufacturer.
♦ Also note the accident prevention regulations applicable in
the respective country.
♦ Note the corresponding safety data sheets for the adhesive.
♦ Do not smoke, eat or drink at the work station.
♦ Use suitable extraction.

• The vehicle, parts and adhesive materials must be at pro‐

cessing temperature (acclimated). The processing tempera‐
ture must be kept for 30 min before work on the adhesive
surfaces starts.
• The adhesive surfaces must be free of oils, adhesive resi‐
due, humidity, paint and oxide coatings.
• Body structural adhesive must only be used on bare metal
components.
• Only use sanding material based on silicon carbide (SIC) for
grinding down the adhesive surface.
• Pay attention that the cleaned surfaces are only touched
with clean gloves in order to avoid transferring hand sweat
or contamination to the adhesive surface.
• Merging must happen immediately after applying the adhe‐
sive, in order to ensure a high-quality and secure bonding.
Otherwise the adhesive bead must be removed and the
surface treatment and application of the adhesive must be
repeated.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Carefully prime the accessible adhesion areas
permitted unless after by
authorised harden‐
AUDI AG. AUDI AG does not guarantee or accept any liability

ing and seal them with body sealant. Protect adhesion areas
with respect to the correctness of information in this document. Copyright by AUDI AG.

in cavities against corrosion using cavity sealant.

9. Body Structural Adhesive D 180 004 M2, Application 35

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

♦ Use the adhesive material within the processing time. Within

this timeframe the adhesive material must be applied and
connected to the body component. Any resistance weld
spots or mechanical joining processes (for example rivets
and bolts) in the area of the adhesive must be performed
within this timeframe.
♦ Do not stress bonded parts until hardened.

Note

During colder seasons, over night or in countries with a cold

climate, suitable measures must be taken to reach the minimum
hardening temperature.

• Optimize the controls of the heating system, for example

deactivate reducing temperatures at night.
• Keep doors and windows closed, and prevent drafts.
• Install auxiliary heaters in the area of the body repair.
• In addition to these guidelines, mind the respective proce‐
dure descriptions for body repairs!

9.1 Adhesive Surfaces, Preparing

⇒ P9.1.1 rocess”, page 40
⇒ 9.1.2 , page 45
⇒ S9.1.3 tability”, page 46
⇒ P9.1.4 rotection”, page 46
⇒ S9.1.5 ample”, page 47

Pre cleaning
Remove solid layers like dirt, rust, paint coats (CDC).
Cleaning
• To prevent spreading possible grease residue when grinding
down afterwards, clean the adhesive surfaces with a lint-free
cloth, soaked with isopropyl alcohol or acetone. Allow the
cleaned surfaces to ventilate for 15 minutes.
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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.

36 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Grinding Down
To improve adhesion, grind down the adhesive surfaces with
grid 150 to 180 sandpaper. Use crossover griding process.
Only use sanding material based on silicon carbide (SIC) for
grinding down the adhesive surface.

9. Body Structural Adhesive D 180 004 M2, Application 37

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Cleaning

Note 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.
After the last cleaning procedure the adhesive must be applied
within four hours, to prevent contamination as well as the for‐
mation of an oxide coating on the aluminum material. Repeat
the preparations after four hours without application of the ad‐
hesive.

• Afterward clean the bare metal adhesive flange areas with a

lint-free cloth, soaked with isopropyl alcohol or acetone, until
no residue is visible on the cloth.
• Allow the cleaned surfaces to ventilate for 15 minutes, the
adhesive surfaces must be completely dry.

38 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Processing conditions
The ambient and material temperature when processing, must
be at least “minimum temperature 15 °C (59 °F)” and a most
“maximum temperature 35 °C (95 °F)”.
Higher processing temperatures reduce the processing time.
Processing time at 15 ° C (59 °F) 80 min
Processing time at 18 ° C (65 °F) 75 min
Processing time at 20 ° C (68 °F) 65 min
Processing time at 23 ° C (73 °F) 60 min
Processing time at 25 ° C (77 °F) 50 min
Processing time at 30 ° C (86 °F) 40 min
Processing time at 35 ° C (95 °F) 30 min

9. Body Structural Adhesive D 180 004 M2, Application 39

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

9.1.1 Joining Process

Note

♦ If the adhesive escapes on both sides along the entire length

of the joining area, too much was applied.
♦ 1 cartridge with 195 ml is enough for approximately 5 meters
of flange.

Adhesive cartridges must be used with plunger adhesive guns.

Tools
Prepare the Cartridge Gun -VAG1628- or -
Pneumatic Gun - 18 Bar -VAS6648- or -
Pneumatic Cartridge Gun -VAG1761/1- for seam sealing.
1 - Press out the adhesive without mixing tube, until both com‐
ponents exit the cartridge.
2 - Attach the mixing tube to the cartridge and check the exiting
adhesive.

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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.

40 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

3 - Pay attention that both components evenly mix in the mixing

tube.
4 - Before application to the joining area, apply a 10 to 20 cm
bead on a paper towel or similar and throw away later on. The
hardening process can also be checked with this bead.
5 - In addition, apply an approximately 10 cm long sample ad‐
hesive bead on a paper towel or similar.
Apply the adhesive.
Applying adhesive on both joining area flanges.

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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.

Spreading the adhesive flat on both joining area flanges with

clean tools. Application height 0.5 mm

9. Body Structural Adhesive D 180 004 M2, Application 41

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

• Locations uncoated with cataphoretic dip coating (CDC), or

bare metal locations in cavities must be painted or filled with
structural adhesive.
– Apply an additional adhesive bead to the center of the join‐
ing area.

42 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Connect the parts.

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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.

9. Body Structural Adhesive D 180 004 M2, Application 43

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Connecting the parts

Note

♦ The connection must happen immediately after applying the

adhesive, in order to ensure a high-quality and secure bond‐
ing.
♦ Otherwise the adhesive bead must be removed and the
surface treatment and application of the adhesive must be
repeated.
♦ The layer thickness of the adhesive after bonding must not
exceed 1 mm.

– Remove excess adhesive.

44 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Remove excess material with a clean towel.

Clean visible surfaces with a clean towel soaked in acetone.
Hardened material can only be removed mechanically.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

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

The body structural adhesive used hardens at temperatures

between a minimum of 18 °C (65 °F) and a maximum of 80 °C
(176 °F) .
The hardening process can be sped up by heat (for example an
infrared heater or in a paint booth).
Infrared heaters only heat up sections of the body and are thus
only suitable for small repairs.
Only use devices with a temperature setting, automatic distance
measuring and visualization of the measuring point.
Do not stress bonded parts until assembling stability is reached.

9. Body Structural Adhesive D 180 004 M2, Application 45

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

9.1.3 Assembling Stability

Note

♦ The temperature of the object must be above the minimum

temperature for hardening for the entire time.
♦ If the minimum temperature for hardening has not been kept
for the specified time, the waiting period must be prolonged
or additional heat must be applied to the adhesive bond.
♦ If the minimum temperature for hardening falls below signifi‐
cantly, this can lead to irreversible damages in the bonded
joint. This has a negative effect on the strength of the bon‐
ded joint.

Note

After the assembly stability has been reached the vehicle can
be lifted off the alignment system. Assembly work can be per‐
formed.

• Moving and further processing at the vehicle after repair

bonding is only allowed after a minimum curing time of 12 h
at 23 °C(73 °F).
The waiting period can be reduced by applying heat. For exam‐
ple , curing time at 60 °C (140 °F) 60 min.

Note

♦ The temperature of the object must be above the minimum

temperature for hardening for the entire time.
♦ If the minimum temperature for hardening has not been kept
for the specified time, the waiting period must be prolonged
or additional heat must be applied to the adhesive bond.
♦ If the minimum temperature for hardening falls below signifi‐
cantly, this can lead to irreversible damages in the bonded
joint. This has a negative effect
Protected by on the strength
copyright. of the
Copying for private bon‐ purposes, in part or in whole, is not
or commercial
ded joint. 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.

After this time the vehicle meets the crash requirements and
may be moved under traffic laws.
The vehicle can be handed over to the customer.
The time frame from connecting the repaired parts until opera‐
tion must be a minimum of 96 h at 18 °C. (65°F)

9.1.4 Corrosion Protection

Carefully prime the accessible adhesion areas after hardening
and seal them with body sealant.
Protect adhesion areas in cavities against corrosion using cavity
sealant.

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9.1.5 Work Sample

Note

A work sample must be created and checked to guarantee and

for verification of a correct bond. The result of this work sample
must be documented in the adhesive report. The creation of the
work sample is described in the processing instructions of the
adhesive.

• With a negative result of the working sample (no correct

hardening), no correct bonding can be ensured.
• In this case measures must be taken to ensure correct hard‐
ening, consult the adhesive supervisor or repeat the adhe‐
sion if necessary.
Check and evaluate the hardening of the work sample -1- after
reaching assembling stability by breaking the sample -arrow-.
The adhesive must break and contain no liquid or soft compo‐
nents.
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with respect to the correctness of information in this document. Copyright by AUDI AG.

• Document the test results in the adhesive reports.

9. Body Structural Adhesive D 180 004 M2, Application 47

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

10 Pneumatic Edge Milling Unit

VAS882 005, Application

Note

Note the attached operating instructions.

Delivery

1 - Toolbox
2 - Edge Milling Unit with Ma‐
chine Attachment
3 - Adjustment Gauge
4 - Pin Wrench
5 - Protective Cover
6 - Flat Head Milling Tool -
6mm VAS882 005/1
7 - Round Head Milling Tool -
6mm VAS882 005/2
8 - Flat Head Milling Tool -
6mm for Aluminum VAS882
005/3
9 - Spot Weld Breaker - Cut‐
ting Oil VAS882 001/5
10 - Drill Wax for Aluminum
Milling Tool

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

48 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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⇒ 10.1 , page 49
⇒ t10.2 he Milling Cutter”, page 51
⇒ F10.3 langes, Disconnecting”, page 61
⇒ S10.4 urface Panels, Separating”, page 67
⇒ E10.5 dges, Disconnecting”, page 70
⇒ R10.6 eplacing”, page 73
⇒ H10.7 ead Milling Cutter for Disconnecting Laser Weld
Seams”, page 75
⇒ P10.8 anels”, page 77

10.1 Basics

Note

♦ Always use a cutting oil VAS882 001/5 -1- during milling procedures on steel panels. This ensures that
there are no flying sparks,
♦ The service life of the milling tool will be prolonged.

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10. Pneumatic Edge Milling Unit VAS882 005, Application 49

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

♦ Always use the drill wax -1- during milling procedures on aluminum panels.
♦ This prevents the milling tool from clogging. The service life of the milling tool will be prolonged.

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Note

During front side procedures using the milling tool -2-, the protective cover -1- must be used.

50 Rep. Gr.00 - General, Technical Data

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10.2 Operation/Changing the Milling Cutter

Only install clean tools!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Before installing the authorised
permitted unless Machine Attachment
by AUDI AG. AUDI AG-1-, doesclean and or accept any liability
not guarantee
shavings from the thread. This is necessary to guarantee
with respect to the correctness of information in this document. Copyright by AUDI AG.

that the threads are not damaged.

10. Pneumatic Edge Milling Unit VAS882 005, Application 51

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Installing the tool:

– Loosen/tighten the threaded pin at the spindle using the pin
wrench -1-. Perform a test run for a minimum of 30 seconds
without load.

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52 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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Changing the Milling Cutter

– Remove the machine attachment including the nut -1- from
the machine -2-.

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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.

10. Pneumatic Edge Milling Unit VAS882 005, Application 53

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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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.

– Remove the machine attachment with the nut -1- from the
machine -2-.

54 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Open the mount using the 2.5 mm pin wrench -1-.

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10. Pneumatic Edge Milling Unit VAS882 005, Application 55

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the milling cutter -1-.

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56 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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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.

– To tension, align the surface of the milling cutter in direction

of the threaded pin.
Only in this position -A- the milling cutter -1- can be pushed all
the way into the mount, because in the inside -C- of the mount
the milling cutter is positioned by a threaded pin -B-.

10. Pneumatic Edge Milling Unit VAS882 005, Application 57

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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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.

– Insert a new milling cutter into the milling tool -2-. Push the
milling cutter -1- in all the way.

58 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Tighten
with the threaded
respect pin using
to the correctness the 2.5
of information in thismm pin wrench
document. Copyright by-1- toAG.
AUDI
secure the milling cutter in the milling tool -2-.

10. Pneumatic Edge Milling Unit VAS882 005, Application 59

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Attach the machine attachment by hand.

Note
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Lightly tighten thepermitted
lock nut -1-authorised
unless by hand. 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.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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10.3 Clinch Flanges, Disconnecting

Adjusting

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10. Pneumatic Edge Milling Unit VAS882 005, Application 61

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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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.

A - The milling cutter is preset to 0.8 mm to mill steal panels.

B - The milling cutter is preset to 1.2 mm to mill aluminum
panels.

Note

Screw the machine attachment all the way down and tighten the
lock nut!

Disconnect the clinch flanges.

– Position the Flat Head Milling Tool - 6mm VAS882 005/1
and work on the panel. The surface of the machine attach‐
ment, with the desired depth, is used as a guide and depth
setting.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Correct:
– Screw the attachment all the way down into the machine.
Tighten the lock nut -1- by hand to lock the machine attach‐
ment -2-.

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10. Pneumatic Edge Milling Unit VAS882 005, Application 63

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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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.

Incorrect:
– The machine attachment is NOT screwed down all the way.
The lock nut is NOT tightened.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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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.

• 90° to the wheel arch -A-, correct

• Direction of milling to the right
• At an angle to the wheel arch -B-, incorrect

10. Pneumatic Edge Milling Unit VAS882 005, Application 65

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• 90° to the wheel arch -A-, correct

• Direction of milling to the right
• At an angle to the wheel arch -B-, incorrect

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10.4 Curved/Flat Surface Panels, Separat‐

ing
Adjusting
Position the adjustment gauge -1- onto the surface of the ma‐
chine attachment -2-.
Align the desired depth via the flat head milling tool. Turn the
machine attachment. When the Flat Head Milling Tool - 6mm
VAS882 005/1 is contacting the gauge, then the milling depth is
set.

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10. Pneumatic Edge Milling Unit VAS882 005, Application 67

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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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.

With this setting, thick walled panels, for example longitudinal

members, can be separated.
– Adjust the mark on the machine attachment

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– Adjust the depth of the milling cutter using the gauge, pre‐
cisely guide the milling cutter with the contact surface of the
machine attachment over the panel.
– For tight a radius, set the milling cutter deeper in order to
better separate.

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10. Pneumatic Edge Milling Unit VAS882 005, Application 69

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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10.5 Outer Edges, Disconnecting

Fast and secure disconnection of outer edges.
♦ 1= marking on the attachment

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70 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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– During all applications and milling procedures performed in
the front area of the machine attachment the ensure direc‐
tion of milling towards the left.

10. Pneumatic Edge Milling Unit VAS882 005, Application 71

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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– The two level setting allows a precise guidance and depth

adjusted milling.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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Adjusting

10.6 Roof, Replacing

Roof Edges, Disconnecting
Adjusting
– Adjust the depth of the Flat Head Milling Tool - 6mm
VAS882 005/1.

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10. Pneumatic Edge Milling Unit VAS882 005, Application 73

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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– The top of the machine attachment allows a precise guid‐

ance of the Flat Head Milling Tool - 6mm VAS882 005/1
without damaging components below.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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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.

10.7 Round Head Milling Cutter for Discon‐

necting Laser Weld Seams
Adjusting
– Position the adjustment gauge -1- onto the surface of the
machine attachment. Align the desired depth via the Round
Head Milling Tool - 6mm VAS882 005/2. Turn the attach‐
ment. When the Round Head Milling Tool - 6mm VAS882
005/2 is contacting the gauge, then the milling depth at the
edge milling tool -2- is set.

10. Pneumatic Edge Milling Unit VAS882 005, Application 75

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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– Mill off the laser seam, this way panels can be disconnected
from each other.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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10.8 Aluminum Panels

Adjusting
– Adjust the marking at the attachment

10. Pneumatic Edge Milling Unit VAS882 005, Application 77

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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with respect to the correctness of information in this document. Copyright by AUDI AG.

Flat Head Milling Tool - 6mm for Aluminum VAS882 005/3

– With this setting, thick coated aluminum panels, for example
longitudinal members, can be separated.

78 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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10. Pneumatic Edge Milling Unit VAS882 005, Application 79

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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11 Body Dimensions

Note

Dimensions are only for checking. The alignment bracket set is

standard.

Special tools and workshop equipment required

♦ Measure the body dimension using the Telescoping Gauge
-VAS5160- or with the Telescoping Gauge VAS5159 -
VAS5159-

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80 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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12 Front Body, Sedan and Wagon

A - 1250 mm ± 2.0 mm
Distance between fender
mounts.

B - 1092 mm ± 2.0 mm
Diagonal dimension of sus‐
pension strut tower mounts.

C - 780 mm ± 2.0 mm
Distance for suspension strut
tower mounts.

C - 1130 mm ± 2.0 mm
Distance to the rear suspen‐
sion strut tower mount.

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12. Front Body, Sedan and Wagon 81

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

A - 1015 mm ± 2.0 mm
Distance between the impact
absorber mounts.

B - 853 mm ± 2.0 mm
Distance between the impact
absorber mounts.

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12.1 Center Body, Sedan and Wagon

⇒ F12.2 loor Assembly, Sedan and Avant”, page 84
⇒ F12.3 loor Assembly, Sedan and Avant”, page 85
⇒ B12.4 ody, Sedan”, page 86
⇒ B12.5 ody, Avant”, page 87

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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A - 1051 mm ± 2.0 mm
Distance between the A and
B-pillars.

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12. Front Body, Sedan and Wagon 83

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A - 850 mm ± 2.0 mm
Distance between the B- and
C-pillars

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12.2 Front Floor Assembly, Sedan and Avant

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A - 872 mm ± 2.0 mm
Distance between the sub‐
frame retainers.

B - 980 mm ± 2.0 mm
Diagonal dimension between
the subframe retainers

C - 752 mm ± 2.0 mm
Distance between the sub‐
frame retainers.

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12.3 Rear Floor Assembly, Sedan and Avant

12. Front Body, Sedan and Wagon 85

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A - 930 mm ± 2.0 mm
Distance between the rear
axle mounts

B - 1336 mm ± 2.0 mm
Diagonal dimension between
the longitudinal members and
the axle mounts

C - 922 mm ± 2.0 mm
Distance between rear longi‐
tudinal members.

12.4 Rear Body, Sedan

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A - 1050 mm ± 2.0 mm
Distance between longitudinal
members.

B - 1122 mm ± 2.0 mm
Distance between the tail
lamp mounts

C - 546 mm ± 2.0 mm
Distance between window
crossmember and upper rear
cross panel.

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12.5 Rear Body, Avant

12. Front Body, Sedan and Wagon 87

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

A - 946 mm ± 2.0 mm
Distance between window
crossmember and upper rear
cross panel.

B - 1164 mm ± 2.0 mm
Distance between the tail
lamp mounts

C - 1050 mm ± 2.0 mm
Distance between longitudinal
members.

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13 Bonded Joints
⇒ J13.1 oints”, page 89
⇒ B13.2 onded Joints”, page 89
⇒ J13.3 oints, Checking and Repairing”, page 89
⇒ M13.4 ethods for Partial Replacement”, page 90
The body of the Audi A4 features bonded joints and spot-wel‐
ded bonded joints for increased rigidity and strength.

13.1 Bonded Joints

In bonded joints, the sheet metal parts are only bonded by
adhesive.

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.

13.2 Spot-Welded Bonded Joints

In spot-welded bonded joints, an electrically conductive adhe‐
sive is used between the panels, which allows for welding
through without any problems.

The welding current must not be increased for spot-weld bond‐

ing. The pre-press period must be extended to approximately
30 - 50 cycles because of the displacement of the adhesive.
The fumes produced must be exhausted.
Spot-weld bonding is not performed as a service.

13.3 Bonded Joints, Checking and Repair‐

ing
Particular attention should be given to these areas when diag‐
nosing collision damage and servicing.
Note the following points: do not use a chisel to test the
strength of a joint and do not release the tension by hammering,
as this will destroy the bonded joint.

13. Bonded Joints 89

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

These areas should be inspected particularly closely when di‐

agnosing collision damage and after performing straightening
work.
If the area is not accessible with pop rivets, it must be re‐
paired with a gas-shielded weld seams. In this case, the entire
area must be welded again, as the heat produced by welding
destroys the bonded joint. The gas-shielded arc weld seams
should be welded working from the thinner to the thicker panel.
At the same time, the fumes must be ventilated.

13.4 Repair Methods for Partial Replace‐

ment
All spot-welded bonded joints and some bonded joints can be
replaced if a repair is required with welded joints.
Do not make the repair with only the same weld points and
seams as originally used in production, because these alone
are not adequate.
Ensure good weld penetration at all connections.
Seal off repaired flanges and apply cavity sealant.
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.

90 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

14 Tools
⇒ page 94
Special tools and workshop equipment required
♦ Resistance Spot Welder -VAS6239 A-
♦ Resistance Spot Welder -VAS6525-
♦ Resistance Spot Welder -VAS6530A-
♦ Resistance Spot Welder -VAS6535-
♦ Resistance Spot Welder -VAS6545A-
♦ Gas-Shielded Welder -VAS6044- or -VAS6045-
♦ Welding Unit -VAS2001C-
♦ Welding Emission Exhaust System -VAS892 003-
♦ Fume Extraction Swing Arm -VAS6571/1-
♦ FD Bolt Socket -VAS852007A-
♦ Flow Drill Socket Repair Set -VAS6631-
♦ Measuring and Alignment System -VAS6526- Basic
♦ Measuring and Alignment System - Professional -VAS6527-
♦ Measuring and Alignment System - Professional Plus -
VAS6528-
♦ Pneumatic Brush Grinder Set -VAS6446A-
♦ Drill - 1100 Watt -VAS6267A-
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
♦ Flat Blade Scraper with
-VAS5448-
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Pneumatic-Hydraulic Riveter Set -VAS6790-

♦ One-Handed Angle Grinder -VAS5167B-
♦ Double Cartridge Adhesive Gun -VAS5237-

14. Tools 91
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Telescoping Gauge - 41.5-92.5cm -VAS5159- or Telescop‐

ing Gauge - 92-260cm -VAS5160-

♦ Mechanical Door Brace -VAG1438-

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.

♦ Double Suction Lifter -VAG1344- or Installation Magnets -

VAS6739-

♦ Pop Rivet Pliers -VAG 1753B-

92 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Gauge - Gap Adjustment -3371-

♦ Tensioning Strap -T10038-

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.

♦ Pneumatic Jig Saw -VAS5108- or Body Saw -VAS6598- or

Pneumatic Body Saw -VAS6780-

♦ Spot-Weld Breaker -VAS6322 A- or

Rechargeable Riveter -VAS843 001-

14. Tools 93
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

14.1 Straightening Rack

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

♦ The item numbers in the illustrations are identical to the end

numbers on the alignment bracket mountings.
♦ The item numbers are circled for the alignment bracket
mountings for the body with and without the assemblies.
♦ The required basic set size is indicated for the alignment
bracket mountings.

Used together with the MZ Plus Straightening Bracket System

-VAS6630-.
Alignment Bracket Set Supplement Audi A4 2016 Alignment
Bracket -VAS801 025-
Audi A4 2016 Portal Gauge -VAS802 025-
– Refer to assembly plan supplied with alignment bracket set
for detailed information on the assembly.

94 Rep. Gr.00 - General, Technical Data

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

50 – Body Front
1 Safety Precautions
⇒ P2 recautions”, page 2

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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.

1. Safety Precautions 95
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 65 55 00

2 Impact Absorber Mount, Replacing

⇒ 2.1 , page 96
⇒ 2.2 , page 97

1 - Impact Absorber Mount

2 - Front Longitudinal Member

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.

2.1 Tools
Special tools and workshop equipment required
♦ Gas-Shielded Welder 250A
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

96 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

2.2 Procedure
Separating Points
– Loosen the original joint using the Spot Weld Breaker.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

2. Impact Absorber Mount, Replacing 97

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Impact Absorber Mount

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Fit and secure the new part on the vehicle using the Align‐
ment Bracket Set.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

98 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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. Impact Absorber Mount, Replacing 99

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 72 55 00

3 Longitudinal Member for Upper

Wheel Housing, Replacing Partial
Section
⇒ 3.1 , page 100
⇒ 3.2 , page 101

1 - Upper Wheel Housing

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

Longitudinal Member with respect to the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

❑ Upper Section
2 - Suspension Strut Tower
3 - Molded Foam Part
4 - A-Pillar Connection
5 - Separation Cut
6 - Upper Wheel Housing
Longitudinal Member
❑ Lower Section
7 - Front Wheel Housing

3.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill

100 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Only use the tools approved by Audi AG for performing repair

work correctly. Refer to ⇒ 14 , page 91 .

3.2 Procedure
– Perform the upper and lower separation cut offset to each
other using the Body Saw as shown, to reach the necessary
strength when welding.
– Loosen the original joint using the Spot Weld Breaker.

– Perform the upper and lower separation cut offset to each

other using the Body Saw as shown, to reach the necessary
strength when welding.
– Loosen the original joint using the Spot Weld Breaker.
– Remove the upper and lower section of the longitudinal
member for the wheel housing -1- together. 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.

3. Longitudinal Member for Upper Wheel Housing, Replacing Partial Section 101
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

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.

102 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part
♦ Longitudinal Member Upper Section for the Upper Wheel
Housing
♦ Longitudinal Member Lower Section
Protected for the
by copyright. Upper
Copying Wheel
for private or commercial purposes, in part or in whole, is not
Housing 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.
New Part, Preparing
– Transfer the separation cut to the new part.
– Cut the new parts with the Body Saw.
– Grind down the welding areas to bare metal.

3. Longitudinal Member for Upper Wheel Housing, Replacing Partial Section 103
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Fit the lower section of the longitudinal member for the
wheel housing -1- with the vehicle on the Alignment Bracket
Set and secure.
– Butt weld the separating cut with a gas-shielded arc continu‐
ous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

104 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Fit the upper section of the longitudinal member for the

wheel housing and secure.
– Butt weld the separating cut with a gas-shielded arc continu‐
ous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

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.

3. Longitudinal Member for Upper Wheel Housing, Replacing Partial Section 105
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

106 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 79 55 02

4 Front Longitudinal Member, Replac‐

ing Partial Section
⇒ 4.1 , page 107
⇒ 4.2 , page 108

1 - Inner Separation Cut

2 - Front Longitudinal Member
❑ Inner section
3 - Impact Absorber Mount
4 - Outer Separation Cut
5 - Longitudinal Member End
Panel
❑ Outer panel

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.

4.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

4. Front Longitudinal Member, Replacing Partial Section 107

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

4.2 Procedure
Separating Points
– Measure and mark the separation cut.
– Perform the separation cut as shown using the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.
♦ Dimension -a- = 200 mm.
♦ Dimension -b- = 170 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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

108 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Front Longitudinal Member - Sub-Partpermitted 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.
♦ Front Longitudinal Member End Panel - Sub-Part
♦ Impact Absorber Mount
New Part, Preparing
– Transfer the separation cut to the new part.
– Cut the new parts with the Body Saw.
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

4. Front Longitudinal Member, Replacing Partial Section 109

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
When using different types of steel and materials ofpermitted
different unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
strengths, one of the inverters listed below must be used to
with respect to the correctness of information in this document. Copyright by AUDI AG.

perform spot welding work correctly.

Welding
– Fit new parts to vehicle standing on Alignment Bracket Set
and secure.
– Check the fit with attachments.
– Butt weld the separating cut all around with a gas-shielded
arc continuous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

110 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

4. Front Longitudinal Member, Replacing Partial Section 111

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 72 55 00

5 Upper Wheel Housing Longitudinal

Member, Replacing
⇒ 5.1 , page 112
⇒ 5.2 , page 113

1 - Upper Wheel Housing

Longitudinal Member
❑ Upper Section
2 - Suspension Strut Tower
3 - A-Pillar Connection
4 - Upper Wheel Housing
Longitudinal Member
❑ Lower Section
5 - Front Wheel Housing

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.

5.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

112 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

5.2 Procedure
Separating Points
– Loosen the original joint using the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.

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.

– Loosen the original joint with the Rechargeable Riveter

-VAS843 001- or Pneumatic-Hydraulic Riveter - Booster -
VAS6790/20-. Use the Punch Insert to do so.
– Loosen the original joint using the Spot Weld Breaker.

5. Upper Wheel Housing Longitudinal Member, Replacing 113

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Loosen the original joint with the Rechargeable Riveter

-VAS843 001- or Pneumatic-Hydraulic Riveter - Booster -
VAS6790/20-. Use the Punch Insert to do so.
– Loosen the original joint using the Spot Weld Breaker.

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.

114 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

Be careful not to damage the hood release cable when separat‐

ing the longitudinal member.

– Remove the remaining material using the One-Handed An‐

gle Grinder.

5. Upper Wheel Housing Longitudinal Member, Replacing 115

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Longitudinal Member Upper Section for the Upper Wheel
Housing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Longitudinal Member Lower Section for the Upper Wheel
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Housing with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ End Plate
♦ Body Structural Adhesive -D 180 004 M2-
New Parts, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

116 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Apply Body Structural Adhesive to the entire riveted area
using the Compressed Air Glue Gun. Refer to ⇒ S9 tructural
Adhesive D 180 004 M2, Application”, page 35 .

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. Upper Wheel Housing Longitudinal Member, Replacing 117

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– FitProtected
and secure theCopying
by copyright. new part onorthe
for private vehicle
commercial usingin the
purposes, part orAlign‐
in whole, is not
ment Bracket
permitted Set. by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
– Drill 7.0 mm diameter holes for the Pop Rivets -6.5 mm- at
the punch rivet positions using a Drill.
– Rivet the new part with Pop Rivets -6.5 mm-. Use the Re‐
chargeable Riveter - VAS843 001- or Pneumatic-Hydraulic
Riveter - Booster -VAS6790/20- to do so.

118 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the new part with a Resistance Spot Welder using a

straight-line spot weld seam.
– Drill 7.0 mm diameter holes for the Pop Rivets -6.5 mm- at
the punch rivet positions using a Drill.
– Rivet the new part with Pop Rivets -6.5 mm-. Use the Re‐
chargeable Riveter - VAS843 001- or Pneumatic-Hydraulic
Riveter - Booster -VAS6790/20- to do so.

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. Upper Wheel Housing Longitudinal Member, Replacing 119

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Fit and secure the new parts.

– Check the fit with attachments.
– Weld the new part with a Resistance Spot Welder using a
straight-line spot weld seam. 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
– Weld the new part with a Gas-Shielded Welder using a gas-
with respect to the correctness of information in this document. Copyright by AUDI AG.

shielded arc plug weld seam.

120 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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. Upper Wheel Housing Longitudinal Member, Replacing 121

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 74 55 04

6 Front Longitudinal Member with

Suspension Strut Tower, Replacing
⇒ 6.1 , page 122
⇒ 6.2 , page 123

1 - Suspension Strut Tower

2 - Reinforcements on the A-
Pillar
3 - Outer Footwell Crossmem‐
ber
4 - Front Longitudinal Member
❑ Ultra high-strength hot
formed steel
❑ Rear section
5 - Front Wheel Housing
6 - Front Longitudinal Member
❑ Front section 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.

6.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
♦ Rechargeable Riveter

122 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Pneumatic Glue Gun

♦ Pneumatic-Hydraulic Riveter Set
♦ Punch Insert
♦ Rechargeable Rivet Gun Supplementary Set
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

6.2 Procedure
• Upper wheel housing longitudinal member is already re‐
moved. Refer to ⇒ W5 heel Housing Longitudinal Member,
Replacing”, page 112 .

Note

It is not permitted to perform any repair or reshaping work on

the front of the Audi A4, because there is the danger that there
may be cracks in the aluminum cast parts, which are not visible.

Separating Points
– Loosen the original joint with the Rechargeable Riveter
-VAS843 001- or Pneumatic-Hydraulic Riveter - Booster -
VAS6790/20-. Use the Punch Insert to do so.
– Loosen the original joint using the Spot Weld Breaker.

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. Front Longitudinal Member with Suspension Strut Tower, Replacing 123

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Loosen the original joint with the Rechargeable Riveter

-VAS843 001- or Pneumatic-Hydraulic Riveter - Booster -
VAS6790/20-. Use the Punch Insert to do so.
– Loosen the original joint using the Spot Weld Breaker.

124 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

6. Front Longitudinal Member with Suspension Strut Tower, Replacing 125

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Longitudinal Member with Suspension Strut Tower
♦ Body Structural Adhesive -D 180 004 M2-
New Parts, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

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.

126 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Drill 8 mm holes for the gas-shielded arc plug weld seam

using a Drill.

6. Front Longitudinal Member with Suspension Strut Tower, Replacing 127

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Apply Body Structural Adhesive to the entire riveted area
using the Compressed Air Glue Gun. Refer to ⇒ S9 tructural
Adhesive D 180 004 M2, Application”, page 35 .

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.

128 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Fit and secure the new part on the vehicle using the Align‐
ment Bracket Set.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
– Drill the holes for the Pop Rivets -WHT 005 413 A- at the
positions of the punch rivet using the Drill 7.0 mm diameter.
– Rivet the new part using the Pneumatic-Hydraulic Riveter -
Booster -VAS6790/20 - Pop Rivets -WHT 005 413 A-.

6. Front Longitudinal Member with Suspension Strut Tower, Replacing 129

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
– Drill the holes for the Pop Rivets -WHT 005 413 A- at the
positions of the punch rivet using the Drill 7.0 mm diameter.
– Rivet the new part using Pneumatic-Hydraulic Riveter -
Booster -VAS6790/20- Pop Rivets -WHT 005 413 A-.

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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.

130 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Longitudinal member for upper wheel housing already re‐

moved. Refer to ⇒ W5 heel Housing Longitudinal Member,
Replacing”, page 112 .

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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.

6. Front Longitudinal Member with Suspension Strut Tower, Replacing 131

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 74 55 04

7 Front Longitudinal Member, Replac‐

ing
⇒ 7.1 , page 132
⇒ 7.2 , page 133

Note

Before replacing the longitudinal member, use the Crack Detec‐

tion Kit -VAG2014- to check if the suspension strut tower is
damaged, otherwise this must be replaced with it.

1 - Front Longitudinal Member

2 - Plenum Chamber
3 - Suspension Strut Tower

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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.

7.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder

132 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ One-Handed Angle Grinder

♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

7.2 Procedure
– Roughly cut out the longitudinal member using the Pneumat‐
ic Body Saw.
– Loosen the original joint using a Spot Weld Breaker.
– Remove the inner longitudinal member.

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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.

– Loosen the original joint with the Rechargeable Rivet‐

er -VAS843 001- or Pneumatic-Hydraulic Riveter Set -
VAS6790-.
– Loosen the original joint using a Spot Weld Breaker.
– Loosen the longitudinal member with the One-Handed Angle
Grinder.

7. Front Longitudinal Member, Replacing 133

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Parts
♦ Longitudinal Member with Reinforcements
♦ End Plate
♦ Impact Absorber Mount
♦ Molded Foam Part
♦ Pop Rivet -WHT 005 413 A-
♦ Body Structural Adhesive -D 180 004 M2-
New Part, Preparing
– Insert the longitudinal member with the Alignment Set - Audi
A4 2016> -VAS801 025- and mark the holes for the gas-
shielded arc plug weld seam and rivet connection.
– Remove the section.

134 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Drill 8 mm holes for the gas-shielded arc plug weld seam

using a Drill.
– Use the One-Handed Angle Grinder to grind the contact
surface for the Pop Rivets -WHT 005 413 A-.

7. Front Longitudinal Member, Replacing 135

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Apply Body Structural Adhesive to the entire riveted area

using the Compressed Air Glue Gun. Refer to ⇒ S9 tructural
Adhesive D 180 004 M2, Application”, page 35 .

136 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Drill 7.0 mm holes for the Pop Rivets -WHT 005 413 A-
using the Drill.
– Rivet the new part using the Pop Rivets -WHT 005 413
A-. To do so, use the Pneumatic-Hydraulic Riveter Set -
VAS6790-.

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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.

7. Front Longitudinal Member, Replacing 137

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Weld the longitudinal member with a gas-shielded arc plug
weld seam using the Gas-Shielded Welder.
– Weld the longitudinal member with a straight-line spot weld
seam using a Resistance Spot Welder.

138 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Weld the longitudinal member with a gas-shielded arc plug

weld seam using the Gas-Shielded Welder.
– Drill 7.0 mm holes for the Pop Rivets -WHT 005 413 A-
using the Drill.

7. Front Longitudinal Member, Replacing 139

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

140 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 81 55 00

8 Upper Footwell Crossmember, Re‐

placing
⇒ 8.1 , page 141
⇒ 8.2 , page 142

1 - Upper Footwell Cross‐

member
2 - Bulkhead
3 - A-Pillar Reinforcement
4 - Floor Panel
5 - Tunnel
6 - Floor Panel
7 - A-Pillar Reinforcement

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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.

8.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

8. Upper Footwell Crossmember, Replacing 141

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

8.2 Procedure
Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Loosen the center tunnel in the area -1-.
– Remove the crossmember footwell upward.

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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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

142 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Upper Footwell Crossmember
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill. 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
– Grind down the welding areas towith
bare metal.
respect to the correctness of information in this document. Copyright by AUDI AG.

8. Upper Footwell Crossmember, Replacing 143

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Fit and secure the new part.
– Align the center tunnel in the area -1-.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

144 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

8. Upper Footwell Crossmember, Replacing 145

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 50 79 49 50

9 Threads on Subframe Fastener,

Servicing
⇒ 9.1 , page 146

• The subframe is removed. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40; Subframe, Stabilizer Bar and Control
Arm

Note

The thread repair on this vehicle is described for example on

the front mount for the subframe. It is identical for the other
mounts.

9.1 Tools
Special tools and workshop equipment required
♦ Thread Repair Kit M12x1.5 -VAS6058A- 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
♦ Pneumatic Brush Grinder Set with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Drill
♦ One-Handed Angle Grinder
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

146 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Threaded Plate (Welded in

Subframe)

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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.

Note

The threaded plate is not a re‐

placement part and can only be
serviced one time if damaged.

2 - Heli-Coil Insert

Thread Repair Set Contents

9. Threads on Subframe Fastener, Servicing 147

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - 12.5 mm Spiral Bit

2 - M12 x 1.5 Thread Tap
3 - Installation Spindle
4 - M12 x 1.5 x 24 Threaded
Insert (HeliCoil Plus - Thread
Inserts -VAS6058/1-)
5 - Tang Break-Off Tool with
Magnetic Tip

Thread, Servicing
Thread, Drilling
– Drill out the threads using the spiral bit.

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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.

148 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

♦ Use the Drill - 1100 Watt -VAS6297A- for drilling and grinding.
♦ When drilling, the drill must be held by a second technician using an additional handle.
♦ Do not tilt the drill.

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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.

9. Threads on Subframe Fastener, Servicing 149

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Threads, Cutting
– Cut the threads with the thread tap. 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.

150 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Threaded Insert, Inserting

– Turn the threaded insert -3- onto the installation spindle until
the driving pin -2- makes contact on the drive tab -1- of
installation spindle.

– Clean the threaded bushing (blow with compressed air).

Note

The threaded insert must be able to turn easily.

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
– Screwwith
therespect
threaded insert into
to the correctness the threaded
of information plate
in this document. until the
Copyright by AUDI AG.
threaded insert is flush with the outside of the threaded plate
(visual inspection).

9. Threads on Subframe Fastener, Servicing 151

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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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.

– Install the subframe (tightening specifications). Refer to

⇒ Suspension, Wheels, Steering; Rep. Gr. 40; Subframe,
Stabilizer Bar and Control Arm.

152 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

10 Special Tools
Special tools and workshop equipment required
♦ Rechargeable Riveter - Accessory Set 1 -VAS5279/1-

♦ Pneumatic Jig Saw -VAS5108- or Body Saw VAS6598 -

VAS6598- or Pneumatic Body Saw -VAS6780-

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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.

♦ One-Handed Angle Grinder VAS5167B -VAS5167B-

♦ Gas-Shielded Welder 195A -VAS6044A- or Gas-Shielded
Welder -VAS6045A-
♦ Gas-Shielded Welder -VAS6045A-
♦ Thread Repair Kit M12x1.5 -VAS6058-
♦ Resistance Spot Welder -VAS6239A- or Resistance Spot
Welder -VAS6525- or Resistance Spot Welder -VAS6530A-
or Resistance Spot Welder -VAS6535- or Resistance Spot
Welder -VAS6545A-
♦ Drill - 1100 Watt -VAS6267A-

10. Special Tools 153

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Spot-Weld Breaker -VAS6322A- or Spot Weld Breaker -

VAS882001-

♦ Pneumatic Brush Grinder Set -VAS6446A-

♦ Pneumatic Body Saw -VAS6780-
♦ Pneumatic-Hydraulic Riveter - Booster -VAS6790/20-
♦ Rechargeable Riveter -VAS843001-

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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.

154 Rep. Gr.50 - Body Front

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

51 – Body Center, Chassis, Roof

1 Safety Precautions
⇒ P2 recautions”, page 2

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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.

1. Safety Precautions 155

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

2 Permitted Separation Cuts on Entire

Sidewall

Note

♦ Only use welding tools approved by Audi AG.

♦ Gas-shielded arc continuous weld seams are permitted on
the separation cuts shown.

Sedan

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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.

Avant

156 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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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.

2. Permitted Separation Cuts on Entire Sidewall 157

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 03 55 00

3 Roof, Replacing, Sedan

⇒ 3.1 , page 158
⇒ 3.2 , page 159
⇒ w3.3 ith Sliding/Tilting Sunroof”, page 177
⇒ 3.4 , page 178
⇒ 3.5 , page 179

1 - Roof
2 - Bonded Area
3 - Separation Cut

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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.

3.1 Tools
Special tools and workshop equipment required
♦ Gauge - Gap Adjustment
♦ One-Handed Angle Grinder
♦ Pneumatic Brush Grinder Set
♦ Body Saw
♦ Locking Pliers, 18-18

158 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Tensioning Strap
♦ Pneumatic Glue Gun
♦ Double Cartridge Adhesive Gun
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

1 - Two-Part Window Adhe‐

sive -D 004 660 M2-
– Open the seal.

2 - Static Mixer
3 - Extension Hose
Part no. 000 809 937

– Attach it on the stat‐

ic mixer -2-using the
adapter -4-.

4 - Adapter

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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.

Note

The adapter is needed for the Two-

Part Window Adhesive.

3.2 Procedure
Separating Points

Note

To prevent damage and contaminants tape off the roof pillar

with adhesive tape.

3. Roof, Replacing, Sedan 159

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Roughly cut out the roof using a Body Saw at a distance of

approximately 30 mm parallel to the Plasmatron seam -1-.
– Loosen the original joint using a Spot Weld Breaker.
– Cut through the adhesive between the roof and roof cross‐
members from the vehicle interior using the Window Cutter
-VAG1561 A-.

Note

♦ When removing the remaining material on roof, make sure

that side connections (side panel or side wall frame) are not
damaged.
♦ Do not use any cutting and grinding discs.
♦ Remove all adhesive residue and sealant residue on the
front and rear roof crossmembers.
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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.
– Cut the remainder of the roof using Tin Snips.
– Use pliers to grab the remainders and break them off from
the Plasmatron seam by moving them back and forth.

160 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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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.

Note

♦ Do not damage the roof pillars when removing the remaining

roof material.
♦ Do not use cutting or grinding discs; use a lamellar disc
instead.

– Remove any excess adhesive and sealant on the front and

rear roof crossmembers.
– Remove the remaining material using the One-Handed An‐
gle Grinder.

3. Roof, Replacing, Sedan 161

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Roof
♦ One-Part Assembly Adhesive -D 190 MKD A3-, 3 cartridge
sets
♦ Glass/Paint Primer -D 009 200 02-
♦ Two-Part Window Adhesive -D 004 660 M2-
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Body Structural Adhesive -D 180 004 M2-
with respect to the correctness of information in this document. Copyright by AUDI AG.

New Part, Preparing

Instructions for Using the Extension Hose for Window Adhesive
– Remove the static mixer from the window adhesive set.

162 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the front cap of the static mixer.

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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.

3. Roof, Replacing, Sedan 163

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Drill a 9 mm opening in the static mixer -a- using a Protected

Drill. 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.

164 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Shorten the inner part of the mixer in order to be able to

install the hose completely.

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.

3. Roof, Replacing, Sedan 165

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Attach the extension hose to the mixer.

166 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Applying
– Place the roof on the roof frame and check the roof align‐
ment to the roof pillars (visual inspection).
– Check the roof fit.
– Remove the roof.
– Tape off the outside of the roof parallel to the side adhesion
area with adhesive tape.
– Apply the Glass/Paint Primer -D 009 200 02- in the roof
frame area -A-.

3. Roof, Replacing, Sedan 167

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Sand the left and right adhesive areas on the roof and on the
roof reinforcement, as well as the welding areas on the roof
crossmembers down to the bare metal.
This will ensure that the Body Structural Adhesive forms a good
bond to the adhesion area.

168 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Tape off the outside of the roof parallel to the side adhesion
area with adhesive tape.
– Position four Double Suction Lifters -VAG1344- or Installa‐
tion Magnets -VAS6739- on the outside of the roof.
– Clean the roof frame, the roof reinforcement and the roof
with Cleaning Solution -D 009 401 04-.
– Apply the Glass/Paint Primer -D 009 200 02- approximately
5 cm -b- wide on the inside of the roof and on the inner side
flange -a-.

3. Roof, Replacing, Sedan 169

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– For the corresponding bead geometry, cut off approximately

2 mm from the nozzle -B-.

– Apply the One-Part Assembly Adhesive -D 190 MKD A3-

using the Pneumatic Cartridge Gun -V.A.G 1761/1- onto the
roof crossmember in the area where it was bonded at the
factory.

170 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

New Part, Preparing

– Apply two continuous adhesive beads of Body Structural
Adhesive using the Compressed Air Glue Gun on the bevels
of the roof pillars in the area of the zero gap. Refer to ⇒
S9 tructural Adhesive D 180 004 M2, Application”, page 35 .

3. Roof, Replacing, Sedan 171

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Apply a continuous adhesive bead of Body Structural Adhe‐

sive using the Compressed Air Glue Gun on the roof side
flanges. Refer to ⇒ S9 tructural Adhesive D 180 004 M2,
Application”, page 35 .

172 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Mount the roof immediately and align it.

– Secure the roof using the Mole Grips 18-18 -VAS5430/1-.
Roof Depth Dimension, Adjusting
– Secure the roof also with two Tensioning Straps -T10038-
-1-.
– Adjust the depth dimension using a drill bit or a piece of
wood for example -2-.
Depth dimension for the area center front door -a = 3.0 mm -
Depth dimension for the area center rear door -a = 2.5 mm-

3. Roof, Replacing, Sedan 173

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Also weld the roof with a gas-shielded arc continuous weld
seam using the Gas-Shielded Welder.
– Grind down the gas shielded arc continuous weld seams
with a One-Handed Angle Grinder.
– Weld the roof with a straight-line spot weld seam using the
Resistance Spot Welder.

174 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Grind the right and left zero gap -1- to form.

3. Roof, Replacing, Sedan 175

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

Follow the processing instructions. Process the window adhe‐

sive at approximately 20 °C.

– Apply one cartridge of Two-Part Window Adhesive -DA004

660 M2- -3- into each roof pillar using the Double Cartridge
Gun -VAS5237-.
♦ 1 = Body Structural Adhesive -D 180 004 M2-
♦ 2 = Glass/Paint Primer -D 009 200 02-
♦ 3 = Two-Part Window Adhesive -D 004 660 M2-

176 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 03 55 02
3.3 Vehicles with Sliding/Tilting Sunroof

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.

3. Roof, Replacing, Sedan 177

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Roof
2 - Plasmatron Seam
3 - Bonded Area

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.

3.4 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ Drill
♦ One-Handed Angle Grinder
♦ Pneumatic Glue Gun
♦ Double Cartridge Adhesive Gun
♦ Locking Pliers, 18-18
♦ Body Saw
♦ Spot Weld Breaker
♦ Tensioning Strap
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

178 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

3.5 Procedure
Separating Points
– Loosen the original joint using a Spot Weld Breaker.
– Roughly cut out the roof using a Body Saw at a distance of
approximately 30 mm parallel to the Plasmatron seam -1-.
– Cut through the adhesive between the roof and roof cross‐
members from the vehicle interior using the Window Cutter
-VAG1561 A-.

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.

Note

Be careful not to damage the roof pillars with cutting and when moving the remaining parts of the roof up and
down.

– Cut the remainder of the roof using Tin Snips.

– Use pliers to grab the remainders and break them off from
the Plasmatron seam by moving them back and forth.

3. Roof, Replacing, Sedan 179

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
Be careful not to damage the roof frame when removing the
remaining material on the roof frame.
Do not use any cutting or grinding discs.

180 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Sliding/Tilting Sunroof
♦ Cleaning Solution -D.009.401.04- 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
♦ Two-Part Window Adhesive -D 004 660 M2-, (three cartridge
with respect to the correctness of information in this document. Copyright by AUDI AG.
sets)
♦ Glass/Paint Primer -D 009 200 02-
♦ One-Part Assembly Adhesive -D 190 MKD A3-,1 cartridge
♦ Body Structural Adhesive -D 180 004 M2-

Note

♦ To ensure a proper and long-lasting roof repair, always fol‐

low the procedure exactly.
♦ Adhesion area must not be coated with primer before adher‐
ing the roof.

– Sand the left and right adhesive areas on the roof and on the
roof reinforcement, as well as the welding areas on the roof
crossmembers down to the bare metal.

3. Roof, Replacing, Sedan 181

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Apply One-Part Assembly Adhesive -D 190 MKD A3- with

Pneumatic Cartridge Gun -VAG1761/1- on the roof frame.

182 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Apply a continuous adhesive bead -1- and -2- of Body Struc‐

tural Adhesive using the Compressed Air Glue Gun onto the
roof pillars. Refer to ⇒ S9 tructural Adhesive D 180 004 M2,
Application”, page 35 .

3. Roof, Replacing, Sedan 183

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Apply a continuous adhesive bead of Body Structural Adhe‐

sive using the Compressed Air Glue Gun on the roof side
flange -1-. Refer to ⇒ S9 tructural Adhesive D 180 004 M2,
Application”, page 35 .

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.

184 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Position four Double Suction Lifters -VAG1344- or Installa‐

tion Magnets -VAS6739- on the outside of the roof.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Mount the roof permitted
immediately and align it.
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.

– Secure the roof using the Mole Grips 18-18 -VAS5430/1-.

Roof Depth Dimension, Adjusting
– Secure the roof also with two Tensioning Straps -T10038-
-1-.
– Adjust the depth dimension using a drill bit or a piece of
wood for example -2-.
Depth dimension for the area center front door -a = 3.0 mm -
Depth dimension for the area center rear door -a = 2.5 mm-

3. Roof, Replacing, Sedan 185

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

Let the adhesion area on the roof harden for 60 minutes using a
radiant heater at approximately 65 to 80 °C. Always monitor the
temperature with a temperature sensor.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Weld the roof with a straight-line spot weld seam using the
Resistance Spot Welder.

186 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Also weld the roof with a gas-shielded arc continuous weld

seam using the Gas-Shielded Welder.
– Grind down the gas shielded arc continuous weld seams
with a One-Handed Angle Grinder.

3. Roof, Replacing, Sedan 187

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the reinforcement frame on the inner side panel 4 x 15

mm with gas-shielded arc continuous weld seam using the
Gas-Shielded Welder.

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.

188 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Grind the right and left zero gap -1- to form.

3. Roof, Replacing, Sedan 189

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Apply one cartridge of Two-Part Window Adhesive -DA004

660 M2- -3- into each roof pillar using the Double Cartridge
Gun -VAS5237-.
♦ 1 = Body Structural Adhesive -D 180 004 M2-
♦ 2 = Glass/Paint Primer -D 009 200 02-
♦ 3 = Two-Part Window Adhesive -D 004 660 M2-

190 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

3. Roof, Replacing, Sedan 191

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 03 55 12

4 Vehicles with Sliding/Tilting Sunroof,

Avant
⇒ 4.1 , page 192
⇒ 4.2 , page 193

1 - Roof
2 - Plasmatron Seam
3 - Bonded Area

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.

4.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Locking Pliers, 18-18
♦ Tensioning Strap
♦ Body Saw
♦ Spot Weld Breaker

192 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Pneumatic Glue Gun

♦ Double Cartridge Adhesive Gun
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

4.2 Procedure
Separating Points
– Roughly cut out the roof using a Body Saw at a distance of
approximately 30 mm parallel to the Plasmatron seam -1-.
– Loosen the original joint using a Spot Weld Breaker.
– Cut through the adhesive between the roof and roof cross‐
members from the vehicle interior using the Window Cutter
-VAG1561 A-.

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.

Note

Be careful not to damage the roof pillars with cutting and when moving the remaining parts of the roof up and
down.

4. Vehicles with Sliding/Tilting Sunroof, Avant 193

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Cut the remainder of the roof using Tin Snips.

– Use pliers to grab the remainders and break them off from
the Plasmatron seam by moving them back and forth.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
Be careful not to damage the roof frame when removing the
remaining material on the roof frame.
Do not use any cutting or grinding discs.

194 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Large Roof
♦ One-Part Assembly Adhesive -D 190 MKD A3-, one car‐
tridge
♦ Body Structural Adhesive -D 180 004 M2-
♦ Cleaning Solution -D 009 401 04-
♦ Glass/Paint Primer -D 009 200 02-
♦ Two-Part Window Adhesive -D 004 660 M2-
New Part, Preparing

Note

♦ To ensure a proper and long-lasting roof repair, always fol‐

low the procedure exactly.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Adhesion areas must not permitted

be treated
with respect towith filler before
the correctness bond‐
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
of information in this document. Copyright by AUDI AG.
ing in roof center section.

– Apply One-Part Assembly Adhesive -D 190 MKD A3- with

Pneumatic Cartridge Gun -VAG1761/1- on the roof frame.

4. Vehicles with Sliding/Tilting Sunroof, Avant 195

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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

– Apply a continuous adhesive bead of Body Structural Adhe‐

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

sive using the Compressed Air Glue Gun on the roof side
flange -1-. Refer to ⇒ S9 tructural Adhesive D 180 004 M2,
Application”, page 35 .

196 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Position four Double Suction Lifters -VAG1344- or Installa‐

tion Magnets -VAS6739- on the outside of the roof.
– Mount the roof immediately and align it.
– Secure the roof with a screw inside the centering hole in the
windshield flange and in the rear lid sealing flange.
– Secure the roof on the windshield opening and on the rear
lid opening using the Mole Grips 18-18 -VAS5430/1-.
Roof Depth Dimension, Adjusting
– Secure the roof also with two Tensioning Straps -T10038-
-1-.
– Adjust the depth dimension using a drill bit or a piece of
wood for example -2-.
Depth dimension for the area center front door -a = 3.0 mm -
Depth dimension for the area center rear door -a = 2.5 mm-

4. Vehicles with Sliding/Tilting Sunroof, Avant 197

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

Let the adhesion area on the roof harden for 60 minutes using a
radiant heater at approximately 65 to 80 °C. Always monitor the
temperature with a temperature sensor.

Note

When using different types of steel and materialspermitted

of different
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
strengths, one of the inverters listed below must be
withused
respectto
to the correctness of information in this document. Copyright by AUDI AG.
perform spot welding work correctly.

Welding
– Spot weld the roof with a straight-line spot weld seam using
the Resistance Spot Welder.

198 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Also weld the front part of the roof in with a gas-shielded arc
continuous weld seam using the Gas-Shielded Welder.
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.

4. Vehicles with Sliding/Tilting Sunroof, Avant 199

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Weld the reinforcement frame on the inner side panel 8 x 15

mm with gas-shielded arc continuous weld seam using the
Gas-Shielded Welder.

200 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Grind the right and left zero gap -1- to form.

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.

4. Vehicles with Sliding/Tilting Sunroof, Avant 201

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

♦ After bonding the joint, the vehicle must be left standing for
8 hours on a level surface at a room temperature of 15 °C to
allow the adhesive components to harden (curing time).
♦ Further work may only be performed on the vehicle after the
curing time has passed.

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.

202 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 03 55 02

5 Roof, Replacing (Avant)

⇒ 5.1 , page 203
⇒ 5.2 , page 209

1 - Roof
2 - Plasmatron Seam
3 - Bonded Area

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.

5.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ Drill
♦ Pneumatic Glue Gun
♦ Double Cartridge Adhesive Gun
♦ Suction Lifter or Magnet
♦ Gauge - Gap Adjustment
♦ Body Saw

5. Roof, Replacing (Avant) 203

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Spot Weld Breaker

♦ Locking Pliers, 18-18
♦ Tensioning Strap
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

1 - Two-Part Window Adhe‐

sive -D 004 660 M2-
– Open the seal.

2 - StaticProtected
Mixer by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Extension Hoseto the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect

Part no. 000 809 937

– Attach it on the stat‐

ic mixer -2- using the
adapter -4-.

4 - Adapter

Note

The adapter is needed for the Two-

Part Window Adhesive.

Instructions for Using the Extension Hose for Window Adhesive

– Remove the static mixer from the window adhesive set.

204 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the front cap of the static mixer.

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. Roof, Replacing (Avant) 205

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Drill a 9 mm opening in the static mixer -a- using a Drill.

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.

206 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Shorten the inner part of the mixer in order to be able to

install the hose completely.

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. Roof, Replacing (Avant) 207

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Attach the extension hose to the mixer.

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.

208 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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

Separating Points
– Roughly cut out the roof using a Body Saw at a distance of
approximately 30 mm parallel to the Plasmatron seam -1-.
– Drill out the original joint for the windshield and rear lid open‐
ings using a Spot Weld Breaker.
– Cut through the adhesive between the roof and roof cross‐
members from the vehicle interior using the Window Cutter
-VAG1561 A-.

5. Roof, Replacing (Avant) 209

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

Be careful not to damage the roof pillars with cutting and when
moving the remaining parts of the roof up and down.

– Cut the remainder of the roof using Tin Snips.

– Use pliers to grab the remainders and break them off from
the Plasmatron seam by moving them back and forth.

210 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

♦ When removing the remaining roof material -2-, do not dam‐

age the roof pillars -1-.
♦ Do not use cutting or grinding discs; use a lamellar disc
instead.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Remove all adhesive residue and unless
sealing compound from
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
the front and rear roof crossmembers
with respect tousing a FlatofBlade
the correctness information in this document. Copyright by AUDI AG.
Scraper.
– Grind the adhesive surfaces down to bare metal.

5. Roof, Replacing (Avant) 211

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Roof
♦ One-Part Assembly Adhesive -D 190 MKD A3-,1 cartridge
♦ Cleaning Solution -D 009 401 04-
♦ Two-Part Window Adhesive -D 004 660 M2-, 5 cartridge sets
♦ Glass/Paint Primer -D 009 200 02-
♦ Body Structural Adhesive -D 180 004 M2-
New Part, Preparing
Applying
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.
– Place the roof on the roof frame and check the roof align‐
ment to the roof pillars (visual inspection).
– Check the roof fit with the rear lid and the windshield.
– Secure the roof with a metal screw in the windshield flange
and in the rear lid sealing flange.
– Remove the roof.
– Apply the Glass/Paint Primer -D 009 200 02- in the roof
frame area -a-.

212 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Sand the left and right adhesive

Protected by areas
[Link] the for
Copying roof and
private on the purposes, in part or in whole, is not
or commercial
roof reinforcement, as well as the
permitted welding
unless authorisedareas
by AUDI on
AG. the
AUDI roof
AG does not guarantee or accept any liability
crossmembers down to the withbare metal.
respect to the correctness of information in this document. Copyright by AUDI AG.

– Grind the outer sides of the welding flange on the openings

for the windshield and rear lid down to the bare metal.

5. Roof, Replacing (Avant) 213

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Tape off the outside of the roof parallel to the side adhesion
area with adhesive tape.
– Position four Double Suction Lifters -VAG1344- or Installa‐
tion Magnets -VAS6739- on the outside of the roof.
– Clean the roof frame, the roof reinforcement and the roof
with Cleaning Solution -D 009 401 04-.
– Apply the Glass/Paint Primer -D 009 200 02- approximately
5 cm -b- wide on the inside of the roof and on the inner side
flange -a-.

214 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– For the corresponding bead geometry, cut off approximately

2 mm from the nozzle -B-.

– Apply the One-Part Assembly Adhesive -D 190 MKD A3-

using the Pneumatic Cartridge Gun -V.A.G 1761/1- onto the
roof crossmember in the area where it was bonded at the
factory.

5. Roof, Replacing (Avant) 215

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Apply two continuous adhesive beads of Body Structural

Adhesive using the Compressed Air Glue Gun on the bevels
of the roof pillars in the area of the zero gap. Refer to ⇒
S9 tructural Adhesive D 180 004 M2, Application”, page 35 .

216 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Apply a continuous adhesive bead of Body Structural Adhe‐

sive using the Compressed Air Glue Gun on the roof side
flanges. Refer to ⇒ S9 tructural Adhesive D 180 004 M2,
Application”, page 35 .

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. Roof, Replacing (Avant) 217

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Mount the roof immediately and align it.

– Secure the roof using the Mole Grips 18-18 -VAS5430/1-.
Roof Depth Dimension, Adjusting
– Secure the roof also with two Tensioning Straps -T10038-
-1-.
– Adjust the depth dimension using a drill bit or a piece of
wood for example -2-.
Depth dimension for the area center front door -a = 3.0 mm -
Depth dimension for the area center rear door -a = 2.5 mm-

218 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Roughly spread any leaking Body Structural Adhesive at the

roof edge.

Note

Let the adhesion area on the roof harden for 60 minutes using a
radiant heater at approximately 65 to 80 °C. Always monitor the
temperature with a temperature sensor.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Weld in the new part with a straight-line spot weld seam
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

using the ResistancewithSpot

respectWelder.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information in this document. Copyright by AUDI AG.

5. Roof, Replacing (Avant) 219

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Also weld the roof with a gas-shielded arc continuous weld

seam using the Gas-Shielded Welder.
– Grind down the gas shielded arc continuous weld seams
with a One-Handed Angle Grinder.

220 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Grind the right and left zero gap -1- to form.

5. Roof, Replacing (Avant) 221

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

Follow the processing instructions. Process the window adhe‐

sive at approximately 20 °C.

– Apply one cartridge of Two-Part Window Adhesive -DA004

660 M2- -3- into each roof pillar using the Double Cartridge
Gun -VAS5237-.
♦ 1 = Body Structural Adhesive -D 180 004 M2-
♦ 2 = Glass/Paint Primer -D 009 200 02-
♦ 3 = Two-Part Window Adhesive -D 004 660 M2-

222 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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. Roof, Replacing (Avant) 223

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 07 55 50

6 Front Roof Crossmember, Replac‐

ing
⇒ 6.1 , page 224
⇒ 6.2 , page 225

1 - Right Side Wall Frame

2 - Front Roof Crossmember
3 - Left Side Wall Frame

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.

6.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

224 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

6.2 Procedure
• Roof already removed. Refer to ⇒ R3 eplacing, Sedan”,
page 158 .
• Roof already removed. Refer to ⇒ w3.3 ith Sliding/Tilting
Sunroof”, page 177 .
• Roof already removed. Refer to ⇒ R5 eplacing (Avant)”,
page 203 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

6. Front Roof Crossmember, Replacing 225

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Front Roof Crossmember

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Fit and secure the new part.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Instead of the bonded joint applied during production weld
the roof crossmember with a Gas-Shielded Welder left and
right every 2 x 20 mm using gas-shielded arc continuous
weld seam.

226 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.
• Install the roof. Refer to ⇒ R3 eplacing, Sedan”, page 158 .
• Install the roof. Refer to ⇒ w3.3 ith Sliding/Tilting Sunroof”,
page 177 .
• Install the roof. Refer to ⇒ R5 eplacing (Avant)”, page 203 .

6. Front Roof Crossmember, Replacing 227

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 05 55 50

7 Roof Pillar, Replacing, Sedan

⇒ 7.1 , page 228
⇒ 7.2 , page 229

1 - A-Pillar Separation Cut

2 - Roof Pillar
3 - B-Pillar Separation Cut
4 - C-Pillar Separation Cut
5 - Molded Foam Part
6 - D-Pillar Separation Cut
7 - Molded Foam Part

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.

7.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

228 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

7.2 Procedure
• Roof already removed. Refer to ⇒ R3 eplacing, Sedan”,
page 158 .
• Roof already removed. Refer to ⇒ w3.3 ith Sliding/Tilting
Sunroof”, page 177 .
Separating Points
Permitted Separation Cuts on Entire Sidewall. Refer to ⇒
S2 eparation Cuts on Entire Sidewall”, page 156 .
– Make the separation cuts according to the degree of dam‐
age with the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.

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.

– Loosen the original joint using the Spot Weld Breaker.

7. Roof Pillar, Replacing, Sedan 229

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

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.

230 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part
♦ Side Panel
New Part,
Protected Preparing
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
–withTransfer
respect to thethe separation
correctness cutsin to
of information this the newCopyright
document. part. by AUDI AG.
– Cut the new part with the Body Saw.

7. Roof Pillar, Replacing, Sedan 231

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Fit and secure the new part.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Butt weld the separating cuts with a gas-shielded arc contin‐
uous weld seam using a Gas-Shielded Welder.

232 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Butt weld the separating cuts with a gas-shielded arc contin‐

uous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

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.

7. Roof Pillar, Replacing, Sedan 233

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

• Install the roof. Refer to ⇒ R3 eplacing, Sedan”, page 158 .

• Install the roof. Refer to ⇒ w3.3 ith Sliding/Tilting Sunroof”,
page 177 .

234 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 09 55 50

8 Rear Roof Crossmember, Replac‐

ing, Sedan
⇒ 8.1 , page 235
⇒ 8.2 , page 236

1 - Left Roof Frame Connec‐

tion
2 - Roof Crossmember
3 - Right Roof Frame Connec‐
tion

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.

8.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

8. Rear Roof Crossmember, Replacing, Sedan 235

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

8.2 Procedure
• Roof already removed. Refer to ⇒ R3 eplacing, Sedan”,
page 158 .
• Roof already removed. Refer to ⇒ w3.3 ith Sliding/Tilting
Sunroof”, page 177 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

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.

236 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Protected
Rear Roof Crossmember
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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Fit and secure the new part.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Instead of the bonded joint applied during production weld
the roof crossmember with a Gas-Shielded Welder left and
right every 2 x 10 mm using gas-shielded arc continuous
weld seam.

8. Rear Roof Crossmember, Replacing, Sedan 237

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

• Install the roof. Refer to ⇒ R3 eplacing, Sedan”, page 158 .

• Install the roof. Refer to ⇒ w3.3 ith Sliding/Tilting Sunroof”,
page 177 .

238 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 09 55 60

9 Rear Roof Crossmember, Replac‐

ing, Avant
⇒ 9.1 , page 239
⇒ 9.2 , page 240

1 - Roof Crossmember
2 - Right Roof Frame Connec‐
tion
3 - Left Roof Frame Connec‐
tion

9.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
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

♦ One-Handed Angle Grinder

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

♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

9. Rear Roof Crossmember, Replacing, Avant 239

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

9.2 Procedure
• Roof already removed. Refer to ⇒ R5 eplacing (Avant)”,
page 203 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.

– Perform the separation cuts as shown using the Body Saw.

At the same time do not damage the connection to the right
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

and left roof frame.

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.

240 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the remaining material using the One-Handed An‐

gle byGrinder.
Protected 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
– withGrind
respectdown the welding
to the correctness areas
of information to document.
in this bare metal.
Copyright by AUDI AG.

9. Rear Roof Crossmember, Replacing, Avant 241

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Parts
♦ Upper Rear Roof Crossmember
♦ Lower Rear Roof Crossmember
New Part, Preparing
– Transfer the separation cuts to the new part.
– Cut the new part with the Body Saw.

242 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Fit and secure the new part.
– Butt weld the separating cut with a gas-shielded arc continu‐
ous weld seam using a Gas-Shielded Welder.

9. Rear Roof Crossmember, Replacing, Avant 243

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Fit and secure the upper rear roof frame.

– Check the fit with the roof.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a Gas-Shielded Welder using 2 x 10
mm gas-shielded arc continuous weld seam (staggered).

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

• Install the roof. Refer to ⇒ R5 eplacing (Avant)”, page 203 .

9. Rear Roof Crossmember, Replacing, Avant 245

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 05 55 60

10 Roof Pillar, Replacing, Avant

⇒ 10.1 , page 246
⇒ 10.2 , page 247

1 - A-Pillar Separation Cut

2 - Roof Pillar
3 - D-Pillar Separation Cut
4 - Molded Foam Parts
5 - C-Pillar Separation Cut
6 - B-Pillar Separation Cut

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.

10.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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10.2 Procedure
• Roof already removed. Refer to ⇒ R5 eplacing (Avant)”,
page 203 .
Separating Points
– Make the separation cuts according to the degree of dam‐
age with the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.

– Make the separation cuts according to the degree of dam‐

age with the Body Saw.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Loosen the original joint using the Spot Weld Breaker.
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.

10. Roof Pillar, Replacing, Avant 247

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

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.

248 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Side Panel
New Part, Preparing
– Transfer the separation cuts to the new part.
– Cut the new part with the Body Saw.
– Grind down the welding areas to bare metal.

10. Roof Pillar, Replacing, Avant 249

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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.
– Fit and secure the new part.
– Butt weld the separating cuts with a gas-shielded arc contin‐
uous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

250 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Butt weld the separating cuts with a gas-shielded arc contin‐

uous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

10. Roof Pillar, Replacing, Avant 251

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Install the roof. Refer to ⇒ R5 eplacing (Avant)”, page 203 .

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.

252 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 37 55 02

11 Outer A-Pillar, Replacing

⇒ 11.1 , page 253
⇒ 11.2 , page 254

1 - Outer A-pillar
2 - Upper Separation Cut
3 - Side Sill Separation Cut
4 - Separation Cut (Partial
Replacement)
Partial renewal
With this separation cut, a
partial replacement of the A-
pillar is possible.
5 - Separation Cut (Partial
Replacement)
Partial renewal
With this separation cut, a
partial replacement of the A-
pillar is possible.
6 - Separation Cut (Partial
Replacement)
Partial renewal
With this separation cut, a
partial replacement of the A-
pillar is possible.

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.
11.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ Drill
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

11. Outer A-Pillar, Replacing 253

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

11.2 Procedure
Separating Points

Note

If the inner A-pillar is also being replaced, then the separation

cut -1- (dimension -a- = 120 mm) from the edge of the roof must
be made.

– Make the separating cut on the outer A-pillar according to

dimension -1- and loosen using the Body Saw.
Dimension -a- = 80 mm
– Separate the outer A-pillar separation cut -2- using the Body
Saw.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ A-Pillar Sub-Part 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.

New Part, Preparing

– Transfer the separation cuts to the new part and cut with a
Body Saw.
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using the Drill.

11. Outer A-Pillar, Replacing 255

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Butt weld the separation cuts with a gas-shielded arc contin‐
uous weld seam using the Gas-Shielded Welder.
– Weld the A-pillar with a straight-line spot weld seam using a
Resistance Spot Welder.
– Weld the A-pillar with a gas-shielded arc plug weld seam
using the Gas-Shielded Welder.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

11. Outer A-Pillar, Replacing 257

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 38 55 50

12 Inner A-Pillar, Replacing

⇒ 12.1 , page 258
⇒ 12.2 , page 259

1 - Inner A-Pillar
2 - Inner Side Sill

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.

12.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ Drill
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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12.2 Procedure
• Outer A-pillar already removed. Refer to ⇒ A11 -Pillar, Re‐
placing”, page 253 .
• Upper inner A-pillar already removed. Refer to ⇒ I13 nner
A-Pillar, Replacing, Partial Replacement”, page 264 .
• Upper longitudinal member already removed. Refer to ⇒
M3 ember for Upper Wheel Housing, Replacing Partial Sec‐
tion”, page 100 .
Separating Points
– Loosen the original joint using a Spot Weld Breaker.

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.

Partial renewal
To prevent the removal of the upper A-pillar a separation cut
can be made here.
– Perform the separating cut using the Pneumatic Body Saw
as shown.
– Loosen the original joint using the Spot Weld Breaker.

12. Inner A-Pillar, Replacing 259

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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
– Remove the remaining material using the One-Handed An‐
with respect to the correctness of information in this document. Copyright by AUDI AG.
gle Grinder.

260 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Parts
♦ A-Pillar Reinforcement
New Part, Preparing
– Drill the 7 mm diameter holes for the gas-shielded arc plug
weld seam using a Drill.

12. Inner A-Pillar, Replacing 261

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Weld the inner A-pillar reinforcement with a straight-line spot
weld seam using a Resistance Spot Welder
– Weld in the inner A-pillar reinforcement with a gas-shielded
arc plug weld seam using the Gas-Shielded Welder.

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 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Outer A-Pillar, Welding. Refer to ⇒ A11 -Pillar, Replacing”,

page 253 .
• Upper Inner A-Pillar, Welding. Refer to ⇒ I13 nner A-Pillar,
Replacing, Partial Replacement”,
Protected page
by copyright. Copying 264 or
for private . commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Upper Longitudinal
withMember,
respect to theWelding.
correctness ofRefer to in⇒this
information M3 emberCopyright by AUDI AG.
document.
for Upper Wheel Housing, Replacing Partial Section”, page
100 .

12. Inner A-Pillar, Replacing 263

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RO: 51 38 55 52

13 Upper Inner A-Pillar, Replacing,

Partial Replacement
⇒ 13.1 , page 264
⇒ 13.2 , page 265

1 - Upper Inner A-Pillar

2 - Inner A-Pillar Separation
Cut 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
3 - Side Wall Frame with respect to the correctness of information in this document. Copyright by AUDI AG.

13.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ Drill
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

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13.2 Procedure
• Outer A-pillar cut out. Refer to ⇒ A11 -Pillar, Replacing”,
page 253 .
Separating Points
– Make the separation cut on the outer A-pillar according to
dimension -a- and loosen using the Body Saw.
Dimension -a- = 150 mm
– Loosen the original joint using a Spot Weld Breaker.

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.

– Make the separation cut on the inner A-pillar according to

dimension -a- and separate using the One-Handed Angle
Grinder.
Dimension -a- = 100 mm
– Loosen the original joint using a Spot Weld Breaker.

13. Upper Inner A-Pillar, Replacing, Partial Replacement 265

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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
– Maintain the dimension -a- on the inner cover plate and
with respect to the correctness of information in this document. Copyright by AUDI AG.

separate using the One-Handed Angle Grinder.

Dimension -a- = 310 mm
– Loosen the original joint using a Spot Weld Breaker.

266 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.

13. Upper Inner A-Pillar, Replacing, Partial Replacement 267

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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

Upper Inner A-Pillar

Inner A-Pillar Cover Plate
New Part, Preparing
– Transfer the separation cut from the inner A-pillar onto the
new part and cut using the Body Saw.
– The separating cut -a- -a = 140 mm- for the double patch
panel must be maintained.

268 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Drill 8 mm holes for the gas-shielded arc plug weld seam

using the Drill.
– Grind down the welded area for the gas-shielded arc contin‐
uous weld seam using a One-Handed Angle Grinder.
– Grind the inner A-pillar double patch panel -140 mm- with
One-Handed Angle Grinder.
– Drill 12 8 mm diameter holes for the inner A-pillar double
patch panel for the gas-shielded arc plug weld seam using
the Drill.

13. Upper Inner A-Pillar, Replacing, Partial Replacement 269

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform spot welding work correctly.

Welding
– Weld the separation cut on the inner A-pillar cover plate from
the inside to the outside with a gas-shielded arc continuous
weld seam using Gas-Shielded Welder.
– Weld the unless
innerauthorised
A-pillarby lower
AUDI [Link] plate with a gas-shielded
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted AUDI AG does not guarantee or accept any liability
arc plug weldto seam
with respect usingof the
the correctness Gas-Shielded
information Welder.
in this document. Copyright by AUDI AG.

270 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Weld the separation cut on the inner A-pillar from the inside
to the outside with a gas-shielded arc continuous weld seam
using Gas-Shielded Welder.
– Weld the inner A-pillar with a gas-shielded arc plug weld
seam using the Gas-Shielded Welder.

13. Upper Inner A-Pillar, Replacing, Partial Replacement 271

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Weld the double patch panel with Gas-Shielded Welder on

both sides with six gas-shielded arc plug weld seams.

272 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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• Outer A-Pillar, Welding. Refer to ⇒ A11 -Pillar, Replacing”,

page 253 .

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.

13. Upper Inner A-Pillar, Replacing, Partial Replacement 273

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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RO: 51 41 55 52

14 Outer B-Pillar, Replacing

⇒ 14.1 , page 274
⇒ 14.2 , page 275

1 - B-Pillar
Outer B-Pillar

2 - Upper Separation Cut

3 - Lower Separation Cuts
Partial renewal
A partial replacement is possi‐
ble with this separation cut.
4 - Rear Side Sill
5 - Rear Side Sill Separation
Cut
6 - Front Side Sill Separation
Cut
7 - Front Side Sill
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.

14.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

274 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
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14.2 Procedure
Separating Points

Note

Partial replacement is possible with the separation cut -3-.

– Drill out the original joint using the Spot Weld Breaker.
– Make the separation cuts according to the degree of dam‐
age with the Body Saw.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.

14. Outer B-Pillar, Replacing 275

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ B-Pillar Sub-Part
New Part, Preparing
– Transfer the separation cuts to the new part and cut with a
Body Saw.

276 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Check the fit with attachments.
– Weld the B-pillar with a straight-line spot weld seam using
the Resistance Spot Welder.

14. Outer B-Pillar, Replacing 277

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the separation cuts with a gas-shielded arc continuous

weld seam using the Gas-Shielded Welder.

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.

278 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

14. Outer B-Pillar, Replacing 279

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51425552

15 Inner B-Pillar, Replacing, Partial Re‐

placement
⇒ 15.1 , page 280
⇒ 15.2 , page 281

1 - Front Side Sill

2 - Front Side Sill Separation
Cut
3 - B-Pillar Separation Cut
Dimension -a- = 80 mm

4 - Outer B-Pillar
5 - Rear Side Sill
6 - Rear Side Sill Separation
Cut

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.

15.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ Pneumatic Brush Grinder Set
♦ One-Handed Angle Grinder
♦ Mechanical Door Brace
♦ Body Saw
♦ Spot Weld Breaker

280 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

15.2 Procedure
Separating Points

Note

Insert the Mechanical Door Brace -VAG1438- into the door

openings before cutting the inner B-pillar so that the roof cannot
change its position.

Note

A separation cut is only permitted at the described location.

– Make the separation cut on the B-pillar according to the

dimension -a- using the One-Handed Angle Grinder.
Dimension -a- = 80 mm
– Loosen the original joint using a Spot Weld Breaker.
– Make the separation cuts on the side sill as shown using the
Body Saw.

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.

15. Inner B-Pillar, Replacing, Partial Replacement 281

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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
– Loosen the lower B-pillar original joint on the inner side sill
with respect to the correctness of information in this document. Copyright by AUDI AG.

using the Spot Weld Breaker.

282 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Loosen the end plate inner original joint with the Spot Weld
Breaker.

15. Inner B-Pillar, Replacing, Partial Replacement 283

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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

A separation cut is only permitted at the described location.

– Loosen the original joint using a Spot Weld Breaker.

– Make the separation cut on the outer B-pillar according to
dimension -a- using the Body Saw.
Dimension -a- = 10 mm

284 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Make the separation cut on the inner B-pillar according to

dimension -a- and loosen using One-Handed Angle Grinder.
Dimension -a- = 5 mm

15. Inner B-Pillar, Replacing, Partial Replacement 285

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remainder using the One-Handed Angle Grind‐

er.
– Grin the area on the separation cut to bare metal.

286 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Parts
♦ Inner B-Pillar
♦ B-Pillar Reinforcement
♦ End Plate
New Part, Preparing
– Transfer the separation cut to the new part and separate
with a One-Handed Angle Grinder.
– Grind the separation cut area from the inside and outside
down to the bare metal using the One-Handed Angle Grind‐
er.
– Drill 25 8 mm holes for the gas-shielded arc plug weld seam
using the Drill as shown.
– Prepare the flange for welding to the new part.

15. Inner B-Pillar, Replacing, Partial Replacement 287

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Transfer the separation cut to the new part and separate

with a One-Handed Angle Grinder.
– Prepare the flange for welding to the new part.
– Grind the welding surfaces down to bare metal.

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.

288 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Spot weld the inner B-pillar using the Resistance Spot Weld‐
er.

15. Inner B-Pillar, Replacing, Partial Replacement 289

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld in the striker using a Resistance Spot Welder with a

straight-line spot weld seam.

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.

290 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Drill the inner B-pillar and reinforcement holes for the gas-
shielded arc plug weld seam using a Drill.

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.

15. Inner B-Pillar, Replacing, Partial Replacement 291

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Weld the inner B-pillar from the inside to the outside with
a gas-shielded arc continuous weld seam using a Gas-Shiel‐
ded Welder.
– Weld the outer upper and lower B-pillar with a gas-shielded
arc plug weld seam using the Gas-Shielded Welder.

292 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld in the lower B-pillar separating cut with a gas-shielded

arc continuous weld seam using the Gas-Shielded Welder.

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.

15. Inner B-Pillar, Replacing, Partial Replacement 293

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the inner lower B-pillar with a gas-shielded arc plug

weld seam using the Gas-Shielded Welder.
– Additionally weld in the inner B-pillar with a gas-shielded arc
continuous weld seam using the Gas-Shielded Welder.

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.

294 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the inner end plate with a gas-shielded arc continuous

weld seam using a Gas-Shielded Welder.
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.

15. Inner B-Pillar, Replacing, Partial Replacement 295

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Replace the outer B-pillar. Refer to ⇒ B14 -Pillar, Replacing”,

page 274 .

296 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 46 55 01

16 Front Seat Crossmember, Replac‐

ing
⇒ 16.1 , page 297
⇒ 16.2 , page 298

Note

♦ If a thread in the seat cross member is damaged, the com‐

ponent must be replaced.
♦ The following information
Protected by [Link]
Copying forto the orleft
private side ofpurposes,
commercial the vehi‐
in part or in whole, is not
cle. The right sideunless
permitted of the vehicle
authorised is identical.
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.

1 - Front Seat Crossmember

2 - Center Tunnel
3 - Floor Panel
4 - Inner Side Sill

16.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder

16. Front Seat Crossmember, Replacing 297

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Gas-Shielded Welder
♦ Pneumatic Brush Grinder Set
♦ One-Handed Angle Grinder
♦ Drill
♦ Spot Weld Breaker
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

16.2 Procedure
Separating Points
– Loosen the original joint using the Spot Weld Breaker.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

298 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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

♦ Front Seat Crossmember

New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

16. Front Seat Crossmember, Replacing 299

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Welding

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

– Fit and secure the new part.

– Check the fit with attachments.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

300 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

16. Front Seat Crossmember, Replacing 301

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 46 55 02

17 Rear Seat Crossmember, Replacing

⇒ 17.1 , page 302
⇒ 17.2 , page 303

Note

♦ If a thread in the seat cross member is damaged, the com‐

ponent must be replaced.
♦ The following information applies to the left side of the vehi‐
cle. The right side of the vehicle is identical. 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.

1 - Rear Seat Crossmember

2 - Center Tunnel
3 - Floor Panel
4 - Inner Side Sill

17.1 Tools
Special tools and workshop equipment required
♦ Gas-Shielded Welder
♦ Pneumatic Brush Grinder Set

302 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Spot Weld Breaker

♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

17.2 Procedure
Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Remove the seat mount reinforcement -1- and -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
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Loosen the original joint using the Spot Weld Breaker.

17. Rear Seat Crossmember, Replacing 303

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– RemoveProtected
the remaining
by [Link] usingor the
Copying for private One-Handed
commercial An‐or in whole, is not
purposes, in part
gle Grinder.
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.
– Grind down the welding areas to bare metal.

304 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Rear Seat Crossmember
New Parts, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using the Drill.
– Apply a layer of Body Structural Adhesive 4 mm thick to
the surface using the Compressed Air Glue Gun. Refer to ⇒
S9 tructural Adhesive D 180 004 M2, Application”, page 35 .

17. Rear Seat Crossmember, Replacing 305

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Noteunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
with respect to the correctness of information in this document. Copyright by AUDI AG.

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the fit with attachments.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

306 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

17. Rear Seat Crossmember, Replacing 307

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 45 55 50

18 Outer Side Sill, Replacing

⇒ 18.1 , page 308
⇒ 18.2 , page 309

1 - A-Pillar Separation Cut

2 - B-Pillar Separation Cut
3 - Wheel Arch Separation
Cut
4 - Bonded Area
5 - Molded Foam Part
6 - Outer Side Sill
7 - Rear Side Sill Separation
Cut
Partial renewal
Partial replacement is possi‐
ble with the designated sepa‐
ration cut.
8 - Front Side Sill Separation
Cut
Partial renewal
Partial replacement is possi‐
ble with the designated sepa‐
ration cut.

18.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder 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

♦ Pneumatic Brush Grinder Set

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

♦ Flat Chisel
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill

308 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Pneumatic Glue Gun

For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

18.2 Procedure
Separating Points
Permitted Separation Cuts on Entire Sidewall. Refer to ⇒
S2 eparation Cuts on Entire Sidewall”, page 156 .
Partial renewal
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Partial replacement is possible with the designated separating
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

cuts -1-.
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Make the separation cuts according to the degree of dam‐

age with the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.
– Grind down the outer edge of the wheel arch using a One-
Handed Angle Grinder.

– Remove the remaining material using the One-Handed An‐

gle Grinder.

18. Outer Side Sill, Replacing 309

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Completely remove any remaining adhesive and grind the

adhesive surfaces down to bare metal.
– Grind down the welding areas to bare metal.

Replacement Parts
♦ Side Panel
♦ Body Structural Adhesive -D 180 004 M2-
New Part, Preparing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– permitted
Transfer the separation cuts to the new part.
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.
– Cut the new part with the Body Saw.
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the welding areas to bare metal.

310 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Insert the molded foam part -1-. Refer to ⇒ F6.5 oam

Pieces”, page 23 .
– Place the same material on the separating points.
– Apply Body Structural Adhesive to the area that was bonded
during production using the Compressed Air Gun. Refer to ⇒
S9 tructural Adhesive D 180 004 M2, Application”, page 35 .

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.

18. Outer Side Sill, Replacing 311

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the fit with adjacent components.
– Butt weld the separating cuts with a gas-shielded arc contin‐
uous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
– Apply the bead over the bonded area -1-.
Partial renewal
Butt weld the separation cuts -2- with a gas-shielded arc contin‐
uous weld seam using the Gas-Shielded Welder.

312 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

18. Outer Side Sill, Replacing 313

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 47 55 50

19 Inner Side Sill, Replacing

⇒ 19.1 , page 314
⇒ 19.2 , page 315

1 - A-Pillar
2 - Inner Side Sill
3 - B-Pillar Reinforcement
4 - C-Pillar Reinforcement
5 - Separation Cut
Partial renewal
Partial replacement is possi‐
ble with the designated sepa‐
ration cut.
6 - Molded Foam Part
7 - Separation Cut
Partial renewal
Partial replacement is possi‐
ble with the designated sepa‐
ration cut.
8 - Separation Cut
Partial renewal
Partial replacement is possi‐
ble with the designated sepa‐
ration cut.

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.

19.1 Tools
Special tools and workshop equipment required
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

314 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

19.2 Procedure
• The sedan side panel partial section is already removed.
Refer to ⇒ P10 anel, Replacing, Sedan”, page 377 .
• The avant side panel partial section is already removed.
Refer to ⇒ P11 anel, Replacing (Avant)”, page 387 .
• The outer side sill is already removed. Refer to ⇒ S18 ide
Sill, Replacing”, page 308 .
• The outer A-pillar is already removed. Refer to ⇒ A11 -Pillar,
Replacing”, page 253 .
• The inner A-pillar partial section is already removed. Refer to
⇒ A12 -Pillar, Replacing”, page 258 .
• The C-pillar reinforcement partial section is already re‐
moved. Refer to ⇒ R12 einforcement, Replacing, Sedan and
Avant are Identical”, page 396 .
• The inner B-pillar partial section is already removed. Refer to
⇒ B15 -Pillar, Replacing, Partial Replacement”, page 280 .
Separating Points
To prevent the removal of the upper A-pillar a separation cut
can be made here.
– Perform the separating cut using the Pneumatic Body Saw
as shown.
– Loosen the original joint using the Spot Weld Breaker.

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.

19. Inner Side Sill, Replacing 315

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Position the separation cut parallel to the side sill fillet plate
and perform with the Body Saw.
Partial renewal
Make the separation cuts according to the degree of damage
with the Body Saw.

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.

316 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

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.

19. Inner Side Sill, Replacing 317

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Inner Side Sill
New Part, Preparing
Partial renewal
Transfer the separation cuts to the new part.
Cut the new part with the Body Saw.

318 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the fit with adjacent components.
– Weld the new part with a Gas-Shielded Welder from above
and below using the gas-shielded arc continuous weld seam
(staggered) (fillet weld).
Partial renewal
Weld the separation cuts with a gas-shielded arc continuous
weld seam using the Gas-Shielded Welder.

19. Inner Side Sill, Replacing 319

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Inner A-pillars, Installing. Refer to ⇒ A12 -Pillar, Replacing”,

page 258 .
• Outer A-Pillar, Installing. Refer to ⇒ A11 -Pillar, Replacing”,
page 253 .
• C-Pillar Reinforcement, Installing. Refer to ⇒ R12 einforce‐
ment, Replacing, Sedan and Avant are Identical”, page 396 .
• Outer Side Sill, Installing. Refer to ⇒ S18 ide Sill, Replacing”,
page 308 .
• Side Panel Partial Section, Installing. Refer to ⇒ P10 anel,
Replacing, Sedan”, page 377 .
• Side Panel Partial Section, Installing. Refer to ⇒ P11 anel,
Replacing (Avant)”, page 387 .
• Inner B-pillar partial section is already installed. Refer to ⇒
B15 -Pillar, Replacing, Partial Replacement”, page 280 .
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.

320 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 51 73 55 05

20 Center Tunnel, Replacing

⇒ 20.1 , page 321
⇒ 20.2 , page 322

1 - Center Tunnel
❑ With ultra high-strength
steel (hot formed)
2 - Upper Footwell Cross‐
member
3 - Right Longitudinal Member
4 - Right Front Seat Cross‐
member Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Right Rear Seat Cross‐
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.
member
6 - Seat Crossmember of the
Rear Bench Seat
7 - Left Rear Seat Crossmem‐
ber
8 - Left Front Seat Cross‐
member
9 - Left Longitudinal Member

20.1 Tools
Special tools and workshop equipment required
♦ Gas-Shielded Welder
♦ Pneumatic Brush Grinder Set
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

20. Center Tunnel, Replacing 321

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

20.2 Procedure
• The front seat crossmember is already removed. Refer to ⇒
S16 eat Crossmember, Replacing”, page 297 .
• The rear seat crossmember is already removed. Refer to ⇒
S17 eat Crossmember, Replacing”, page 302 .
• The footwell crossmember is already removed. Refer to ⇒
F8 ootwell Crossmember, Replacing”, page 141 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.

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.

– Loosen the original joint using the Spot Weld Breaker.

322 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

20. Center Tunnel, Replacing 323

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Parts
♦ Tunnel
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

324 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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

When using different types of steel and materials of different

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.
strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit the new part to the vehicle standing on Alignment Bracket
Set and secure.
– Check the fit with adjacent components.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

20. Center Tunnel, Replacing 325

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

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.

326 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

• Footwell Crossmember, Installing. Refer to ⇒ F8 ootwell

Crossmember, Replacing”, page 141 .
• Rear Seat Crossmember, Installing. Refer to ⇒ S17 eat
Crossmember, Replacing”, page 302 .
• Front Seat Crossmember, Installing. Refer to ⇒ S16 eat
Crossmember, Replacing”, page 297 .

20. Center Tunnel, Replacing 327

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

21 Special Tools
Special tools and workshop equipment required
♦ Tensioning Strap -T10038-

♦ Double Suction Lifter -VAG1344- or Installation Magnets -

VAS6739-

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.

♦ Mechanical Door Brace -VAG1438-

♦ Spot-Weld Breaker - Breaker -VAG1731/2-

♦ Pneumatic Cartridge Gun -VAG1761/1-

♦ Cartridge Heater -VAG1939A-

328 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Pneumatic Pop Riveter -VAG2003A-

♦ Pneumatic Glue Gun -VAG2005B-

♦ Pneumatic Jig Saw -VAS5108- or Body Saw VAS6598 -

VAS6598- or Pneumatic Body Saw -VAS6780-

♦ Gauge - Gap Adjustment -VAS3371-

♦ Drill -VAS5144-
♦ One-Handed Angle Grinder VAS5167B -VAS5167B-
♦ Double Cartridge Gun -VAS5237-

♦ Flat Chisel -VAS5300/34-

♦ Mole Grips 18-18 -VAS5430/1-
♦ Gas-Shielded Welder -VAS6044A- or Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Gas-Shielded Welder -VAS6045A- 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.
♦ Resistance Spot Welder -VAS6239A- or Resistance Spot
Welder -VAS6525- or Resistance Spot Welder -VAS6530A-
or Resistance Spot Welder -VAS6535- or Resistance Spot
Welder -VAS6545A-

21. Special Tools 329

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

♦ Spot-Weld Breaker -VAS6322A- or Spot Weld Breaker -

VAS882001-

♦ Pneumatic Brush Grinder Set -VAS6446A-

♦ Pneumatic Gun -VAS6453US-
♦ Pneumatic Body Saw -VAS6780-

♦ Gauge - Gap Adjustment -3371-

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.

330 Rep. Gr.51 - Body Center, Chassis, Roof

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

53 – Body Rear
1 Safety Precautions
⇒ P2 recautions”, 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
with respect to the correctness of information in this document. Copyright by AUDI AG.

1. Safety Precautions 331

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

2 Permitted Separation Cuts on Entire

Sidewall

Note

♦ Only use welding tools approved by Audi AG.

♦ Gas-shielded arc continuous weld seams are permitted on
the separation cuts shown.

Sedan

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.

Avant

332 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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. Permitted Separation Cuts on Entire Sidewall 333

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 16 55 00

3 Cross Panel, Replacing, Sedan

⇒ 3.1 , page 334
⇒ 3.2 , page 335

1 - Left Tail Lamp Assembly

Mount
2 - Cross Panel
3 - Right Tail Lamp Assembly
Mount
4 - Cross Panel Separation
Cut
Partial renewal
The partial replacement is
possible with the designated
separation cuts.

3.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ One-Handed Angle Grinder 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.
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

334 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

3.2 Procedure
Separating Points
– Loosen the original joint using the Spot Weld Breaker.
Partial renewal
Make the separation cuts -1- according to the degree of dam‐
age with the Body Saw.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

3. Cross Panel, Replacing, Sedan 335

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part
♦ Rear Cross Panel
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the welding areas to bare metal.
Partial renewal
Transfer the separation cuts to the new part.
Cut the new part with the Body Saw.

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.

336 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the rear lid closing function.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
Partial renewal
Place an additional thickness of the same material in the sepa‐
ration area and weld using a gas-shielded arc continuous weld
seam.

3. Cross Panel, Replacing, Sedan 337

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

338 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 16 55 10

4 Cross Panel, Replacing, Avant

⇒ 4.1 , page 340
⇒ 4.2 , page 340

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Flowing noises indicate leaks on the natural gas system.
Natural gas can escape uncontrolled through leaks in the nat‐
ural gas system.
Death or serious bodily injury by explosion.
– Never work on natural gas systems which have flowing
noise which is readily noticeable.
– Never drive vehicles into the workshop which have a flow‐
ing noise which is readily noticeable.
– Park the vehicle in the open air and create a secure area.

DANGER
Only for vehicles with natural gas-powered technology
When welding, cutting, separating or drilling near natural gas-
carrying components, these components must either be re‐
moved or securely covered before repairing.

DANGER
Fuel Tank or Fuel-Carrying Lines
Extreme caution is necessary when sanding and welding
around tank or other fuel-carrying components. If in doubt,
such components must be removed.

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.

4. Cross Panel, Replacing, Avant 339

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Cross Panel
2 - Right Tail Lamp Assembly
Mount
3 - Cross Panel Separation
Cut
Partial renewal
The partial replacement is
possible with the designated
separation cuts.
4 - Left Tail Lamp Assembly
Mount

4.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill 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
Only use the tools approved
with respect toby
the Audi AGoffor
correctness performing
information repairCopyright by AUDI AG.
in this document.
work correctly. Refer to ⇒ 14 , page 91 .

4.2 Procedure
Separating Points
– Loosen the original joint using the Spot Weld Breaker.
Partial renewal
Make the separation cuts -1- according to the degree of dam‐
age with the Body Saw.

340 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

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.

4. Cross Panel, Replacing, Avant 341

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Rear Cross Panel
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the welding areas to bare metal.
Partial renewal
Transfer the separation cuts to the new part.
Cut the new part with the Body Saw.

342 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.
Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the rear lid closing function.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
Partial renewal
Place an additional thickness of the same material in the sepa‐
ration area and weld using a gas-shielded arc continuous weld
seam.

4. Cross Panel, Replacing, Avant 343

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

344 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 09 55 50

5 Lock Carrier, Replacing, Sedan

⇒ 5.1 , page 345
⇒ 5.2 , page 346

1 - Left Tail Lamp Assembly

Mount
2 - Left Longitudinal Member
3 - Lock Carrier
4 - Right Longitudinal Member
5 - Right Tail Lamp Assembly
Mount

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.

5.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

5. Lock Carrier, Replacing, Sedan 345

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

5.2 Procedure
• Cross panel already removed. Refer to ⇒ P3 anel, Replac‐
ing, Sedan”, page 334 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Remove the lock carrier -1- toward the inside.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

346 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part 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
♦ Lock Carrier with respect to the correctness of information in this document. Copyright by AUDI AG.

New Part, Preparing

– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

5. Lock Carrier, Replacing, Sedan 347

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the fit with adjacent components.
– Check the rear lid closing function.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

348 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Installing the cross panel. Refer to ⇒ P3 anel, Replacing,

Sedan”, page 334 .

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. Lock Carrier, Replacing, Sedan 349

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 16 55 60

6 Lock Carrier, Replacing, Avant

⇒ 6.1 , page 351
⇒ 6.2 , page 351

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20;
Protected Fuel Tanks,
by copyright. Copying for private or commercial purposes, in part or in whole, is not

Checking for Damage.

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.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Flowing noises indicate leaks on the natural gas system.
Natural gas can escape uncontrolled through leaks in the nat‐
ural gas system.
Death or serious bodily injury by explosion.
– Never work on natural gas systems which have flowing
noise which is readily noticeable.
– Never drive vehicles into the workshop which have a flow‐
ing noise which is readily noticeable.
– Park the vehicle in the open air and create a secure area.

DANGER
Only for vehicles with natural gas-powered technology
When welding, cutting, separating or drilling near natural gas-
carrying components, these components must either be re‐
moved or securely covered before repairing.

DANGER
Fuel Tank or Fuel-Carrying Lines
Extreme caution is necessary when sanding and welding
around tank or other fuel-carrying components. If in doubt,
such components must be removed.

350 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Left Tail Lamp Assembly

Mount
2 - Left Longitudinal Member
3 - Lock Carrier
4 - Right Longitudinal Member
5 - Right Tail Lamp Assembly
Mount

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.

6.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

6.2 Procedure
• Cross panel already removed. Refer to ⇒ P4 anel, Replac‐
ing, Avant”, page 339 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Remove the lock carrier toward the inside.

6. Lock Carrier, Replacing, Avant 351

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

352 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Lock Carrier
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the welding areas to bare metal.

6. Lock Carrier, Replacing, Avant 353

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the fit with adjacent components.
– Check the rear lid closing function.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

354 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Installing the cross panel. Refer to ⇒ P4 anel, Replacing,

Avant”, page 339 .

6. Lock Carrier, Replacing, Avant 355

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 10 55 50

7 Tail Lamp Assembly Mount, Replac‐

ing, Sedan
⇒ 7.1 , page 356
⇒ 7.2 , page 357

1 - Side Panel
2 - Water Duct
3 - Cross Panel
4 - Tail Lamp Assembly
Mount

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.

7.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

356 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

7.2 Procedure
• Cross panel already removed. Refer to ⇒ P3 anel, Replac‐
ing, Sedan”, page 334 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Remove the tail lamp mount downward.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

7. Tail Lamp Assembly Mount, Replacing, Sedan 357

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Tail Lamp Assembly Mount
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the welding areas to bare metal.

358 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the new part.
– Check the fit with attachments.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded
Protected arcforplug
by copyright. Copying privateweld seampurposes, in part or in whole, is not
or commercial
using a Gas-Shielded Welder.
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.

7. Tail Lamp Assembly Mount, Replacing, Sedan 359

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Installing the cross panel. Refer to ⇒ P3 anel, Replacing,

Sedan”, page 334 .

360 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 10 55 60

8 Tail Lamp Assembly Mount, Replac‐

ing, Avant
⇒ 8.1 , page 362
⇒ 8.2 , page 362

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

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.

8. Tail Lamp Assembly Mount, Replacing, Avant 361

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Side Panel
2 - Water Duct
3 - Cross Panel
4 - Tail Lamp Assembly
Mount

8.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

8.2 Procedure
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Cross panel already removed. Refer to ⇒ P4 anel, Replac‐
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
ing, Avant”, page 339 . with respect to the correctness of information in this document. Copyright by AUDI AG.

Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Remove the tail lamp mount downward.

362 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

8. Tail Lamp Assembly Mount, Replacing, Avant 363

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part
♦ Tail Lamp Assembly Mount
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the welding areas to bare metal.

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.

364 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure
Protected the new
by copyright. Copyingpart.
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 the
with fit with
respect attachments.
to the correctness of information in this document. Copyright by AUDI AG.

– Weld the new part using a Resistance Spot Welder with a

straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

8. Tail Lamp Assembly Mount, Replacing, Avant 365

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Installing the cross panel. Refer to ⇒ P4 anel, Replacing,

Avant”, page 339 .
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.

366 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 48 55 52

9 Rear Longitudinal Member, Replac‐

ing
⇒ 9.1 , page 368
⇒ 9.2 , page 368

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. There is a risk of fatal or serious bodily injury due
to an explosion.
– Electrically and manually lock the natural gas fuel tank.

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.

9. Rear Longitudinal Member, Replacing 367

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - End Plate
2 - Inner Wheel Housing
3 - Rear Longitudinal Member
4 - Molded Foam Part
5 - Spare Tire Well Cross‐
member
6 - Tail Lamp Assembly
Mount

9.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

9.2 Procedure
• Lock carrier already removed. Refer to ⇒ C5 arrier, Replac‐
ing, Sedan”, page 345 .
• Cross panel already removed. Refer to ⇒ P3 anel, Replac‐
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, Sedan”,
with respectpage 334 . of information in this document. Copyright by AUDI AG.
to the correctness

• Cross panel already removed. Refer to ⇒ P4 anel, Replac‐

ing, Avant”, page 339 .

368 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Spare tire well already removed. Refer to ⇒ T16 ire Well,

Replacing, Sedan and Avant”, page 424 .
Separating Points
– Perform the separation cuts as shown using the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.

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.

– Perform the separation cuts as shown using the Body Saw.

– Loosen the original joint using the Spot Weld Breaker.

9. Rear Longitudinal Member, Replacing 369

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Loosen the original joint using the Spot Weld Breaker.

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.

370 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

9. Rear Longitudinal Member, Replacing 371

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Longitudinal Member
♦ Floor Panel Side
New Part, Preparing
– Transfer the separation cuts to the new part.
– Cut the new part with the Body Saw.
– Grind down the welding areas to bare metal.

372 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note 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
When using different types of steel and materials of different
with respect to the correctness of information in this document. Copyright by AUDI AG.

strengths, one of the inverters listed below must be used to

perform the repair work correctly.

Welding
– Fit the new part to the vehicle standing on Alignment Bracket
Set and secure.
– Check the fit with adjacent components.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

9. Rear Longitudinal Member, Replacing 373

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Weld the new part using a Resistance Spot Welder with a

straight-line spot weld seam.
– Butt weld the separation cut with a gas-shielded arc continu‐
ous weld seam using the Gas-Shielded Welder.

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.

374 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Weld the new part using a Resistance Spot Welder with a

straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
– Butt weld the separation cut with a gas-shielded arc continu‐
ous weld seam using the Gas-Shielded Welder.

9. Rear Longitudinal Member, Replacing 375

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Installing the lock carrier. Refer to ⇒ C5 arrier, Replacing,

Sedan”, page 345 .
• Installing the cross panel. Refer to ⇒ P3 anel, Replacing,
Sedan”, page 334 .
• Installing the cross panel. Refer to ⇒ P4 anel, Replacing,
Avant”, page 339 .
• Installing the spare tire well. Refer to ⇒ T16 ire Well, Replac‐
ing, Sedan and Avant”, page 424 .

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.

376 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 55 55 04

10 Side Panel, Replacing, Sedan

⇒ 10.1 , page 378
⇒ 10.2 , page 378

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. There is a risk of fatal or serious bodily injury due
to an explosion.
– Electrically and manually lock the natural gas fuel tank.

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.

10. Side Panel, Replacing, Sedan 377

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - C-Pillars and D-Pillars

Separation Cut
2 - Molded Foam Part
3 - Side Panel
❑ Includes water duct and
tail lamp mount
4 - Bonded Area
5 - Side Panel Separation Cut
Partial renewal
Partial replacement is possi‐
ble with the designated sepa‐
ration cut.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Moldedpermitted
Foam Part
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.
7 - Side Sill Separation Cut
8 - Molded Foam Part

10.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
♦ Pneumatic Glue Gun
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

10.2 Procedure
Separating Points
Permitted Separation Cuts on Entire Sidewall
– Loosen the original joint using the Spot Weld Breaker.

378 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Grind down the outer edge of the wheel arch using a One-
Handed Angle Grinder.
– Perform the separation cuts as shown using the Body Saw.
Partial renewal
Partial replacement is possible with the designated separating
cut -1-.

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.

– Perform the separation cuts as shown using the Body Saw.

– Loosen the original joint using the Spot Weld Breaker.
– The rear cross panel must not be removed here it is suffi‐
cient when the original joint to the side panel is loosened.

10. Side Panel, Replacing, Sedan 379

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.
– Completely remove any remaining adhesive and grind the
adhesive surfaces down to bare metal.

380 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Side Panel
♦ Molded Foam Parts
♦ Body Structural Adhesive -D 180 004 M2-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
New Part, Preparing
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.

– Transfer the separation cuts to the new part.

– Cut the new part with the Body Saw.
– Grind down the welding areas to bare metal.
Partial renewal
Partial replacement is possible with the designated separating
cut -1-.

10. Side Panel, Replacing, Sedan 381

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Insert the molded foam part -1-. Refer to ⇒ F6.5 oam

Pieces”, Protected
page 23 .
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

– Place the same material on the separating points.

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

– Apply Body Structural Adhesive to the area that was bonded

during production using the Compressed Air Gun. Refer to ⇒
S9 tructural Adhesive D 180 004 M2, Application”, page 35 .

382 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Butt weld the separating cuts with a gas-shielded arc contin‐
uous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Bead over the wheel arch -1-.

10. Side Panel, Replacing, Sedan 383

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Butt weld the separation cut with a gas-shielded arc continu‐

ous weld seam using the Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

384 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Installing the Pop Rivet Screws -WHT 005 180-

– Install the pop rivet screws -a- with Pop Rivet Pliers -
VAS1765 C- and the Pop Rivet Pliers - Supplement Pieces
-VAG1765C/2-.

Note

If there is difficulty due to the large tolerance of the pop rivet screw, insert the screw using a ring or open end
wrench in the Pop Rivet Pliers - Supplement Pieces -VAG1765C/2-.

10. Side Panel, Replacing, Sedan 385

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Installing the cross panel. Refer to ⇒ P3 anel, Replacing,

Sedan”, page 334 .

386 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 55 55 12

11 Side Panel, Replacing (Avant)

⇒ 11.1 , page 388
⇒ 11.2 , page 388

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking forProtected
[Link] 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.
WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. There is a risk of fatal or serious bodily injury due
to an explosion.
– Electrically and manually lock the natural gas fuel tank.

11. Side Panel, Replacing (Avant) 387

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Side Panel
2 - C-Pillar Separation Cut
3 - Molded Foam Part
4 - D-Pillar Separation Cut
5 - Bonded Area
6 - Side Panel Separation Cut
Partial renewal
Partial replacement is possi‐
ble with the designated sepa‐
ration cut.
7 - Side Sill Separation Cut

11.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
♦ Pneumatic Glue Gun
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .
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

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

• Rear lower panel is already removed. Refer to ⇒ P4 anel,

Replacing, Avant”, page 339 .

388 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

A partial replacement is possible with the separating cuts

shown. Place the same material in the separation area and
weld using a gas-shielded arc continuous weld seam.

Separating Points
Permitted Separation Cuts on Entire Sidewall
Partial renewal
Partial replacement is possible with the designated separating
cut -1-.
– Perform the separation cut as shown using the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.
– Grind down the outer edge of the wheel arch using a One-
Handed Angle Grinder.

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.

– Perform the separation cuts as shown using the Body Saw.

– Loosen the original joint using the Spot Weld Breaker.

11. Side Panel, Replacing (Avant) 389

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

390 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Parts
♦ Side Panel
♦ Molded Foam Parts
♦ Body Structural Adhesive -D 180 004 M2-
New Part, Preparing
– Transfer the separation cuts to the new part.
– Cut the new part with the Body Saw.
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the weldingProtected
areas by tocopyright.
bare metal.
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.

11. Side Panel, Replacing (Avant) 391

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Insert the molded foam part -1-. Refer to ⇒ F6.5 oam

Pieces”, page 23 .
– Place the same material on the separating points.
– Apply Body Structural Adhesive to the area that was bonded
during production using the Compressed Air Gun. Refer to ⇒
S9 tructural Adhesive D 180 004 M2, Application”, page 35 .

392 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Butt weld the separating cuts with a gas-shielded arc contin‐
uous weld seam using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam. 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
– Bead over the wheel arch -1-. with respect to the correctness of information in this document. Copyright by AUDI AG.

Partial renewal
Partial replacement is possible with the designated separation
cut -2-.
Butt weld the separation cut -2- with a gas-shielded arc continu‐
ous weld seam using the Gas-Shielded Welder.

11. Side Panel, Replacing (Avant) 393

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Butt weld the separation cut with a gas-shielded arc continu‐

ous weld seam using the Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

394 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

• Install the rear cross panel. Refer to ⇒ P4 anel, Replacing,

Avant”, page 339 .

11. Side Panel, Replacing (Avant) 395

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 69 55 52

12 C-Pillar Reinforcement, Replacing,

Sedan and Avant are Identical
⇒ 12.1 , page 397
⇒ 12.2 , page 397

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.
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.
DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. There is a risk of fatal or serious bodily injury due
to an explosion.
– Electrically and manually lock the natural gas fuel tank.

396 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Upper Inner C-Pillar

2 - Inner Sidewall
3 - Wheel Housing
4 - Upper C-Pillar Reinforce‐
ment
5 - Molded Foam Part
6 - Lower C-Pillar Reinforce‐
ment
7 - Inner Side Sill

12.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

12.2 Procedure
• Side panel already removed. Refer to ⇒ P10 anel, Replac‐
ing, by
Protected Sedan”,
copyright. page
Copying 377 . or commercial purposes, in part or in whole, is not
for private
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Side panel already removed. Refer to ⇒ P11 anel, Replacing
with respect to the correctness of information in this document. Copyright by AUDI AG.

(Avant)”, page 387 .

12. C-Pillar Reinforcement, Replacing, Sedan and Avant are Identical 397
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Loosen the upper C-pillar reinforcement -1- and remove
downward in the direction of the arrow -A-.
Partial renewal
A partial replacement is possible with this separation cut.
– Make separation cut -2- using a Pneumatic Body Saw.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Grind down the welding areas to bare metal.
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.

398 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ C-Pillar Reinforcement
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

12. C-Pillar Reinforcement, Replacing, Sedan and Avant are Identical 399
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Push the upper new part under the inner C-pillar.
– Fit the new part together with the side panel on a vehicle
on the Alignment Bracket Set and secure using the portal
gauge.
– Remove the side panel.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

400 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Side Panel, Installing. Refer to ⇒ P10 anel, Replacing, Se‐

dan”, page 377 .
– Side Panel, Installing. Refer to ⇒ P11 anel, Replacing
(Avant)”, page 387 .

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.

12. C-Pillar Reinforcement, Replacing, Sedan and Avant are Identical 401
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 69 55 00

13 Rear Wheel Housing, Replacing

⇒ 13.1 , page 403
⇒ 13.2 , page 403

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. Death or serious bodily injury by explosion.
– Electrically and manually lock the natural gas fuel tank.

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.

402 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Wheel Housing
2 - Inner Side Panel
3 - Floor Panel Side
4 - Separation Cut
Partial renewal
With the separation cut a
partial replacement can be
performed depending on the
damage. For this the C-pillar
reinforcement does not need
to be removed.
5 - Inner Side Sill

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.

13.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

13.2 Procedure
• Side panel already removed. Refer to ⇒ P10 anel, Replac‐
ing, Sedan”, page 377 .
• Side panel already removed. Refer to ⇒ P11 anel, Replacing
(Avant)”, page 387 .

13. Rear Wheel Housing, Replacing 403

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• C-pillar reinforcement already removed. Refer to ⇒ R12 ein‐

forcement, Replacing, Sedan and Avant are Identical”, page
396 .
Separating Points
Partial renewal
With the separation cut a partial replacement can be performed.
Then the C-pillar reinforcement does not need to be removed.
– Make the separation cuts according to the degree of dam‐
age with the Body Saw.
– Loosen the original joint using the Spot Weld Breaker.

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.

Complete Replacement
– Loosen the original joint using the Spot Weld Breaker.

404 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

13. Rear Wheel Housing, Replacing 405

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Rear Wheel Housing Liner
New Part, Preparing
Partial renewal
With the separation cut a partial replacement can be performed
depending on the damage.
– Transfer the separation cut to the new part. At the same time
allow excess material for overlapping.
– Cut the new part with the Body Saw.

406 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Partial renewal 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.
Fit the new part together with the side panel on a vehicle on the
Alignment Bracket Set and secure using the portal gauge.
Remove the side panel.
Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.
Weld the separation cut from above and below using the Gas-
Shielded Welder using the gas-shielded arc continuous weld
seam.

13. Rear Wheel Housing, Replacing 407

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Complete Replacement
– Fit the new part together with the side panel on a vehicle
on the Alignment Bracket Set and secure using the portal
gauge.
– Remove the side panel.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

408 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– C-Pillar Reinforcement, Installing. Refer to ⇒ R12 einforce‐

ment, Replacing, Sedan and Avant are Identical”, page 396 .
– SideProtected
Panel, by Installing. Refer
copyright. Copying to ⇒orP10
for private anel,purposes,
commercial Replacing,
in part or Se‐
in whole, is not
dan”, pageunless
permitted 377 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.
– Side Panel, Installing. Refer to ⇒ P11 anel, Replacing
(Avant)”, page 387 .

13. Rear Wheel Housing, Replacing 409

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 68 55 50

14 Inner Rear Wheel Housing, Replac‐

ing
⇒ 14.1 , page 411
⇒ 14.2 , page 411

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
Only for vehicles with natural gas-powered technology
When welding, cutting, separating or drilling near natural gas-
carrying components, these components must either be re‐
moved or securely covered before repairing.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. There is a risk of fatal or serious bodily injury due by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
to an explosion. 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.
– Electrically and manually lock the natural gas fuel tank.

410 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Inner Wheel Housing

2 - Inner Side Panel
3 - Floor Panel Side
4 - Rear Longitudinal Member

14.1 Tools
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
Special tools and workshop
with respect equipment
to the correctness required
of information in this document. Copyright by AUDI AG.

♦ Resistance Spot Welder

♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
For performing the repair work correctly only use tools approved
by the Audi AG. Refer to ⇒ 14 , page 91 .

14.2 Procedure
• Side panel already removed. Refer to ⇒ P10 anel, Replac‐
ing, Sedan”, page 377 .
• Side panel already removed. Refer to ⇒ P11 anel, Replacing
(Avant)”, page 387 .

14. Inner Rear Wheel Housing, Replacing 411

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• C-pillar reinforcement already removed. Refer to ⇒ R12 ein‐

forcement, Replacing, Sedan and Avant are Identical”, page
396 .
• Outer wheel housing is already removed. Refer to ⇒
W13 heel Housing, Replacing”, page 402 .
Separating Points
– Loosen the original joint using the Spot Weld Breaker.

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.

– Loosen the original joint using the Spot Weld Breaker.

412 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

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.

14. Inner Rear Wheel Housing, Replacing 413

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Replacement Part
♦ Inner Wheel Housing
New Part, Preparing
– Loosen and remove using the Spot Weld Breaker.
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.
– Grind down the welding areas to bare metal.

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.

414 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Installing
– Fit and secure the new part on the vehicle using the Align‐
ment Bracket Set.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

14. Inner Rear Wheel Housing, Replacing 415

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Weld the new part using a Resistance Spot Welder with a

straight-line spot weld seam.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.

416 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Install the outer wheel housing. Refer to ⇒ W13 heel Hous‐

ing, Replacing”, page 402 .
– C-Pillar Reinforcement, Installing. Refer to ⇒ R12 einforce‐
ment, Replacing, Sedan and Avant are Identical”, page 396 .
– Side Panel, Installing. Refer to ⇒ P10 anel, Replacing, Se‐
dan”, page 377 .
– Side Panel, Installing. Refer to ⇒ P11 anel, Replacing
(Avant)”, page 387 .

14. Inner Rear Wheel Housing, Replacing 417

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 80 55 50

15 Luggage Compartment Floor, Re‐

placing, Only Vehicles with Natural
Gas-Powered Technology
⇒ 15.1 , page 419
⇒ 15.2 , page 419

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
trim panels, longitudinal members,
permitted unless authorised rear
by [Link]
AUDIpiece,
AG doesetc.
not guarantee or accept any liability
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
with respect to the correctness of information in this document. Copyright by AUDI AG.

System - General Information; Rep. Gr. 20; Fuel Tanks,

Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. Death or serious bodily injury by explosion.
– Electrically and manually lock the natural gas fuel tank.

418 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Luggage Compartment
Floor

15.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker

Note

Use tools approved by AUDI AG for performing repair work

correctly. 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.

15.2 Procedure
• Upper Rear Cross Panel, Removing. Refer to ⇒ P4 anel,
Replacing, Avant”, page 339 .
• Cross Panel, Removing. Refer to ⇒ P3 anel, Replacing, Se‐
dan”, page 334 .

15. Luggage Compartment Floor, Replacing, Only Vehicles with Natural Gas-Powered Technology 419
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Separating Points
– Loosen the original joint using a Spot Weld Breaker.

– Remove the remaining material using the One-Handed An‐

gle Grinder.

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.

420 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Luggage Compartment Floor
Pre-treatment only applies to the replacement part
– Grind the welding surfaces down to bare metal.
– Prepare the flange for welding to the new part.
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using the Drill.

15. Luggage Compartment Floor, Replacing, Only Vehicles with Natural Gas-Powered Technology 421
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Fit and secure the luggage compartment floor with the vehi‐
cle on its wheels or on an alignment bracket set.
– Fit and secure the mount.
– Check the fit with the cross panel.
– Weld the luggage compartment floor with a gas-shielded arc
plug weld seam using the Gas-Shielded Welder.

422 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

• Upper Rear Cross Panel, Welding. Refer to ⇒ P4 anel, Re‐

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
placing, Avant”, page 339 .
with respect to the correctness of information in this document. Copyright by AUDI AG.

• Cross Panel, Welding. Refer to ⇒ P3 anel, Replacing, Se‐

dan”, page 334 .

15. Luggage Compartment Floor, Replacing, Only Vehicles with Natural Gas-Powered Technology 423
 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

RO: 53 80 55 50

16 Spare Tire Well, Replacing, Sedan

and Avant
⇒ 16.1 , page 425
⇒ 16.2 , page 425

DANGER
There is a risk of explosions and fatal injuries due to damaged
natural gas tanks.
– The natural gas tank must be checked for damage if com‐
ponents in the rear side or rear area are removed due to
damage, such as the bumper cover, rear lid, underbody
trim panels, longitudinal members, rear lid end piece, etc.
– Check for damage on fuel tanks. Refer to ⇒ Natural Gas
System - General Information; Rep. Gr. 20; Fuel Tanks,
Checking for Damage.

WARNING
Risk of the fuel tank or fuel-carrying components exploding
due to sanding, welding or separating.
Severe injuries and burns are possible.
– When sanding, welding or separating near the fuel system
remove the fuel tank or fuel-carrying components.

DANGER
Extremely dangerous and risks of explosion due to natural
gas. Due to a defective manual fuel tank shut-off natural gas
can escape uncontrolled. A third party can unintentionally ac‐
tivate this. There is a risk of fatal or serious bodily injury due
to an explosion.
– Electrically and manually lockunless
the authorised
natural by gas fuel
AG. tank.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted AUDI AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

424 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

1 - Crossmember Floor Panel

2 - Spare Tire Well Cross‐
member
3 - Right Rear Longitudinal
Member
4 - Spare Tire Well
5 - Left Rear Longitudinal
Member

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.

16.1 Tools
Special tools and workshop equipment required
♦ Resistance Spot Welder
♦ Gas-Shielded Welder
♦ One-Handed Angle Grinder
♦ Body Saw
♦ Spot Weld Breaker
♦ Drill
Only use the tools approved by Audi AG for performing repair
work correctly. Refer to ⇒ 14 , page 91 .

16.2 Procedure
• Lock carrier already removed. Refer to ⇒ C5 arrier, Replac‐
ing, Sedan”, page 345 .
• Cross panel already removed. Refer to ⇒ P3 anel, Replac‐
ing, Sedan”, page 334 .
• Cross panel already removed. Refer to ⇒ P4 anel, Replac‐
ing, Avant”, page 339 .

16. Spare Tire Well, Replacing, Sedan and Avant 425

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

Separating Points
– Loosen the original joint using the Spot Weld Breaker.
– Lift the rear spare tire well.
– Remove the spare tire well toward the rear.

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.

– Remove the remaining material using the One-Handed An‐

gle Grinder.
– Grind down the welding areas to bare metal.

426 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Replacement Part
♦ Spare Tire Well
New Part, Preparing
– Drill 8 mm holes for the gas-shielded arc plug weld seam
using a Drill.

16. Spare Tire Well, Replacing, Sedan and Avant 427

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

Note

When using different types of steel and materials of different

strengths, one of the inverters listed below must be used to
perform the repair work correctly.

Welding
– Place the front spare tire well -1- in the direction of the arrow
-A- under the crossmember and fold down.
– Fit the new part to vehicle standing on its wheels or on
Alignment Bracket Set and secure.
– Check the fit with adjacent components.

428 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.
– Weld the new part with a gas-shielded arc plug weld seam
using a Gas-Shielded Welder.
– Weld the new part using a Resistance Spot Welder with a
straight-line spot weld seam.

16. Spare Tire Well, Replacing, Sedan and Avant 429

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

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.

– Installing the lock carrier. Refer to ⇒ C5 arrier, Replacing,

Sedan”, page 345 .
– Installing the cross panel. Refer to ⇒ P3 anel, Replacing,
Sedan”, page 334 .
– Installing the cross panel. Refer to ⇒ P4 anel, Replacing,
Avant”, page 339 .

430 Rep. Gr.53 - Body Rear

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

17 Special Tools
Special tools and workshop equipment required
♦ Pneumatic Glue Gun -VAG2005B-

♦ Pneumatic Jig Saw -VAS5108- or Body Saw VAS6598 -

VAS6598- or Pneumatic Body Saw -VAS6780-

♦ One-Handed Angle Grinder VAS5167B -VAS5167B-

♦ Gas-Shielded Welder 195A -VAS6044A- or Gas-Shielded
Welder -VAS6045A-
♦ Resistance Spot Welder -VAS6239A- or Resistance Spot
Welder -VAS6525- or Resistance Spot Welder -VAS6530A-
or Resistance Spot Welder -VAS6535- or Resistance Spot
Welder -VAS6545A-
♦ Spot-Weld Breaker -VAS6322A- or Spot Weld Breaker -
VAS882001-

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.

♦ Body Saw VAS6598 -VAS6598- or

♦ Pneumatic Body Saw -VAS6780-

17. Special Tools 431

 Audi A4 2015 ➤, Audi A4 China 2016 ➤
Body Repairs - Edition 06.2021

18 Revision History
DRUCK NUMBER: A008WKI0121
Fac‐ Edit Job Fe Notes Quality
tory Edi‐ Type ed‐ Checke
Edi‐ tion ba d By
tion ck
06.2 07/1 Fac‐ N/ Joe Y
021 2/20 tory A
21 Up‐
date
10.2 11/0 Fac‐ N/ Joe Y
020 3/20 tory A
20 Up‐
date
09.2 09/0 Fac‐ N/ Joe Y
020 2/20 tory A
20 Up‐
date
04.2 05/1 Fac‐ N/ Joe Y
020 3/20 tory A
20 Up‐
date

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.

432 Rep. Gr.53 - Body Rear

 Cautions & Warnings

Please read these WARNINGS and CAUTIONS before proceeding with maintenance and
repair work. You must answer that you have read and you understand these WARNINGS and
CAUTIONS before you will be allowed to view this information.

 If you lack the skills, tools and equipment, or a suitable workshop for any procedure described
in this manual, we suggest you leave such repairs to an authorized Audi retailer or other
qualified shop. We especially urge you to consult an authorized Audi retailer before beginning
repairs on any vehicle that may still be covered wholly or in part by any of the extensive
warranties issued by Audi.

 Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system
or the electrical system. Do not smoke or work near heaters or other fire hazards. Keep an
approved fire extinguisher handy.

 Audi is constantly improving its vehicles and sometimes these changes, both in parts and
specifications, are made applicable to earlier models. Therefore, part numbers listed in this
manual are for reference only. Always check with your authorized Audi retailer parts
department for the latest information.

 Any time the battery has been disconnected on an automatic transmission vehicle, it will be
necessary to reestablish Transmission Control Module (TCM) basic settings using the Audi
Factory Approved Scan Tool (ST).

 Never work under a lifted vehicle unless it is solidly supported on stands designed for the
purpose. Do not support a vehicle on cinder blocks, hollow tiles or other props that may
crumble under continuous load. Never work under a vehicle that is supported solely by a jack.
Never work under the vehicle while the engine is running.

 For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code
before disconnecting the battery or removing the radio. If the wrong code is entered when the
power is restored, the radio may lock up and become inoperable, even if the correct code is
used in a later attempt.
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.
 If you are going to work under a vehicle on the ground, make sure that the ground is level.
Block the wheels to keep the vehicle from rolling. Disconnect the battery negative terminal
(ground strap) to prevent others from starting the vehicle while you are under it.

 Do not attempt to work on your vehicle if you do not feel well. You increase the danger of
injury to yourself and others if you are tired, upset or have taken medicine or any other
substances that may impair you or keep you from being fully alert.

 Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.

 Always observe good workshop practices. Wear goggles when you operate machine tools or
work with acid. Wear goggles, gloves and other protective clothing whenever the job requires
working with harmful substances.

 Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace
when you work near machine tools or running engines. If your hair, clothing, or jewelry were to
get caught in the machinery, severe injury could result.

Page 1 of 3
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of
this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0
 Cautions & Warnings

 Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are
designed to be used only once and are unreliable and may fail if used a second time. This
includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the
recommendations in this manual - replace these fasteners with new parts where indicated,
and any other time it is deemed necessary by inspection.

 Illuminate the work area adequately but safely. Use a portable safety light for working inside or
under the vehicle. Make sure the bulb is enclosed by a wire cage. The hot filament of an
accidentally broken bulb can ignite spilled fuel or oil.

 Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not
create dust by grinding, sanding, or by cleaning with compressed air. Avoid breathing
asbestos fibers and asbestos dust. Breathing asbestos can cause serious diseases such as
asbestosis or cancer, and may result in death.

 Finger rings should be removed so that they cannot cause electrical shorts, get caught in
running machinery, or be crushed by heavy parts.

 Before starting a job, make certain that you have all the necessary tools and parts on hand.
Read all the instructions thoroughly, do not attempt shortcuts. Use tools that are appropriate to
the work and use only replacement parts meeting Audi specifications. Makeshift tools, parts
and procedures will not make good repairs.

 Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or
beverage containers that might mislead someone into drinking from them. Store flammable
fluids away from fire hazards. Wipe up spills at once, but do not store the oily rags, which can
ignite and burn spontaneously.

 Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these
tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque listed.

 Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping
hydrogen gas is ignited, it will ignite gas trapped in the cells and cause the battery to explode.

 Be mindful of the environment and ecology. Before you drain the crankcase, find out the
proper way to dispose of the oil. Do not pour oil onto the ground, down a drain, or into a
stream, pond, or lake. Consult local ordinances that govern the disposal of wastes.

 The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The
A/C system should be serviced only by trained automotive service technicians using approved
refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar
with regulations governing the discharging and disposal of automotive chemical refrigerants.

 Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS),
disconnect the battery negative terminal (ground strap) and the ABS control module
connector.

 Do not expose Protected

any part of the A/C
by copyright. Copyingsystem
for privateto
or high temperatures
commercial purposes, in partsuch as open
or in whole, is not flame.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Excessive heat will
withincrease
respect to thesystem
correctnesspressure
of informationand
in thismay cause
document. the by
Copyright system
AUDI [Link] burst.

Page 2 of 3
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of
this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0
 Cautions & Warnings

 When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM),
the Transmission Control Module (TCM), the ABS control module, and the trip computer. In
cases where one or more of these components is not separately fused, disconnect the control
module connector(s).

 Some of the vehicles covered by this manual are equipped with a supplemental restraint
system (SRS), that automatically deploys an airbag in the event of a frontal impact. The airbag
is operated by an explosive device. Handled improperly or without adequate safeguards, it can
be accidentally activated and cause serious personal injury. To guard against personal injury
or airbag system failure, only trained Audi Service technicians should test, disassemble or
service the airbag system.

 Do not quick-charge the battery (for boost starting) for longer than one minute, and do not
exceed 16.5 volts at the battery with the boosting cables attached. Wait at least one minute
before boosting the battery a second time.

 Never use a test light to conduct electrical tests of the airbag system. The system must only
be tested by trained Audi Service technicians using the Audi Factory Approved Scan Tool (ST)
or an approved equivalent. The airbag unit must never be electrically tested while it is not
installed in the vehicle.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
 Some aerosol tire inflators are highly flammable. Beauthorised
permitted unless extremely cautious
by AUDI AG. AUDI when
AG does repairing
not guaranteea
or tire
accept any liability
that may have been inflated using an aerosol tire inflator.
with respect Keepofsparks,
to the correctness informationopen flame or
in this document. otherby AUDI AG.
Copyright
sources of ignition away from the tire repair area. Inflate and deflate the tire at least four times
before breaking the bead from the rim. Completely remove the tire from the rim before
attempting any repair.

 When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands
or lap while the vehicle is in motion. Objects between you and the airbag can increase the risk
of injury in an accident.

I have read and I understand these Cautions and Warnings.

Page 3 of 3
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other
intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of
this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

Version 2.0