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Service

Body Repairs
Audi A4 2008 ➤
Edition 06.2009

Service Department. Technical Information

Service
Repair Group overview for Body Repairs

Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Audi AG, Ingolstadt A008KKI0120

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Type plate and vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Ultra-high-strength steels (hot-formed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Expanded foam inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Spot-welded/bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 Inspecting and repairing bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.4 Repair methods for replacing body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

cardiagn.com
9 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.1 Body - front (saloon and Avant identical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9.2 Body - centre (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9.3 Body - centre (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.4 Floor group - front (saloon and Avant identical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.5 Floor group - rear (saloon and Avant identical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.6 Body - rear (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.7 Body - rear (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Intermediate piece - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2 Upper wheel housing longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 Suspension strut mounting - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 Front longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5 Front longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6 Longitudinal member reinforcement (front) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1 Roof - Renewal (saloon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
69
permitted1.1 Toolsby AUDI
unless authorised . . . .AG.
. .AUDI
. . .AG
. .does
. . .not
. .guarantee
. . . . . or. .accept
. . . any
. . .liability
...
.................................. 69
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by AUDI AG.
71
1.3 Vehicles with sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Contents i
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

2 Roof - Renewal (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3 Vehicles with sliding/tilting sunroof (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4 Front roof cross member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5 Roof side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5.2 Procedure . . . .authorised
permitted unless . . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG
. .does
. . .not. .guarantee
. . . . . or. accept
. . . . any
. . liability
....................... 132
5.3 Foam-filling roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by AUDI AG.
133
6 Front roof cross member - Renewal (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7 Rear roof frame - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

cardiagn.com
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
8 Rear roof frame - Renewal (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9 A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10 Inner A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
11 Outer B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
12 Inner B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
13 Inner B-pillar - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
13.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
14 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
14.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
15 Inner side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
15.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
15.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
16 Inner side member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
16.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
16.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
17 Inner side member reinforcement - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
17.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
17.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

1 Rear cross panel (top section) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

ii Contents
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2 Rear cross panel (top section) - Renewal (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3 Rear cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4 Rear cross panel - Renewal (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5 Cross panel (inner section) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6 Cross panel (inner section) - Renewal (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7 Tail light mounting - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

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7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
8 Rear longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
9 Rear longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
9.2 by copyright.
Protected ProcedureCopying for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . . in. part
. . .or. in. whole,
. . . .is. not
................................. 243
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10respect Side
with panel - ofRenewal
to the correctness information in .this
. .document.
. . . . . .Copyright
. . . . .by. AUDI. . . .AG.
................................... 250
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
11 Side panel - Renewal (Avant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
12 C-pillar reinforcement - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
13 Rear wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
13.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
14 Spare wheel well - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
14.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
14.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Contents iii
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

iv Contents
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

00 – Technical data
1 General notes
This Manual describes only selected repair operations. Where
repair operations are not described: separate original joint and
repair with replacement panel. Repairs requiring a method differ‐
ent from that used in production are described specifically.
Where sub-parts are available for a repair, they should be match‐
ed up and butt-welded in place (SG continuous seam), unless
otherwise described.
Please refer to the information in the Workshop Manual General
information, Body repairs ⇒ General Information; Body Repairs,
General Body Repairs .

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

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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. General notes 1
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

2 Vehicle identification data

2.1 Type plate and vehicle identification

number
The vehicle identification number is located on the suspension
turret (left-side).

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2.2 Vehicle data sticker
The vehicle data sticker is located in the spare wheel well at the
rear of the vehicle.

2 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

3 Ultra-high-strength steels (hot-

formed)
Ultra-high-strength hot-formed steel panels are employed on the
Audi A4 and Audi A4 Avant to save weight. These panels may
only be cut and butt-welded at the specified locations. The re‐
quired repair method for these joints is indicated in this manual.
Spot-welding may only be performed with the factory-approved
inverter welding equipment.
Inner longitudinal member reinforcement

Inner B-pillar

3. Ultra-high-strength steels (hot-formed) 3

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Tunnel cross-piece

4 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Inner side member reinforcement

3. Ultra-high-strength steels (hot-formed) 5

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Tunnel reinforcement

6 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

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

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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.

Rear longitudinal member

3. Ultra-high-strength steels (hot-formed) 7

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

8 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

4 Expanded foam inserts

Various body cavities of the Audi A4 2008 and A4 Avant are fitted
with expanded foam inserts.
The foam inserts reduce the noise transmitted to the interior when
driving.
These pre-moulded parts are fitted during body manufacture and
subsequently increase their volume in the paint shop drying oven
at approx. 180 °C after priming.

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Expanded foam inserts (Avant)

4. Expanded foam inserts 9

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

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Caution

The replacement foam inserts expand only after reaching

about 180°C. For this reason, an additional filler foam is used
when performing repairs.
Filler foam required for repairs: D 506 KD 1 A3.

Since the temperature necessary for the foam inserts to expand

cannot be achieved under normal workshop conditions, proceed
as follows:
Remove residue of foam material on vehicle.
Restore paint coating; apply two coats (wet on wet) of glass/paint
primer D 009 200 02 if necessary, flash-off time approx.10 mi‐
nutes.
Requirement
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Before continuing with thisunless
permitted procedure, ensure
authorised by AUDI AG.that
AUDIthe replace‐
AG does not guarantee or accept any liability
ment panel is ready forwithinstallation, i.e. cutoftoinformation
respect to the correctness shape,in matched
this document.up
Copyright by AUDI AG.
to the vehicle, corrosion protection applied.

10 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Renewing expanded foam insert

Fix expanded foam insert to vehicle.
Apply filler foam D 506 KD 1 A3 to replacement panel.
Secure new part in position. Gently press in new part in vicinity of
expanded foam insert until it makes contact, and then weld into
place.
The foam hardens within 25 minutes.
Do not weld (SG) within 15 mm of the foam insert (on either side).
After painting the vehicle the repaired area must be cavity-sealed.

4. Expanded foam inserts 11

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

5 Body panel gaps/shut lines

Special tools and workshop equipment required
♦ The panel gaps can be checked with setting gauge -3371- .

Panel gaps - front

♦ Dimension -A- = 5.0 mm ± 0.5 mm
♦ Dimension -B- = 4.5 mm ± 0.5 mm

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♦ Dimension -C- = 5.0 mm ± 0.5 mm
♦ Dimension -D- = 3.0 mm ± 0.5 mm
♦ Dimension -E- = 4.5 mm ± 0.5 mm
♦ Dimension -F- = 3.5 mm ± 0.5 mm
♦ Dimension -G- = 5.5 mm ± 0.5 mm
♦ Dimension -H-Protected
= 4.5 mm ± 0.5 mm
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

♦ Dimension -J- = 3.5 mm ± 0.5 mm

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

12 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

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Panel gaps - rear
♦ Dimension -A- = 4.0 mm ± 0.5 mm
♦ Dimension -B- = 4.5 mm ± 0.5 mm
♦ Dimension -C- (front and rear) = 2.2 mm
♦ Dimension -D- (top and bottom) = 2 mm
♦ Dimension -E- = 5 mm ± 0.5 mm

5. Body panel gaps/shut lines 13

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Panel gaps - rear (Avant)
♦ Dimension -A- = 3.5 mm ± 0.5 mm
♦ Dimension -B- = 4.5 mm ± 0.5 mm
♦ Dimension -C- = 5.0 mm ± 0.5 mm
♦ Dimension -D- = 3.5 mm ± 0.5 mm
♦ Dimension -E- = 2.2 mm ± 0.5 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.

14 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

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5. Body panel gaps/shut lines 15

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

6 Laser welding
AUDI AG introduced laser welding for the production of the
Audi A4 saloon.
The laser welding technique employs a high-energy light beam
directed onto the weld by means of optical lenses or fibre optics.
During the welding process the upper panel is fused onto the par‐
tially molten lower panel, creating a weld joint with no additional
material.
When performing repairs, laser weld seams are replaced by SG
welds or pop rivets.

16 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

7 Bonded joints
Bonded and spot-welded/bonded joints are employed on the
Audi A4 saloon for increased body stiffness and strength.

7.1 Bonded joints

In the case of adhesive-bonded joints, the joint between the sheet
metal parts is formed only by the adhesive.

7.2 Spot-welded/bonded joints

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In spot-welded/bonded joints an electrically conductive adhesive
is used between the panels, which allows good root penetration
for spot welding.
The welding current must not be increased for spot-weld bonding
operations. The pre-press period must be extended to about 30
– 50 cycles because of the displacement of the adhesive. Always
use a fume extractor.
Spot-weld bonding is not carried out in the service sector.

7.3 Inspecting and repairing bonded joints

Particular attention should be given to these joints when diag‐
nosing accident damage and performing body repairs.
Note the following points: Do not use a chisel to test the strength
of a joint or relieve stresses by hammering as this will damage or
destroy the bonded joint.
These joints should be inspected particularly closely when diag‐
nosing accident damage and after performing straightening work
on the body.
If the joint is not accessible with pop rivets, it must be repaired
with an arc-welded seam (SG). In this case the entire area of the
joint must be re-welded, as the heat produced by welding de‐
stroys the adhesive in the bonded joint. The SG seams should be
welded working from the thin to the thick panel. Always use a fume
extractor.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7.4 Repair methods for replacing body parts
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

When performing repair work all spot-welded/bonded joints and

some bonded joints can be replaced with welded joints.
Do not make the repair with only the same spot welds or seams
as originally used in production. These alone are not adequate
for a proper joint.
Ensure good root penetration at all joints.

7. Bonded joints 17
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Seal off repaired joint flanges and apply cavity sealing.

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18 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

8 Straightening jig

Note

♦ The item numbers in the illustrations are identical with the end
numbers on the alignment bracket mountings.
♦ The item numbers of the alignment bracket mountings marked
with a circle are for checking the body with mechanical units
installed.
♦ The required basic set size is given for the alignment bracket
mountings.

Straightening bracket set supplement -VAS 6442- (incl. quattro

models)
Portal gauge -VAS 5007/35-
– Detailed information on setting up the alignment bracket set
can be found in the setup plan enclosed with the equipment.

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8. Straightening jig 19
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

9 Body dimensions

WARNING

These dimensions only serve as a check. Correct dimensions

are defined by the alignment bracket set.

Special tools and workshop equipment required

♦ Measure body dimensions using telescopic gauge -VAS 5160-
or telescopic gauge -VAS 5159- .

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20 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

9.1 Body - front (saloon and Avant identical)

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Distance between wing panel mountings
- A - 1420 ± 2 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
Distance between suspensionwithstrut mountings
respect to the correctness of information in this document. Copyright by AUDI AG.

- B - 856 ± 2 mm
Distance between suspension strut mountings
- C - 870 ± 2 mm

9. Body dimensions 21
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

22 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Distance between impact damper mountings

- A - 930 ± 2 mm
Distance between impact damper mountings
--1008 ± 2 mm

9.2 Body - centre (saloon)

Distance between A-pillar and B-pillar

- A - 924 ± 2 mm
Distance between B-pillars
- B - 1495 ± 2 mm

9. Body dimensions 23
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Distance between A-pillars (saloon and Avant identical)
- A - 1453 ± 2 mm

24 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

9. Body dimensions 25
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Distance between B-pillar and C-pillar

- A - 795 ± 2 mm
Distance between C-pillars
- B - 1435 ± 2 mm

9.3 Body - centre (Avant)

Distance between A-pillars (saloon and Avant identical)

- A - 1453 ± 2 mm

26 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Distance between A-pillar and B-pillar
- A - 911 ± 2 mm
Distance between B-pillars
- B - 1462 ± 2 mm

9. Body dimensions 27
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

28 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Distance between B-pillar and C-pillar

- A - 825 ± 2 mm
Distance between C-pillars
- B - 1435 ± 2 mm

9.4 Floor group - front (saloon and Avant identical)

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9. Body dimensions 29
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Distance between front longitudinal members

- A - 892 ± 2 mm
Diagonal distance between front longitudinal members
- B - 1127 ± 2 mm
Distance between front longitudinal members (at rear)
- C - 756 ± 2 mm

9.5 Floor group - rear (saloon and Avant identical)

30 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Distance between rear longitudinal members

- A - 1439 ± 2 mm
Diagonal distance between longitudinal members
- B - 1879 ± 2 mm
Distance between rear longitudinal members
- C - 955 ± 2 mm

9.6 Body - rear (saloon)

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9. Body dimensions 31
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Distance between rear longitudinal members

- A - 1020 ± 2 mm
Distance between tail light mountings
- B - 1206 ± 2 mm
Distance between window cross member and rear cross panel
(top)
- C - 549 ± 2 mm

9.7 Body - rear (Avant)

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Distance between rear longitudinal members

- A - 1020 ± 2 mm
Distance between tail light mountings
- B - 1187 ± 2 mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Distance between side panels (top) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- C - 1087 ± 2 mm

32 Rep. Gr.00 - Technical data

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Distance between roof flange and rear cross panel flange
- A - 921 ± 2 mm

9. Body dimensions 33
Audi A4 2008 ➤
Body Repairs - Edition 06.2009

50 – Body - front
RO: 50 53 55 00

1 Intermediate piece - Renewal

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

WARNING

Always observe safety precautions.

cardiagn.com
Safety notes ⇒ General Information; Body Repairs, Generalpermitted
Body unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Repairs ; Safety notes . with respect to the correctness of information in this document. Copyright by AUDI AG.

1.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Chisel -VAS 5300/34-
♦ Drill -VAS 5830-
♦ Grinder -VAS 5170-
♦ Compact angle grinder -VAS 5167-
♦ Laser weld seam grinder -VAS 6319-

34 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523 A-

♦ Spot weld breaker -V.A.G 1731-

1.2 Procedure
Cutting locations
– -A- - Grind open laser weld seam using laser weld seam grind‐
er -VAS 6319- .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Detach part.
– Remove remaining material using compact angle grinder -
VAS 5167- .

1. Intermediate piece - Renewal 35

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement parts
♦ Connecting plates
Preparing new part
– Drill 7 mm ∅ holes for SG plug weld seam using drill -VAS
5830- .
– Using compact angle grinder -VAS 5167- , grind Protected
down new by copyright. Copying for private or commercial purposes, in part or in whole, is not
part for SG continuous seam in place of laser weld.
permitted unless authorised by AUDI 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.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Welding in
– Match up reinforcement and weld in using resistance spot
welder : RP spot weld seam.
– Weld in intermediate piece using shielded arc welding equip‐
ment 250A -VAS 6045 A- : SG continuous seam in place of
laser weld.
– Weld in new part using shielded arc welding equipment 250A
-VAS 6045 A- : SG plug weld seam.

1. Intermediate piece - Renewal 37

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

38 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 50 72 55 00

2 Upper wheel housing longitudinal

member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
2.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Laser weld seam grinder -VAS 6319-

2. Upper wheel housing longitudinal member - Renewal 39

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523 A-

♦ Spot weld breaker -V.A.G 1731-

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2.2 Procedure
• Intermediate piece already removed
Cutting locations

Note

Partial renewal is possible with the separating cut shown. Place

a backing plate of the same material behind the joint and make
SG continuous seam.

Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Make separating cut as shown using pneumatic sabre saw -
V.A.G 1523A- .

Note

Take care not to damage the bonnet lock cable when making the separating cut.

– Grind open laser weld Protected

seam using laser
by copyright. weldforseam
Copying private orgrinder - purposes, in part or in whole, is not
commercial
VAS 6319- . permitted unless authorised by AUDI 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 remaining material using compact angle grinder -
VAS 5167- .

40 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Upper wheel housing longitudinal member
Welding in
– Fix new part on alignment bracket.
– Weld in upper wheel housing longitudinal member using re‐
sistance spot welder : RP spot weld seam.
– Weld in upper wheel housing longitudinal member using shiel‐
ded arc welding equipment 250A -VAS 6045A- : SG plug weld
seam.
– Butt weld at separating cut using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG continuous seam.

2. Upper wheel housing longitudinal member - Renewal 41

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

42 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 50 74 55 00

3 Suspension strut mounting - Renew‐

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results
Protectedwhen performing
by copyright. spot or
Copying for private welding
commercial purposes, in part or in whole, is not
operations. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

cardiagn.com
3.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Spot weld breaker -V.A.G 1731-

3.2 Procedure
Cutting locations

Note

Take care not to damage the bonnet lock cable when making the
separating cut.

3. Suspension strut mounting - Renewal 43

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Separate original joint at suspension strut mounting using spot

weld breaker -V.A.G 1731- .

cardiagn.com
– Separate original joint at suspension strut mounting using spot
weld breaker -V.A.G 1731- .
– Take off part.
– Remove remaining material using compact angle grinder -
VAS 5167- .

44 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Replacement 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.
♦ Suspension strut mounting
Preparing new part
– Drill holes for SG plug weld seam in suspension strut mounting
using drill -VAS 5830- .

3. Suspension strut mounting - Renewal 45

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Welding in
– Fix new part on alignment bracket.
– Weld in suspension strut mounting at front using shielded arc
welding equipment 250A -VAS 6045A- : SG plug weld seam.

46 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in suspension strut mounting using resistance spot weld‐
er : RP spot weld seam.

3. Suspension strut mounting - Renewal 47

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

48 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 50 79 55 02

4 Front longitudinal member - Partial

renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
4.1 Tools
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ unless
permitted Shielded
authorisedarc welding
by AUDI equipment
AG. AUDI 250A -VAS
AG does not guarantee 6045A-
or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic sabre saw -V.A.G 1523 A-

4.2 Procedure
Cutting locations
– Dimension -A- = 158 mm
– Cut out longitudinal member using pneumatic sabre saw -
V.A.G 1523A- .

Note

Separating cut must be a straight line.

4. Front longitudinal member - Partial renewal 49

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Cut out longitudinal member using pneumatic sabre saw -
V.A.G 1523A- .

50 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Sub-part - longitudinal member

4. Front longitudinal member - Partial renewal 51

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Preparing new part
– Cut to length if necessary using pneumatic sabre saw -V.A.G
1523A- .

Note

Align longitudinal member with lock carrier, cross member and

headlight to bumper.

Welding in
– Fix new part on alignment bracket.
– Weld in longitudinal member at front using shielded arc weld‐
ing equipment 250A -VAS 6045A- : SG continuous seam.

52 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Weld in longitudinal member at front using shielded arc weld‐

ing equipment 250A -VAS 6045A- : SG continuous seam.

4. Front longitudinal member - Partial renewal 53

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

54 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 50 79 55 04

5 Front longitudinal member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

5.1 Tools

cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special
permitted tools and
unless authorised workshop
by AUDI AG. AUDI AG equipment required
does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Laser weld seam grinder -VAS 6319-

♦ Pneumatic sabre saw -V.A.G 1523 A-

5. Front longitudinal member - Renewal 55

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Spot weld breaker -V.A.G 1731-

5.2 Procedure

Note

The plenum chamber partition panel can be re-used.

cardiagn.com
Cutting locations
– Separate original joint at plenum chamber partition panel us‐
ing spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

56 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
WARNING

If the inner longitudinal member reinforcement is damaged it

must also be renewed.

– Make separating cut at longitudinal member using pneumatic

sabre saw -V.A.G 1523A- . Take care not to damage internal
reinforcement. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Offset separating cuts to with
achieve the required strength when
respect to the correctness of information in this document. Copyright by AUDI AG.

welding.
– Grind open laser weld seam using laser weld seam grinder -
VAS 6319- .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

5. Front longitudinal member - Renewal 57

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Offset separating cuts to achieve the required strength when
welding.
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

58 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI 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 longitudinal member
♦ Longitudinal member
Preparing new parts
– Transfer separating cut to new part using pneumatic sabre
saw -V.A.G 1523A- .

5. Front longitudinal member - Renewal 59

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Transfer permitted
separating cut to new part using pneumatic sabre
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

saw -V.A.G 1523A- .

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

60 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Welding in
– Match up new parts and secure on alignment bracket.
– Butt weld at separating cut using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG continuous seam.
– Weld in longitudinal member using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG plug weld seam.

5. Front longitudinal member - Renewal 61

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Match up new parts and secure on alignment bracket.
– Butt weld at separating cut using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG continuous seam.
– Weld in longitudinal member using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG plug weld seam.

62 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in plenum chamber partition panel using shielded arc
welding equipment 250A -VAS 6045A- : SG plug weld seam.

5. Front longitudinal member - Renewal 63

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

64 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 50 81 55 00

6 Longitudinal member reinforcement

(front) - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
6.1 Tools
Special tools and workshop equipment required
♦ Shielded arc welding equipment 250A -VAS 6045A-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Drill -VAS 5830- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

6.2 Procedure
♦ Longitudinal member 1 + 2 (front) already removed
Cutting locations
– Drill out welds on longitudinal member reinforcement from in‐
side using drill -VAS 5830- .

6. Longitudinal member reinforcement (front) - Renewal 65

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Drill out welds on longitudinal member reinforcement from in‐

side using drill -VAS 5830- .
– Grind open laser weld seam using laser weld seam grinder -
VAS 6319- .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

66 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Longitudinal member reinforcement
Welding in
– Weld in longitudinal member reinforcement using shielded arc
welding equipment 250A -VAS 6045A- : SG plug weld seam.

6. Longitudinal member reinforcement (front) - Renewal 67

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

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

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

68 Rep. Gr.50 - Body - front

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

51 – Body - centre
RO: 51 03 55 00

1 Roof - Renewal (saloon)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

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

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding

cardiagn.com
operations.

1.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Drill -VAS 5830-
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic sabre saw -V.A.G 1523 A-

1. Roof - Renewal (saloon) 69

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Spot weld breaker -V.A.G 1731-

♦ Replacement breaker for high-strength steel -V.A.G 1731/2-

♦ Pneumatic pop riveter -V.A.G 2003A-
♦ Mole grips, 18-18 -VAS 5430/1-
♦ Tensioning strap -T10038-

cardiagn.com
♦ Pneumatic cartridge gun -V.A.G 1761/1-
♦ Cartridge heater -V.A.G 1939 A-
♦ Double cartridge gunProtected
-VAS by 5237-
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

70 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

1.2 Procedure
Cutting locations

1. Roof - Renewal (saloon) 71

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Roughly cut out roof using pneumatic sabre saw -V.A.G
1523A- .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Make separating cuts at plasmatron weld seam.

WARNING

Do not damage roof cross member (front and rear) when sep‐
arating.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove remaining material using compact angle permitted
grinder -
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
VAS 5167- .
Take care not to damage roof frame when removing remaining
material from roof frame.
Do not use cutting discs or rough-filing discs.

72 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Note

Observe safety precautions listed in General notes, Body repairs

and General body repairs.

Replacement parts
♦ Roof
♦ Single-component assembly adhesive -D 190 MKD A3- , 1
cartridge
♦ 2-component body adhesive -DA 180 A00 A2- , 2 sets of car‐
tridges
♦ Silicone remover -LSE 020 100 A3-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Zinc spray permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Pop rivet -N 909 236 01-

1. Roof - Renewal (saloon) 73

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Preparing new part

Note

♦ It is important to keep to the following procedure to ensure a

satisfactory and effective roof repair.
♦ Bonded areas must not be treated with filler coat before bond‐
ing in centre roof section.

– Fit roof and fix in position with self-tapping screws.

cardiagn.com

– After fitting roof, match up jointing brackets and mark positions

accordingly.
Protected Make
by copyright. sure
Copying there
for private is access
or commercial for riveting
purposes, in part or intool from
whole, is not
below,unless
permitted especially
authorised around
by AUDI AG. front
AUDI deformation element.
AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

74 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Take off roof and jointing brackets.
– Drill ∅ 5 mm holes at marked positions in roof frame using drill
-VAS 5830- .
• Do not drill rivet holes in spot welds;
Protected this could
by copyright. adversely
Copying for private or affect
commercial purposes, in part or in whole, is not
the stiffness of the body. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
• Jointing bracket A: drill holes for 2 rivets with drill -VAS 5830- .
• Jointing bracket B: drill holes for 2 rivets with drill -VAS 5830- .
• Jointing bracket C: drill holes for 4 rivets with drill -VAS 5830- .
• Jointing bracket D: drill holes for 3 rivets with drill -VAS 5830- .

1. Roof - Renewal (saloon) 75

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Fit roof in position in order to drill holes in jointing brackets.
– Slide jointing brackets into marked positions so they make
contact with inside edge of roof frame.
– Fix jointing brackets in position with mole grips, 18-18 -VAS
5430/1- .
– Start holes in jointing brackets by applying drill -VAS 5830-
through previously drilled rivet holes.
– Detach roof and jointing brackets from body.
– Drill holes in jointing brackets outside vehicle and deburr
holes.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

76 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Clean all bonding surfaces with silicone remover LSE 020 100
A3.
– Apply adhesive D 190 MKD A3 to roof frame using pneumatic
cartridge gun -V.A.G 1761/1- .

1. Roof - Renewal (saloon) 77

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Cut static mixer from adhesive set D 180 KD3 A2 down to the
4th notch to obtain the required bead cross section.

– Prepare adhesive cartridges required for bonding.

– Apply adhesive beads onto roof side members using double
cartridge gun -VAS 5237- .

78 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Note

Also apply adhesive in area of contact surfaces of all jointing

brackets on roof frame.

– Apply adhesive bead onto previously cleaned new roof panel

(replacement part) using double cartridge gun -VAS 5237- .

1. Roof - Renewal (saloon) 79

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fit roof and fix in position with self-tapping screws.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

80 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Fit jointing brackets.

Note

Before fitting jointing brackets, apply adhesive at contact surface

for roof.

Rivet in jointing brackets using pneumatic pop riveter -V.A.G

2003A- and pop rivets N 909 236 01.

1. Roof - Renewal (saloon) 81

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in roof at front using resistance spot welder : RP spot
weld seam.
– Make additional weld for roof at front using shielded arc weld‐
ing equipment 250A -VAS 6045A- : SG continuous seam.

82 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in roof at rear using resistance spot welder : RP spot
weld seam.
– Make additional weld for roof at rear using shielded arc weld‐
ing equipment 250A -VAS 6045A- : SG continuous seam.

1. Roof - Renewal (saloon) 83

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Note

RO: 51 03 55 00
1.3 Vehicles with sliding/tilting sunroof

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

84 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .
The method of bonding in the roof with jointing brackets is the
same as for vehicles without sunroof.

1.4 Tools
Special tools and workshop equipment required
♦ Resistance spot welder
Protected -VASCopying
by copyright. 6239forA-private
or or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Resistance spotwith
welder -VAS 6525- or
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Resistance spot welder -VAS 6530- or

♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-

cardiagn.com
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Drill -VAS 5830-
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic sabre saw -V.A.G 1523 A-

♦ Spot weld breaker -V.A.G 1731-

♦ Replacement breaker for high-strength steel -V.A.G 1731/2-

♦ Pneumatic pop riveter -V.A.G 2003A-
♦ Mole grips, 18-18 -VAS 5430/1-

1. Roof - Renewal (saloon) 85

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Tensioning strap -T10038-

♦ Pneumatic cartridge gun -V.A.G 1761/1-

♦ Cartridge heater -V.A.G 1939 A-
♦ Double cartridge gun -VAS 5237-

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

86 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

1.5 Procedure
Cutting locations

Note

Only 3 jointing brackets are installed on vehicles with sliding/tilting sunroof.

cardiagn.com
The front jointing bracket -A- is not fitted.
In place of jointing bracket -A-, pop rivet N 909 236 01 is set here
in area adjacent to deformation element using pneumatic pop riv‐
eter -V.A.G 2003A- .

1. Roof - Renewal (saloon) 87

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
This rivet joins the roof
Protected frameCopying
by copyright. to theforslide/tilt sunroofpurposes,
private or commercial frame.in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

88 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

1. Roof - Renewal (saloon) 89

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 03 55 00

2 Roof - Renewal (Avant)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

2.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic pop riveter -V.A.G 2003A-
♦ Mole grips, 18-18 -VAS 5430/1-
♦ Tensioning strap -T10038-

90 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523A-

♦ Spot weld breaker -V.A.G 1731-

cardiagn.com
♦ Replacement breaker for high-strength steel -V.A.G 1731/2-
♦ Pneumatic cartridge gun -V.A.G 1761/1-
♦ Cartridge heater -V.A.G 1939 A-
♦ Pneumatic gun -VAS 6453-

2.2 Procedure

WARNING

Do not damage roof cross member

Protected (front
by copyright. and
Copying rear)orwhen
for private sep‐
commercial purposes, in part or in whole, is not
arating. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Cutting locations
– Roughly cut out roof using pneumatic sabre saw -V.A.G
1523A- .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Make separating cuts at plasmatron weld seam.

2. Roof - Renewal (Avant) 91

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Remove remaining material using compact angle grinder -
VAS 5167- .
Take care not to damage roof frame when removing remaining
material from roof frame.
Do not use cutting discs or rough-filing discs.

92 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement parts
♦ Roof
♦ Pop rivet -N 909 236 01-
♦ Single-component assembly adhesive -D 190 MKD A3- , 1
cartridge
♦ 2-component body adhesive -DA 180 A00 A2- , 2 sets of car‐
tridges
♦ Silicone remover -LSE 020 100 A3-
♦ Zinc spray

2. Roof - Renewal (Avant) 93

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Preparing new part

Note

♦ It is important to keep to the following procedure to ensure a

satisfactory and effective roof repair.
♦ Bonded areas must not be treated with filler coat before bond‐
ing in centre roof section.

– Fit roof and fix in position with self-tapping screws.

cardiagn.com

– After fitting roof, match up jointing brackets and mark positions

accordingly. Make sure there is access for riveting tool from
below, especially around front deformation element.

94 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

2. Roof - Renewal (Avant) 95

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Take off roof and jointing brackets.
– Drill ∅ 5 mm holes at marked positions in roof frame using drill
-VAS 5830- .

Note

Do not drill rivet holes in spot welds; this could adversely affect the stiffness of the body.

• Jointing bracket A: drill holes for 2 rivets with drill -VAS 5830- .
• Jointing bracket B: drill holes for 2 rivets with drill -VAS 5830- .
• Jointing bracket C: drill holes for 4 rivets with drill -VAS 5830- .
• Jointing bracket D: drill holes for 2 rivets with drill -VAS 5830- .
• Jointing bracket E: drill holes for 3 rivets with drill -VAS 5830- .

96 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Fit roof in position in order to drill holes in jointing brackets.

– Slide jointing brackets into marked positions so they make
contact with inside edge of roof frame.
– Fix jointing brackets in position with mole grips, 18-18 -VAS
5430/1- .
– Start holes in jointing brackets by applying drill -VAS 5830-
through previously drilled rivet holes.
– Detach roof and jointing brackets from body.
– Drill holes in jointing brackets outside vehicle and deburr
holes.

2. Roof - Renewal (Avant) 97

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

98 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Clean all bonding surfaces with silicone remover LSE 020 100
A3.
– Apply adhesive D 190 MKD A3 to roof frame using pneumatic
cartridge gun -V.A.G 1761/1- .

2. Roof - Renewal (Avant) 99

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Cut static mixer from 2-component body adhesive set DA 180

A 00 A2 down to 4th notch to obtain required bead cross sec‐
tion.

– Prepare adhesive cartridges required for bonding.

– Apply adhesive beads to roof side members using pneumatic
gun -VAS 6453- .

100 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Note

Also apply adhesive in area of contact surfaces of all jointing brackets on roof frame.

2. Roof - Renewal (Avant) 101

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Clean replacement roof panel and apply adhesive bead using

pneumatic gun -VAS 6453- .

cardiagn.com
– Fit roof and fix in position with self-tapping screws.

102 Rep. Gr.51 - Body - centre

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Body Repairs - Edition 06.2009

cardiagn.com
– Fit jointing brackets.

Note

Before fitting jointing brackets, apply body adhesive DA 180 A 00

A2 at contact surface for roof.

Rivet in jointing brackets using pneumatic pop riveter -V.A.G

2003A- and pop rivets N 909 236 01.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI 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. Roof - Renewal (Avant) 103

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

104 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

2. Roof - Renewal (Avant) 105

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
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 completing 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).
♦ Do not continue working on the vehicle until the curing time
has elapsed.

106 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

3 Vehicles with sliding/tilting sunroof

(Avant)

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

3.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VASProtected
6530-byorcopyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Resistance spot welder -VAS 6535- or to the correctness of information in this document. Copyright by AUDI AG.
with respect

♦ Resistance spot welder -VAS 6545-

♦ Compact angle grinder -VAS 5167-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Pneumatic pop riveter -V.A.G 2003A-
♦ Mole grips, 18-18 -VAS 5430/1-
♦ Tensioning strap -T10038-

3. Vehicles with sliding/tilting sunroof (Avant) 107

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523A-

♦ Spot weld breaker -V.A.G 1731-

cardiagn.com
♦ Replacement breaker for high-strength steel -V.A.G 1731/2-
♦ Pneumatic cartridge gun -V.A.G 1761/1-
♦ Cartridge heater -V.A.G 1939 A-
♦ Pneumatic gun -VAS 6453-

3.2 Procedure
Cutting locations
– Roughly cut out roof using pneumatic sabre saw -V.A.G
1523A- .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Make separating cuts at plasmatron weld seam.

108 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Remove remaining material using compact angle grinder -

VAS 5167- .
Take care not to damage roof frame when removing remaining
material from roof frame.
Do not use cutting discs or rough-filing discs.

3. Vehicles with sliding/tilting sunroof (Avant) 109

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Match up roof and fix in position with self-tapping screws.

110 Rep. Gr.51 - Body - centre

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Body Repairs - Edition 06.2009

cardiagn.com
Overview of front riveting positions

3. Vehicles with sliding/tilting sunroof (Avant) 111

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Overview of rear riveting positions

112 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Mark riveting positions on roof frame flange (12x on each side of

vehicle). Make sure there is access for riveting tool from below,
especially around deformation elements.

3. Vehicles with sliding/tilting sunroof (Avant) 113

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Drill rivet holes (∅5 mm) from above using drill -VAS 5830- .

114 Rep. Gr.51 - Body - centre

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cardiagn.com
Replacement parts
♦ Roof
♦ Single-component assembly adhesive -D 190 MKD A3- , 1
cartridge
♦ 2-component body adhesive -DA 180 A00 A2- , 1 cartridge set
♦ Silicone remover -LSE 020 100 A3-
♦ Zinc spray
♦ Pop rivet -N 909 236 01-
Preparing new part

Note

♦ It is important to keep to the followingProtected

procedure to ensure
by copyright. a private or commercial purposes, in part or in whole, is not
Copying for
satisfactory and effective roof repair. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Bonded areas must not be treated with filler coat before bond‐
ing in centre roof section.

– Clean all bonding surfaces with silicone remover LSE 020 100
A3.

3. Vehicles with sliding/tilting sunroof (Avant) 115

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Apply adhesive D 190 MKD A3 to roof frame using pneumatic

cartridge gun -V.A.G 1761/1- .
– Use one continuous adhesive bead on front roof frame and 4
smaller adhesive beads on rear roof frame.

Note
cardiagn.com
Do not apply the adhesive until after mixing the two components;
try out first with a bead of adhesive approx. 10 cm long.

– Apply continuous adhesive bead around zero-gap joint.

– Prepare adhesive cartridges required for bonding.
– Apply adhesive beads to roof side members using pneumatic
gun -VAS 6453- .
– Apply adhesive to side roof frame
Protected flangeCopying
by copyright. around complete
for private or commercial purposes, in part or in whole, is not
contact area of reinforcement 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.
– Apply adhesive to front and rear roof cross members in contact
area of reinforcement frame.

116 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Clean replacement roof panel and apply adhesive bead using

pneumatic gun -VAS 6453- .

3. Vehicles with sliding/tilting sunroof (Avant) 117

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Fit roof and fix in position with self-tapping screws and

2 clamping fixtures at front and rear.
– Roughly smooth over adhesive emerging from joints.

118 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Additionally secure roof with tensioning straps -T10038- .

3. Vehicles with sliding/tilting sunroof (Avant) 119

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Note

♦ After completing 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).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Do not continue working on the vehicle until thewith
curing
respecttime
to the correctness of information in this document. Copyright by AUDI AG.
has elapsed.

– Weld in roof at rear using resistance spot welder : RP spot

weld seam.
– Make additional weld for roof at rear using shielded arc weld‐
ing equipment 250A -VAS 6045A- : SG continuous seam.

120 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Weld in roof at front using resistance spot welder : RP spot

weld seam.
– Make additional weld for roof at front using shielded arc weld‐
ing equipment 250A -VAS 6045A- : SG continuous seam.

3. Vehicles with sliding/tilting sunroof (Avant) 121

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Sectional view of rivets (Seitenwandrahmen = side panel frame;

Dach = roof; Kleber = adhesive; Blindniet = pop rivet)

122 Rep. Gr.51 - Body - centre

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Body Repairs - Edition 06.2009

cardiagn.com
Rivet in roof frame using pneumatic pop riveter -V.A.G 2003A-
and pop rivets N 909 236 01 (Säule B = B-pillar).

3. Vehicles with sliding/tilting sunroof (Avant) 123

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Rivet in roof frame using pneumatic pop riveter -V.A.G 2003A-
and pop rivets N 909 236 01.

124 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
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3. Vehicles with sliding/tilting sunroof (Avant) 125

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 08 55 50

4 Front roof cross member - Renewal

4.1 Tools

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Always observe safety precautions. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

cardiagn.com
Safety notes ⇒ General Information; Body Repairs, General Body
Repairs ; Safety notes .
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

4.2 Procedure
• Roof already removed
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

126 Rep. Gr.51 - Body - centre

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cardiagn.com
Replacement part
♦ Roof cross member
Welding in
– Match up and fix new part in position.
– Weld in new part using resistance spot welder : RP spot weld
seam.

4. Front roof cross member - Renewal 127

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– In place of bonded joint, weld in roof cross member using
shielded arc welding equipment 250A -VAS 6045A- : 1 x 10
mm SG continuous seam (staggered - with gaps).

128 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
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4. Front roof cross member - Renewal 129

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 05 55 50

5 Roof side member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .
Various body cavities ofProtected
the Audi A4 2008 are fitted with expanded
by copyright. Copying for private or commercial purposes, in part or in whole, is not

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

The foam inserts serve as a reinforcement for roof carrier units.

These pre-moulded parts are fitted during body manufacture and
subsequently increase their volume in the paint shop drying oven
at approx. 180 °C after priming.

Note

cardiagn.com
In place of these structural inserts, the roof side member must be
filled with foam.

130 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
5.1 Tools

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

Special tools and workshop equipment required

♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-

5. Roof side member - Renewal 131

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Spot weld breaker -V.A.G 1731-

5.2 Procedure
• Roof already removed
Cutting locations
– Make separating cuts as shown.
– Separate original joint.

cardiagn.com
– Remove remaining material using compact angle grinder -
VAS 5167- .

132 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ Roof side member
Welding in
– Match up and fix new part in position.
– Weld in new part using resistance spot welder -VAS 6239 A- :
RP spot weld seam.
– Weld in at separating cuts using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG continuous seam.

cardiagn.com
5.3 Foam-filling roof side member

Note

♦ After foam-filling is completed, the vehicle must be left stand‐

ing for 24 hours on a level surface at a room temperature of
15°C to allow the adhesive components to harden (curing
time).
♦ Do not continue working on the vehicle until the curing time
has elapsed.

5. Roof side member - Renewal 133

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Caution

The replacement foam inserts expand only after reaching

about 180°C. For this reason, a 2-component epoxy hard foam
is used when performing repairs.
The material required for repairs is 2-component epoxy hard
foam -AKD 506 12 A- .

Note

One cartridge of 2-component epoxy hard foam -AKD 506 12 A-

is required for each side of the car.

As the required temperatures cannot be achieved under normal

workshop conditions, proceed as follows:
It is important to keep exactly to the procedure as described:
Heat the cartridge of structural foam
Protected by material
copyright. Copying for 30 minutes
for private in purposes,
or commercial a in part or in whole, is not

cardiagn.com
water bath at a constant temperature
with respect to theof approx.of 60
correctness °C. in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
information

The cartridge can also be heated at 60° C in a suitable oven, if

available.
Prepare static mixer for foaming operation.
Inject foam into holes.
Replacement parts
♦ 2-component epoxy hard foam -AKD 506 12 A-
Special tools and workshop equipment required
♦ Double cartridge gun -VAS 5237-

– Heat the cartridge of structural foam material for 30 minutes in

a water bath at a constant temperature of approx. 60 °C.
The cartridge can also be heated at 60° C in a suitable oven, if
available.

134 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

1 - Cartridge of 2-component
structural foam material
– Open cap.

2 - Static mixer
3 - Extension hose
4 - Adapter

– Screw onto structural

foam cartridge -1- to‐
gether with static mixer
-2-.

cardiagn.com
Overview of steps 1 – 6 when injecting foam by means of double
cartridge gun -VAS 5237-

5. Roof side member - Renewal 135

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Elongated hole - A - (aperture for crash element)

Mask off holes for roof trim moulding - B - with commercially
available adhesive tape.

136 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Preparing extension hose
– Mark hose at 20 mm, 60 mm and 100 mm.

5. Roof side member - Renewal 137

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Step 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

– Apply extension hose at right angles and insert hose approx.

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

100 mm into aperture for front crash element.

– Start injecting foam material and continue until first mark is
reached (graduation 11 on cartridge gun).

138 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Step 2
– When first mark is reached, pull hose out approx. 40 mm.
– Continue injecting foam until second mark (graduation 16).

5. Roof side member - Renewal 139

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Step 3
– When second mark is reached, pull hose out once more ap‐
prox. 40 mm.
– Continue injecting foam until third mark (graduation 23).
Pull extension hose out of aperture.

Note

In order to install the roof trim moulding, the 2-component epoxy hard foam must be cleaned out of the rivet
holes and the holes for the crash element.

140 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
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cardiagn.com
Step 4
– Apply extension hose at right angles and insert hose approx.
100 mm into aperture for rear crash element.
– Start injecting foam material and continue until fourth mark is
reached (graduation 31 on cartridge gun).

5. Roof side member - Renewal 141

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Step 5
– When mark is reached, pull hose out approx. 40 mm.
– Continue injecting foam until fifth mark (graduation 37).

142 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Step 6
– When mark is reached, pull hose out approx. 40 mm.
– Continue injecting foam until cartridge is completely empty.

Note

In order to install the roof trim moulding, the 2-component epoxy hard foam must be cleaned out of the rivet
holes and the holes for the crash element.

5. Roof side member - Renewal 143

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Note

♦ After foam-filling is completed, the vehicle must be left stand‐

144 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 08 55 50

6 Front roof cross member - Renewal

(Avant)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

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

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

6.2 Procedure
• Roof already removed
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

6. Front roof cross member - Renewal (Avant) 145

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ Roof cross member
Welding in

146 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Match up and fix new part in position.
– Weld in new part using resistance spot welder : RP spot weld
seam.

6. Front roof cross member - Renewal (Avant) 147

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– In place of bonded joint, weld in roof cross member using
shielded arc welding equipment 250A -VAS 6045A- : 2 x 20
mm SG continuous seam on both sides.

148 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

6. Front roof cross member - Renewal (Avant) 149

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 09 55 50

7 Rear roof frame - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

7.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

7.2 Procedure
• Roof already removed
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

150 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement parts
♦ Rear roof frame
Welding in
– Match up and fix new part in position.
– Weld in new part using resistance spot welder : RP spot weld
seam.

7. Rear roof frame - Renewal 151

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Note

This joint is additionally bonded. Make additional 2 x 10 mm SG continuous seam (staggered - with gaps) in
place of bonded joint.

– Weld in remaining joint using shielded arc welding equipment

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
250A -VAS 6045A- : SG continuous seam (staggered -permitted
with unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
gaps). with respect to the correctness of information in this document. Copyright by AUDI AG.

152 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

7. Rear roof frame - Renewal 153

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 09 55 50

8 Rear roof frame - Renewal (Avant)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

8.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 6267-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

8.2 Procedure
• Roof already removed
Cutting locations
– Separate original joint using drill -VAS 6267- .

154 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

View from below

– Separate original joint using drill -VAS 6267- .

8. Rear roof frame - Renewal (Avant) 155

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Remove remaining material using compact angle grinder -
VAS 5167- .

156 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
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cardiagn.com
Replacement parts
♦ Roof frame (upper rear)
♦ Roof frame (lower rear)
Welding in
– Match up and fix new part in position.
– Weld in new part using resistance spot welder : RP spot weld
seam.

8. Rear roof frame - Renewal (Avant) 157

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Note

This joint is additionally bonded. Make additional 2 x 10 mm SG

continuous seam (staggered - with gaps) in place of bonded joint.

158 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 37 55 00

9 A-pillar - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .
Protected by copyright. Copying for private or 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.

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

9.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic sabre saw -V.A.G 1523A-

9. A-pillar - Renewal 159

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Hot air blower -V.A.G 1416-

♦ Spot weld breaker -V.A.G 1731-

cardiagn.com
9.2 Procedure Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Cutting locations
– Make separating cut at top according to extent of damage us‐
ing pneumatic sabre saw -V.A.G 1523A- .
– Take care not to damage inner reinforcement when making
separating cut in sill.
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

Note

Partial renewal is possible with the separating cuts illustrated. Place a backing plate of the same material behind
the joint and make SG continuous seam.

160 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ A-pillar (sub-part)
Preparing new part
Welding in
– Place backing plate of same material behind separating cuts.
– Butt weld at separating cuts using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG continuous seam.

9. A-pillar - Renewal 161

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Protected by copyright. Copying for private or 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 in A-pillar using resistance spot welder : RP spot weld
with respect to the correctness of information in this document. Copyright by AUDI AG.

seam.

162 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in A-pillar using shielded arc welding equipment 250A -
VAS 6045A- : SG continuous seam.
– Weld in A-pillar at bottom using resistance spot welder : RP
spot weld seam.
– In place of bonded joint, weld in A-pillar using shielded arc
welding equipment 250A -VAS 6045A- : SG continuous seam
(staggered - with gaps).

9. A-pillar - Renewal 163

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Renewing expanded foam insert
– Pre-heat relevant area of body evenly with hot air blower -
V.A.G 1416- (600°C rating) for 3.5 minutes. Then install part
and heat again for 3.5 minutes until a visible amount of foam
comes out.

WARNING

During this operation take care to apply the hot air evenly to
avoid damage (discolouration) to the paintwork and the plastic
stiffener.

164 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

9. A-pillar - Renewal 165

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 38 55 50

10 Inner A-pillar - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

10.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Hand cartridge gun -VAS 5155-

♦ Hole punch pliers -V.A.G 1329-

166 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Spot weld breaker -V.A.G 1731-

10.2 Procedure
• Outer A-pillar already cut out.
• Intermediate piece already cut out.
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .

cardiagn.com
– -A- Separate original joint at A-pillar (top) using spot weld
breaker -V.A.G 1731- .
– Pull out inner A-pillar from below.
– Remove remaining material using compact angle grinder -
VAS 5167- .

10. Inner A-pillar - Renewal 167

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
2-component body adhesive -DA 001 730 A1-
Inner A-pillar
Preparing new part
♦ Make 7 mm ∅ holes for SG plug weld seam using hole punch
pliers -V.A.G 1329- .

168 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Welding in
– Apply 2-component body adhesive -DA 001 730 A1- to inner
A-pillar using hand cartridge gun -VAS 5155- .

10. Inner A-pillar - Renewal 169

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Weld in inner A-pillar using resistance spot welder : RP spot

weld seam.
– Weld in A-pillar using shielded arc welding equipment 250A -
VAS 6045A- : SG plug weld seam.

170 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

10. Inner A-pillar - Renewal 171

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 42 55 50

11 Outer B-pillar - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

11.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

♦ Replacement breaker for high-strength steel -V.A.G 1731/2-

172 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523A-

11.2 Procedure

Note

Partial renewal is possible with the separating cuts illustrated.

Place a backing plate of the same material behind the joint and
make SG continuous seam.

cardiagn.com
Cutting locations

Note

The inner B-pillar is made of high-strength steel.

– Separate original joint using spot weld breaker -V.A.G 1731- .

– Make separating cuts as shown using pneumatic sabre saw -
V.A.G 1523A- .

11. Outer B-pillar - Renewal 173

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ B-pillar (sub-part)
Preparing new part
– Transfer separating cuts to new part and cut to shape using
pneumatic sabre saw -V.A.G 1523A- .

174 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Welding in
– Match up inner B-pillar with no load on vehicle and fix in posi‐
tion.
– Weld in outer B-pillar using resistance spot welder : RP spot
weld seam.

11. Outer B-pillar - Renewal 175

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Place a backing plate of the same material behind the joints

and weld in using shielded arc welding equipment 250A -VAS
6045A- : SG continuous seam.

176 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

11. Outer B-pillar - Renewal 177

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 42 55 50

12 Inner B-pillar - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed belowProtected
must by copyright. Copying for private or commercial purposes, in part or in whole, is not
be used to ensure correct results when performing spot 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.
operations.

12.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

♦ Pneumatic sabre saw -V.A.G 1523A-

178 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

12.2 Procedure

Note

The inner B-pillar is made of high-strength steel.

Cutting locations
Make separating cuts as shown.

Note

On USA vehicles the roof panel has to be renewed as well be‐

cause of the additional internal reinforcements in the B-pillar.

Caution

Take care not to damageProtected

internal roof frame.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

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

– The separating cuts may only be made at the positions shown.

– Separate original joint using spot weld breaker -V.A.G 1731- .
– Make separating cuts with pneumatic sabre saw -V.A.G
1523A- .

12. Inner B-pillar - Renewal 179

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

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

cardiagn.com
permitted unless authorised by AUDI 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 separating cuts with pneumatic sabre saw -V.A.G

1523A- .
– Separate original joint using spot weld breaker -V.A.G 1731- .

180 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement parts
♦ Inner B-pillar
Preparing new part
– Transfer separating cut to new part using compact angle grind‐
er -VAS 5167- .

12. Inner B-pillar - Renewal 181

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Match up inner B-pillar with no load on vehicle and fix in posi‐
tion.
– Weld in inner B-pillar using shielded arc welding equipment
250A -VAS 6045A- : SG continuous seam (staggered - with
gaps).
– Weld in inner B-pillar using resistance spot welder : RP spot
weld seam.

182 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Place
permitted backing
unless authorisedplate
by AUDIofAG.same
AUDI AGmaterial behindorjoints.
does not guarantee accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Match up outer B-pillar with no load on vehicle and fix in po‐
sition.
– Weld in outer B-pillar at separating cuts using shielded arc
welding equipment 250A -VAS 6045A- : SG continuous seam.
– Weld in outer B-pillar using resistance spot welder : RP spot
weld seam.

12. Inner B-pillar - Renewal 183

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

184 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 42 55 52

13 Inner B-pillar - Partial renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

13.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI 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 sabre saw -V.A.G 1523A-

13. Inner B-pillar - Partial renewal 185

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

13.2 Procedure
• Outer B-pillar already cut out
Cutting locations
– Make separating cuts with pneumatic sabre saw -V.A.G
1523A- .

– Separate original joint using spot weld breaker -V.A.G 1731- .

– Make separating cut at B-pillar to match replacement part.

186 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Inner B-pillar (bottom) replacement part

13. Inner B-pillar - Partial renewal 187

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Welding in
– Match up inner B-pillar with no load on vehicle and fix in posi‐
tion.
– Weld in inner B-pillar using shielded arc welding equipment
250A -VAS 6045A- : SG continuous seam (staggered - with
gaps).
– Butt weld new part using shielded arc welding equipment 250A
-VAS 6045A- : SG continuous seam.

188 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

13. Inner B-pillar - Partial renewal 189

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 47 55 50

14 Outer side member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

14.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Shielded arc welding equipment 250A -VAS 6045A- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic glue gun -V.A.G 2005 B-

♦ Spot weld breaker -V.A.G 1731-

190 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523A-

14.2 Procedure
Cutting locations
– Make separating cuts at side member as shown using pneu‐
matic sabre saw -V.A.G 1523A- .
– Detach part.

cardiagn.com

– Remove remaining material using compact angle grinder -

VAS 5167- .

14. Outer side member - Renewal 191

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Body adhesive DA 001 730 A1
♦ Inner side member
Preparing new part
– Clean bonding area (it must be free of dust and grease).
– Grind down bonding surface (on body side of joint) to bare
metal.
– Clean beaded flange (it must be free of dust and grease).
– Place backing plates of same material behind joints.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Welding in permitted unless authorised by AUDI 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 in side member using shielded arc welding equipment
250A -VAS 6045A- : SG continuous seam.
– Weld in side member using resistance spot welder -VAS 6237
L- : RP spot weld seam.
– Apply body adhesive DA 001 730 A2 using pneumatic glue
gun -V.A.G 2005 B- .

192 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

14. Outer side member - Renewal 193

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 47 55 50

15 Inner side member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

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

cardiagn.com
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Special tools and workshop equipment required
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

♦ Pneumatic sabre saw -V.A.G 1523A-

15.2 Procedure
• Outer side member already cut out
• Inner B-pillar already cut out
• Part section of C-pillar already cut out
• Lock reinforcement already cut out

194 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

• Outer A-pillar already cut out

• Inner A-pillar already cut out
• Side panel already cut out.
Cutting locations
– Make separating cut at side member (top) as shown using
pneumatic sabre saw -V.A.G 1523A- .

15. Inner side member - Renewal 195

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Remove remaining material using compact angleProtected
grinder -
by copyright. Copying for private or commercial purposes, in part or in whole, is not
VAS 5167- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

196 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Inner side member
Welding in
– Weld in side member with fillet weld at inner side member re‐
inforcement using shielded arc welding equipment 250A -VAS
6045A- : SG continuous seam (staggered - with gaps).

15. Inner side member - Renewal 197

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in side member with fillet weld at inner side member re‐
inforcement using shielded arc welding equipment 250A -VAS
6045A- : SG continuous seam (staggered - with gaps).

198 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

15. Inner side member - Renewal 199

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 47 55 52

16 Inner side member - Partial renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

16.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Spot weld breaker -V.A.G 1731-
♦ Compact angle grinder -VAS 5167-

♦ Pneumatic sabre saw -V.A.G 1523A-

16.2 Procedure
• Outer side member already removed
• Inner side member already removed
• Inner B-pillar (part section) already removed
• Outer A-pillar already removed

200 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

• Inner A-pillar already removed

• Side panel already removed
Cutting locations
– Make separating cuts according to extent of damage using
pneumatic sabre saw -V.A.G 1523A- .

– Make separating cuts according to extent of damage using

pneumatic sabre saw -V.A.G 1523A- .
– Separate laser weld seam using compact angle grinder -VAS
5167- and remove remaining material.

16. Inner side member - Partial renewal 201

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Inner side member
Welding in
– Weld in at separating cuts using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG continuous seam.
– Weld in side member with fillet weld at web plate using shiel‐
ded arc welding equipment 250A -VAS 6045A- : SG continu‐
ous seam (staggered - with gaps).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI 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 - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Weld in at separating cuts using shielded arc welding equip‐

ment 250A -VAS 6045A- : SG continuous seam.
– Weld in side member with fillet weld at web plate using shiel‐
ded arc welding equipment 250A -VAS 6045A- : SG continu‐
ous seam (staggered - with gaps).

16. Inner side member - Partial renewal 203

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

204 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 51 47 55 50

17 Inner side member reinforcement -

Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Due to the different types of steel and panelpermitted
thicknesses em‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
ployed, one of the resistance spot welding units listed below must
with respect to the correctness of information in this document. Copyright by AUDI AG.

be used to ensure correct results when performing spot welding

operations.

cardiagn.com
17.1 Tools
Special tools and workshop equipment required
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Spot weld breaker -V.A.G 1731-

♦ Replacement breaker for high-strength steel -V.A.G 1731/2-

♦ Compact angle grinder -VAS 5167-

17.2 Procedure
• Outer side member already removed
• Inner side member already removed
• Inner B-pillar (part section) already removed
• Outer A-pillar already removed
• Inner A-pillar already removed
• Side panel already removed

Note

The inner side member reinforcement consists of high-strength

steel.

17. Inner side member reinforcement - Renewal 205

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .

cardiagn.com
– Separate original joint using spot weld breaker -V.A.G 1731- .

206 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Separate original joint at inside of floor panel using spot weld

breaker -V.A.G 1731- .
– Detach part.
– Remove remaining material using compact angle grinder -
VAS 5167- .

17. Inner side member reinforcement - Renewal 207

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Inner side member reinforcement
Welding in
– Weld in inner side member reinforcement using shielded arc
welding equipment 250A -VAS 6045A- : SG plug weld seam.

208 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in inner side member reinforcement using shielded arc
welding equipment 250A -VAS 6045A- : SG plug weld seam.

17. Inner side member reinforcement - Renewal 209

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in inner side member reinforcement using shielded arc
welding equipment 250A -VAS 6045A- : SG plug weld seam.

210 Rep. Gr.51 - Body - centre

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

17. Inner side member reinforcement - Renewal 211

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

53 – Body - rear
RO: 53 16 55 02

1 Rear cross panel (top section) - Re‐

newal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must

cardiagn.com
be used to ensure correct results when performing spot welding
operations.

1.2 Procedure
Cutting locations Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Separate original jointwith
using spot
respect to theweld breaker
correctness -V.A.G
of information 1731-
in this . Copyright by AUDI AG.
document.

– Separate original joint using drill -VAS 5830- .

– Detach part.

212 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Rear cross panel

Welding in
– Weld in cross panel using resistance spot welder : RP spot
weld seam.

1. Rear cross panel (top section) - Renewal 213

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

214 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 16 55 02

2 Rear cross panel (top section) - Re‐

newal (Avant)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
2.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ Resistance spottowelder -VAS 6545- in this document. Copyright by AUDI AG.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect the correctness of information

♦ Drill -VAS 5830-

♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

2.2 Procedure
• Top section of rear cross panel already removed
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Separate original joint using drill -VAS 5830- .
– Detach part.

2. Rear cross panel (top section) - Renewal (Avant) 215

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Remove remaining material using compact angle grinder -
VAS 5167- .

216 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Rear cross panel
Welding in
– Weld in cross panel using resistance spot welder : RP spot
weld seam.

2. Rear cross panel (top section) - Renewal (Avant) 217

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

218 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 16 55 00

3 Rear cross panel - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

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

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Drill -VAS 5830-
♦ Compact angle grinder -VAS 5167-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Spot weld breaker -V.A.G 1731-

3. Rear cross panel - Renewal 219

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523A-

3.2 Procedure
• Top section of rear cross panel already removed
• Top section of cross panel already removed

Note

cardiagn.com
Partial renewal is possible with the separating cuts illustrated.
Place a backing plate of the same material behind the joint and
make SG continuous seam.

Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Detach part.
– Remove remaining material using compact angle grinder -
VAS 5167- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

220 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ Rear cross panel
Welding in
– Weld in cross panel using resistance spot welder : RP spot
weld seam.
– Place a backing plate of the same material behind the joints
and weld in using shielded arc welding equipment 250A -VAS
6045A- : SG continuous seam.

3. Rear cross panel - Renewal 221

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

222 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 16 55 00

4 Rear cross panel - Renewal (Avant)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

4.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Drill -VAS 5830-
♦ Compact angle grinder -VAS 5167-
♦ Spot weld breaker -V.A.G 1731-

4.2 Procedure
• Top section of cross panel already removed

Note

Partial renewal is possible with the separating cuts illustrated.

Place a backing plate of the same material behind the joint and
make SG continuous seam.

Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .

4. Rear cross panel - Renewal (Avant) 223

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Separate original joint using drill -VAS 5830- .

– Detach part.

cardiagn.com
– Remove remaining material using compact angle grinder -
VAS 5167- .

224 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Rear cross panel
Welding in
– Weld in cross panel using resistance spot welder : RP spot
weld seam.

4. Rear cross panel - Renewal (Avant) 225

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

226 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 09 55 50

5 Cross panel (inner section) - Renew‐

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

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.
Due to the different types of steel and panel thicknesses em‐
ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
5.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 5830-
♦ Spot weld breaker -V.A.G 1731-

5.2 Procedure
• Top sections of cross panel already removed
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Separate original joint using drill -VAS 5830- .
– Detach part.
– Remove remaining material using compact angle grinder -
VAS 5167- .

5. Cross panel (inner section) - Renewal 227

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Cross panel
Welding in
– Weld in new part using resistance spot welder : RP spot weld
seam.

228 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
cardiagn.com
permitted unless authorised by AUDI 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. Cross panel (inner section) - Renewal 229

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 09 55 50

6 Cross panel (inner section) - Renew‐

al (Avant)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
6.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Compact angleProtected
grinder by -VAS
copyright.5167-
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Drill -VAS 5830- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Spot weld breaker -V.A.G 1731-

6.2 Procedure
• Top sections of cross panel already removed
Cutting locations
– Separate original joint using drill -VAS 5830- .
– Detach part.

230 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Remove remaining material using compact angle grinder -
VAS 5167- .

6. Cross panel (inner section) - Renewal (Avant) 231

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Cross panel
Welding in
– Weld in new part using resistance spot welder : RP spot weld
seam.

232 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

6. Cross panel (inner section) - Renewal (Avant) 233

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 10 55 50

7 Tail light mounting - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing
Protectedspot welding
by copyright. Copying for private or commercial purposes, in part or in whole, is not
operations. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7.1 Tools

7.2 Procedure
• Upper section of cross panel already cut out
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Pull out tail light mounting downwards.
– Remove remaining material using compact angle grinder -
VAS 5167- .

234 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ Tail light mounting
Preparing new part
– Check gap between new panel and tail light / rear lid.
Welding in
– The tail light mounting is now tilted into the installation position,
pulled up and fitted into place.
– Weld in new part using shielded arc welding equipment 250A
-VAS 6045A- : SG plug weld seam.
– Weld in tail light mounting using resistance spot welder : RP
spot weld seam.

7. Tail light mounting - Renewal 235

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

236 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 48 55 52

8 Rear longitudinal member - Partial re‐

newal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
8.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Protected
Shielded arc welding equipment 250A -VAS 6045A-
by copyright. Copying for private or commercial purposes, in part or in whole, is not

♦ permitted
Spot weld
with respect tobreaker -V.A.G
the correctness 1731-in this document. Copyright by AUDI AG.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
of information

8. Rear longitudinal member - Partial renewal 237

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Pneumatic sabre saw -V.A.G 1523A-

8.2 Procedure
• Rear cross panel sections and mounting plate already re‐
moved
• Spare wheel well already removed
Cutting locations

cardiagn.com
– Cut out longitudinal member (part section) using pneumatic
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
sabre saw -V.A.G 1523A- . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Separate original joint using spot weld breaker -V.A.G 1731- .

– Remove remaining material using compact angle grinder -
VAS 5167- .

238 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Cut out longitudinal member (part section) using pneumatic

sabre saw -V.A.G 1523A- .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

8. Rear longitudinal member - Partial renewal 239

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Longitudinal member part section
Welding in
– Locate and secure section of longitudinal member on align‐
ment bracket.
– Butt weld longitudinal member using shielded arc welding
equipment 250A -VAS 6045A- : SG continuous seam.

240 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Butt weld longitudinal member using shielded arc welding

equipment 250A -VAS 6045A- : SG continuous seam.
– Weld in remaining joint using resistance spot welder .

8. Rear longitudinal member - Partial renewal 241

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

242 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 48 55 50

9 Rear longitudinal member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

9.1 Tools

cardiagn.com
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools
permitted and
unless workshop
authorised by AUDIequipment
AG. AUDI AG does required
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Welding unit (inverter) -VAS 6237 L-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Spot weld breaker -V.A.G 1731-

9.2 Procedure
• Rear cross panel sections and mounting plate already re‐
moved
• Spare wheel well already removed
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

9. Rear longitudinal member - Renewal 243

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Separate reinforcements at original joint using spot weld
breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

244 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Separate original joint at longitudinal member using spot weld

breaker -V.A.G 1731- .

9. Rear longitudinal member - Renewal 245

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Longitudinal member
Welding in
– Locate and secure section of longitudinal member on align‐
ment bracket.
– Butt weld longitudinal member using shielded arc welding
equipment 250A -VAS 6045A- : SG plug weld seam.
– Weld in longitudinal member using resistance spot welder : RP
spot weld seam.

246 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in longitudinal member using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG plug weld seam.

9. Rear longitudinal member - Renewal 247

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Weld in longitudinal member using shielded arc welding equip‐

ment 250A -VAS 6045A- : SG plug weld seam.

248 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

9. Rear longitudinal member - Renewal 249

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 55 55 00

10 Side panel - Renewal

Includes rain channel and tail light mounting.

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units Protected
listed below must
by copyright. Copying for private or commercial purposes, in part or in whole, is not
be used to ensure correct results when performing spot welding
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

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

cardiagn.com
10.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Pneumatic glue gun -V.A.G 2005 B-

250 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Fold crimping tool -V.A.G 1585-

♦ Spot weld breaker -V.A.G 1731-

cardiagn.com
♦ Pneumatic sabre saw -V.A.G 1523A-

10.2 Procedure
• Cross panels already removed.

Note

Partial renewal is possible with the separating cuts illustrated.

Place a backing plate of the same material behind the joint and
make SG continuous seam.

Cutting locations
– Grind through outer edge of wheel arch using compact angle
grinder -VAS 5167- .
– Make separating cuts as shown using pneumatic sabre saw -
V.A.G 1523A- . Do not damage internal reinforcements.
– Separate original joint using spot weld breaker -V.A.G 1731- .

10. Side panel - Renewal 251

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Separate original joint using spot weld breaker -V.A.G 1731- .

– Remove remaining material using compact angle grinder -
VAS 5167- .

252 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

10. Side panel - Renewal 253

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement parts
♦ Side panel (sub-part)
♦ Body adhesive DA 001 730 A1
Preparing new part
– Transfer separating cut to new part using pneumatic sabre
saw -V.A.G 1523A- .
– Clean bonding area (it must be free of dust and grease).
– Grind down bonding surface (on body side of joint) to bare
metal.
– Clean beaded flange (it must be free of dust and grease).
Welding in
– Place a backing plate of the same material behind the joints
and weld in using shielded arc welding equipment 250A -VAS
6045A- : SG continuous seam.

254 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Weld in side panel using resistance spot welder : RP spot weld
seam.

10. Side panel - Renewal 255

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Weld in side panel using resistance spot welder : RP spot weld

seam.

256 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Apply body adhesive DA 001 730 A1 using pneumatic glue
gun -V.A.G 2005 B- .
– Bead over wheel housing flange using fold crimping tool -
V.A.G 1585- .

10. Side panel - Renewal 257

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

258 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 55 55 00

11 Side panel - Renewal (Avant)

Includes rain channel and tail light mounting.

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

cardiagn.com
11.1 Tools
Special tools and workshop equipment required
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Resistance spot welder -VAS 6535- orunless 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.
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 5830-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic glue gun -V.A.G 2005 B-

11. Side panel - Renewal (Avant) 259

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Fold crimping tool -V.A.G 1585-

♦ Spot weld breaker -V.A.G 1731-

cardiagn.com
♦ Pneumatic sabre saw -V.A.G 1523A-

11.2 Procedure
• Cross panels already removed.

Note

Partial renewal is possible with the separating cuts illustrated.

Place a backing plate of the same material behind the joint and
make SG continuous seam.

260 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

11. Side panel - Renewal (Avant) 261

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Make separating cut as shown using pneumatic sabre saw -

V.A.G 1523A- . Do not damage internal reinforcements.
– Separate original joint using spot weld breaker -V.A.G 1731- .

262 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Remove remaining material using compact angle grinder -
VAS 5167- .

11. Side panel - Renewal (Avant) 263

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement parts
♦ Side panel (sub-part)
♦ Body adhesive DA 001 730 A1
Preparing new part
– Transfer separating cuts to new part using pneumatic sabre
saw -V.A.G 1523A- .
– Drill 7 mm ∅ holes for SG plug weld seam using drill -VAS
5830- .
– Clean bonding area (it must be free of dust and grease).
– Clean beaded flange (it must
unlessbe free of
authorised dustAG.
by AUDI andAUDI grease).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

264 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Grind down bonding surface (on body side of joint) to bare
metal.

11. Side panel - Renewal (Avant) 265

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Welding in
– Place a backing plate of the same material behind the joints
and weld in using shielded arc welding equipment 250A -VAS
6045A- : SG continuous seam.
Spot-welding may only be performed with the factory-approved
inverter welding equipment.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Weld in side panel using resistance spotpermitted
welderunless
-VAS 6237by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
L- : RP spot weld seam. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Weld in side panel using shielded arc welding equipment 250A

-VAS 6045A- : SG plug weld seam.

266 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
– Place a backing plate of the same material behind the joint and
weld in using shielded arc welding equipment 250A -VAS
6045A- : SG continuous seam.
– Weld in side panel using resistance spot welder : RP spot weld
seam.
– Weld in side panel using shielded arc welding equipment 250A
-VAS 6045A- : SG plug weld seam.

11. Side panel - Renewal (Avant) 267

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

– Apply body adhesive DA 001 730 A1 using pneumatic glue

gun -V.A.G 2005 B- .
– Bead over wheel housing flange using fold crimping tool -
V.A.G 1585- .

268 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Expanded foam inserts ⇒ page 9
General notes on expanded foam inserts

11. Side panel - Renewal (Avant) 269

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com

270 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 69 55 52

12 C-pillar reinforcement - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

12.1 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
12.2 Procedure with respect to the correctness of information in this document. Copyright by AUDI AG.

• Side panel already cut out.

Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .

12. C-pillar reinforcement - Renewal 271

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ C-pillar reinforcement
Welding in
– Weld in C-pillar reinforcement using resistance spot welder :
RP spot weld seam.

272 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

12. C-pillar reinforcement - Renewal 273

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 69 55 52

13 Rear wheel housing - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

13.1 Tools

cardiagn.com
Special tools and workshop equipment required
♦ Welding unit (inverter) -VAS 6237 L-
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6530- or
♦ Resistance spot welder -VAS 6535- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 5830-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Pneumatic punch and offset tool -VAS 1996-

274 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

♦ Spot weld breaker -V.A.G 1731-

♦ Pneumatic sabre saw -V.A.G 1523A-

cardiagn.com
13.2 Procedure
• Side panel already cut out.
• C-pillar reinforcement already removed.
Cutting locations
– Make separating cuts as shown using pneumatic sabre saw -
V.A.G 1523A- .
– Separate original joint using spot weld breaker -V.A.G 1731- .

13. Rear wheel housing - Renewal 275

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Replacement part
♦ Rear wheel housing liner
– Prepare separating cut on body side for joddle-joining using
pneumatic punch and offset tool -VAS 1996- .
– Transfer separating cut plus 10 mm for overlap to new part
and cut off using pneumatic sabre saw -V.A.G 1523A- .

276 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Welding in
– Weld in wheel housing using resistance spot welder : RP spot
weld seam.
– Weld in wheel housing using shielded arc welding equipment
250A -VAS 6045A- : SG continuous seam (staggered - with
gaps).

13. Rear wheel housing - Renewal 277

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

278 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

RO: 53 80 55 50

14 Spare wheel well - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

Note

Due to the different types of steel and panel thicknesses em‐

ployed, one of the resistance spot welding units listed below must
be used to ensure correct results when performing spot welding
operations.

14.1 Tools

cardiagn.com
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Shielded arc welding equipment 250A -VAS 6045A-
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Spot weld breaker -V.A.G 1731-
♦ Drill -VAS 5830-

14.2 Procedure
• Cross panels already removed.
Cutting locations
– Separate original joint using spot weld breaker -V.A.G 1731- .

14. Spare wheel well - Renewal 279

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

Replacement part
♦ Spare wheel well
Preparing new part
– Drill 7 mm ∅ holes for SG plug weld seam using drill -VAS
5830- .

280 Rep. Gr.53 - Body - rear

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

cardiagn.com
Welding in
– Weld in spare wheel well using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG plug weld seam.

14. Spare wheel well - Renewal 281

Audi A4 2008 ➤
Body Repairs - Edition 06.2009

282 Rep. Gr.53 - Body - rear

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