Rear Doors: Adjustments Audi A3 8P facelift

REAR DOOR ADJUSTMENT USING TEMPLATE T40038/5

Special tools and workshop equipment required

Scheme 1

1. Template T40038/5

Use the T40038/5 as described in the following for testing (for example, for wind noises) and for adjusting door.

Note. Some illustrations depict other templates, this has no effect on the testing and adjusting procedure.

For testing contact pressure of sealing lips on roof trim molding, use a standard bank card -1- or similar means.

Scheme 2

Using a standard bank card, drive off contact area of sealing lip to roof trim molding with light pressure.

When doing this, card must not sink in between sealing lip -1- and roof trim molding -2-.

T40038/5

Template has a "Min" and "Max" marking so that lateral adjustment of door can be checked.

Note. "Min" and "Max." markings indicate the minimum and maximum door pre-tension. This means the "Max" marking indicates the door is adjusted to maximum pre-tension (maximum toward inside).

Adjusting "Max"

In this position (max), doors are adjusted to maximum pre-tension (furthest inward).

Position template at dimension -a- = 90 mm and "Max" marking facing door window

Scheme 3

Make sure that points -1- and -3- make contact.

At point -2- of template, there must be a gap.

In this position (max), doors are adjusted to maximum pre-tension (furthest inward).

If there is no gap at point -2-, or there is a gap at point -1-, the window frame is set too far outward (insufficient pre-tension) and must be adjusted.

Adjusting "Min"

In this position "Min", doors are adjusted to minimum pre-tension (furthest outward).

Position template at dimension -a- = 90 mm and "Min" marking facing door window

Scheme 4

Make sure that points -2- and -3- make contact on door window.

At point -1- of template, there must be a gap.

In this position (min), doors are adjusted to minimum pre-tension (furthest outward).

If point -1- has no gap, or if template cannot be brought into contact at point -2-, window frame is set too far outward and must be adjusted.

Height adjustment at window frame

If height of window frame must be adjusted, then the collared shoulder bolts -1- must be replaced with a standard bolt.

Scheme 5

Now, the window frame height can be adjusted.

Install the seals -2- and -3- into the window frame.

Position adjusting template as shown on roof, or on upper edge of rain channel.

For a correct adjustment, lower edge of window frame must be located between markings -a-, (line on template -arrow-) or -b-.

Scheme 6

Check/adjust inclination of window frame.

Door position can be assessed using lower side of T40038/5 (illustration shows other template).

Scheme 7

No door recess in relation to side panel -2- is permitted.

Recess of front door -1- to side panel -2- is not permitted (wind noise).

Projection (maximum 0.8 mm) of front door to side panel must be in range of template cut-out -arrow-.

Scheme 8

Scheme 9

1. Window Frame For correct door adjustment, sealing lip must make clean contact to contours at roof frame and at B-pillar, see arrows.
2. Door Window Adjust door until the result is dimension -c- = 4 mm in area -b- = 320 mm. Dimension -a- of front door edge starting at B-pillar = 90 mm. NOTE: Check dimension -c- using T40038/5.
3. Window Frame Door window -2- must drive as far as dimension -d- = 7.5 mm -1 mm into window frame at B-pillar.

Scheme 10

1. Door Handle Mount Releasing see scheme 27.
2. Door Handle Before disassembling, remove window frame and window regulator. Removal, refer to «WINDOW FRAME AND WINDOW REGULATOR»(ref-496066-S08546185142012082100000).
3. Operating Rod Clip into door lock (Scheme 11).
4. Clip Engage operating rod in clip, swivel clip 90° and engage at operating rod.
5. Handle Trim Removing see scheme 28
6. Socket Head Bolt 20 Nm
7. Door Lock Removal: The door trim panel is removed. Window frame and window regulator removed, refer to «WINDOW FRAME AND WINDOW REGULATOR»(ref-496066-S08546185142012082100000). To remove, unscrew multi-point bolts -6- and remove door lock downward.

Scheme 11

When installing a new door lock, clip operating rod -1- into casing -2-.

Move slide -3- of casing -2- upward to engage operating rod.

Pull securing pin -4- out of door lock.

Scheme 12

1. Window Frame Removal: Remove door trim. Refer to «Removal and Installation»(ref-496058-S22585871132012082100000) Disconnect electrical connectors. Remove window regulator motor (Scheme 13). Remove bolts -7- and -8-. Remove the bolts -3- and the bolts -5-; -6- and lift the window frame with the window regulator up and out of the door. Installing: Insert window frame and window regulator into door from above. Knock in the upper profile halves of door-side gasket into window frame at top. Position seals between door and window frame. Loosely screw in collared shoulder bolts -3- at front and rear. Insert the bolt -8-. Tighten the bolts -3- hand-tight. Lightly press window frame -1- inward at top. Remove the front and rear adjustment bushings -arrow a- using a 9 mm inner socket. Insert the bolt -5-. Tighten collared shoulder bolts -3- to 32 Nm. Tighten bolts -5- at front and rear to 32 Nm. Tighten bolt -8- to 10 Nm. Tighten the locking pin -arrow b- inside the window frame to 32 Nm. Knock in lower half of door seal into inner door plate. Secure window regulator rail with bolts -7- to inner door plate. Press threaded pin of window regulator reel through inner door plate until it engages.
2. Rear Door
3. Bolt 32 Nm
4. Cover After combination bolts -5- have been tightened to tightening specification (32 Nm), press covers into door trim.
5. Combination Bolt 32 Nm Before tightening combination bolts to tightening specification, adjustment bushings must make contact using an Allen wrench (width across flats 9 mm).
6. Collar Screws 3.5 Nm
7. Collar Bolts 6 Nm
8. Bolt 6 Nm

Scheme 13

To remove, unscrew bolts -2- and remove window regulator motor.

Install window regulator motor. Refer to WINDOW REGULATOR MOTOR .

Scheme 14

TORX bolt -T45- -1- (quantity: 2; installed from inside the vehicle) 32 Nm.

Upper door hinge -2-.

Fitting bolt -3- -T45- 32 Nm.

Scheme 15

B-pillar trim removed.

TORX screws -T45- -1- 32 Nm bolted to -B- pillar from interior of vehicle.

Lower door hinge -2-.

Cover cap -3-.

TORX bolt -T45- -4- 32 Nm.

Fitting bolt -T45- -5- 32 Nm.

Re-grease lubrication points -arrows- in service interval.

Front door -6-.

Scheme 16

1. Window Frame Removal: Remove door trim. Refer to «Removal and Installation»(ref-496058-S22585871132012082100000) Window frame removed together with window regulator from door. Refer to «WINDOW FRAME AND WINDOW REGULATOR»(ref-496066-S08546185142012082100000) . Door window -4- removed To remove, unscrew countersunk screw -7- and remove window regulator from window frame. Installing: When installing, make sure that guide rail, arrow -A-, runs parallel to guide arrow -B-. Tighten bolts -7- to 6 Nm.
2. Triangular Panel Before removing, disassemble window frame and window regulator. Remove the bolt -3- and remove panel sideways.
3. Screw 4 Nm
4. Countersunk Screw 6 Nm
5. Door Window Removal: Run door window down. Remove the bolts -5- and remove door windows from window regulator. Installing: Insert window into window regulator. Screw bolts -5- into window regulator, but do not tighten yet. Drive door window upward into window frame. Pull door window toward front into window guide on window frame at B-pillar and tighten bolts -5- to 4 Nm.
6. Socket Head Screw 4 Nm -0.5 Nm
7. Window Regulator Window frame removed together with window regulator from door. Refer to «WINDOW FRAME AND WINDOW REGULATOR»(ref-496066-S08546185142012082100000) . Door window removed. To remove, unscrew countersunk screw -4- and remove window regulator from window frame.

Scheme 17

1. Window Frame Removed. Refer to «WINDOW FRAME AND WINDOW REGULATOR»(ref-496066-S08546185142012082100000)
2. Inner Window Recess Seal Door trim removed. Refer to «Removal and Installation»(ref-496058-S22585871132012082100000)
3. Window Guide NOTE: Seal must not be installed by knocking it on, rather seal must be pressed in. Use soapy water to assist assembly of seal. Slide onto window frame from side. Use soap solution to assist assembly. Securing piece must engage audibly into corners -arrows-, adhere further if necessary
4. Inner Door Seal
5. Door Window
6. Door Trim Removed