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Hood, Lids (Except Cabriolet) Audi A4 B6

Exterior Body Panels 3 illustrations ~2348 words

Hood, assembly overview

The following list pertains to (Scheme 2).

  1. Hood Removing: Detach and unclip line of windshield washer. Second person required for supporting and lifting hood. Detaching gas-filled strut -5- from hood -1-, see «Removing and installing gas-filled strut»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__removing-and-installing-gas-filled-strut) . Remove nuts -4-. Remove hood. Installing: Install in reverse order. Adjusting: Center hood -1- between fenders. Adjust hood height by means of hood lock, see «REMOVING AND INSTALLING HOOD LOCK LOWER SECTION»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__removing-and-installing-hood-lock-lower) . Use buffer stops to align hood in relation to fenders, see «BUFFER STOPS FOR HEIGHT ADJUSTMENT»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__buffer-stops-for-height-adjustment) . Joint dimension, see «JOINT DIMENSIONS»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__joint-dimensions) .
  2. Hood hinge Hood -1- must be removed or securely supported. Remove bolts -3- and nuts -4- to remove.
  3. Combination bolt 21 Nm
  4. Hex nut 21 Nm
  5. Gas-filled strut Removing and installing, see «REMOVING AND INSTALLING GAS-FILLED STRUT»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__removing-and-installing-gas-filled-strut)

Removing and installing gas-filled strut

  1. Support hood or secure so that it cannot fall.
  2. Lift retaining springs at both ends of gas-filled strut slightly with a screwdriver and unclip gas-filled strut.
  3. To install gas-filled strut, press on ball stud and lock in place.
  4. Gas-filled strut cylinder is secured at body end.

Releasing gas from gas-filled strut

  1. Clamp gas-filled strut in vice in area x = 50 mm.
  2. Saw open cylinder of gas-filled strut in first third of overall cylinder length - starting from reference edge on piston rod end. WARNING: Only clamp in the area indicated above so as to avoid danger of accidents. Wear protective goggles while sawing. CAUTION: It is also appropriate to cover sawing location with a cloth to absorb any oil spray.

Buffer stops for height adjustment

  1. Buffer stops -1- and -2- must lie gently against lock carrier when hood is closed. NOTE: Buffer stops can be used to adjust height of hood.

Removing and installing radiator grille

  1. Release catches -arrows- to remove.
  2. Swivel top of radiator grille outward then pull downward and out.
  3. To install, attach bottom of radiator grille in center (ensure correct centering) and swivel in direction of arrow.
  4. Dimension a = 1.5 + 0.5 mm
  5. Dimension b = 0.7 +/- 0.5 mm
  6. When installing make sure radiator grille engages fully (audibly).

Removing and installing catch hook

  1. To remove, unscrew hex bolts -2- and detach catch hook -1-.
  2. To install, tighten hex nuts to 11 Nm.

Removing and installing hood lock lower section

  1. Disengaging Bowden Cable for hood, see «HOOD CABLE, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__hood-cable-assembly-overview) .
  2. Remove bolts -2- (4x). Tightening torque 14 Nm
  3. Remove lock lower section -1-.
  4. To adjust hood, move lower section of lock up or down.

Adjusting lock carrier buffer stop

  1. Buffer stop must lie gently against inner panel when hood is closed.
  2. When re-adjusting headlights, reposition buffer stop only for precision adjustment. Tightening torque 15 Nm

Joint dimensions

Note. Joint dimensions can be checked using special tool 3371.

  1. Dimension -A- = 5.5 mm + 0.5 mm
  2. Dimension -B- = 5.5 mm + 0.5 mm
  3. Dimension -C- = 3.5 mm + 0.5 mm
  4. Dimension -D- = 4 mm +/- 0.5 mm
  5. Dimension -E- = 1.5 mm +/- 0.5 mm
  6. Dimension -F- = 1.5 mm +/- 0.5 mm
  7. Dimension -G- = 2.5 mm +/- 0.5 mm

Removing

  1. Unfasten clips -2-.
  2. Remove cover -1-.

Installing

Installation is reverse of removal.

Note. Take care not to cover drain holes when installing impact protection.

  1. Install reinforcing piece and align with drain holes.
  2. Press on impact protection evenly.

Installation is reverse of removal.

Scheme 2

Scheme 2: Installing
Scheme 2: Installing

Hood cable, assembly overview

The following list pertains to see scheme 13.

  1. Hood cable Removing: Raise vehicle. Removing wheel housing liner. See «WHEEL HOUSING LINER»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet) . Removing driver's storage compartment See «DRIVER-SIDE STORAGE COMPARTMENT (WITH AND WITHOUT KNEE BOLSTER) ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/mirrors/#interior-equipment-except-cabriolet__driver-side-storage-compartment-with-and-without) . Remove bolt - 3 - Pull off clip -4-. Unclip cable from hood lock lower section and unhook attachment lug arrow -A-. Remove cable -1- from open retaining clips - 6 - and pull into wheel housing towards lock carrier. Installing: Move ball on cable of hood lock lower section into assembly position. Install in reverse order.
  2. Operating lever
  3. Bolt 2.4 Nm
  4. Clip
  5. Hood lock lower section Removing and installing, see «REMOVING AND INSTALLING HOOD LOCK LOWER SECTION»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__removing-and-installing-hood-lock-lower) Can be moved to adjust height of hood.
  6. Retaining clip

Rear lid and rear lid lock, removing, assembly overview

The following list pertains to see scheme 14.

  1. Rear lid Removing: Removing warning triangle and holder -5- Remove rear lid lining. Unplug connectors and pull them out of rear lid. Remove nuts of bolts securing both hinges to rear lid, see «REMOVING AND INSTALLING REAR LID HINGES»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet) Second person required for supporting and lifting rear lid. Installing: Install in reverse order.
  2. Buffer stop Adjusting, see «BUFFER STOP, ADJUSTINGX»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__buffer-stop-adjusting)
  3. Expanding nut
  4. Bolt
  5. Holder To remove, take out warning triangle, remove bolts - 4 - and detach holder.
  6. Striker plate Removing and installing, see «REMOVING AND INSTALLING STRIKER PLATE»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__removing-and-installing-striker-plate) Adjusting, see «ADJUSTING REAR LID»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__adjusting-rear-lid)
  7. Nut 8 Nm

Removing And Installing Striker Plate

  1. Removing rear cross panel trim. See «REAR CROSS PANEL TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__rear-cross-panel-trim-assembly-overview) (except Avant) or «REAR CROSS PANEL TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) (Avant).
  2. Remove nuts -1-. Tightening torque 8 Nm
  3. Install in reverse order.

Adjusting rear lid

  1. Removing rear cross panel trim. See «REAR CROSS PANEL TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__rear-cross-panel-trim-assembly-overview) (except Avant) or «REAR CROSS PANEL TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) (Avant). NOTE: Install gas-filled struts before adjusting a new rear lid.
  2. Loosen nuts -1-, striker plate -2- can now be moved.
  3. Close rear lid carefully until rear lid is flush with side panel.
  4. Open rear lid carefully and tighten nuts -1- to 8 Nm.

Note. Joint dimensions can be checked using special tool 3371.

Dimension A = 4.0 mm +/- 0.5 mm

Dimension B = 2.0 mm + 0.5 mm

Scheme 3

Scheme 3: Joint dimensions
Scheme 3: Joint dimensions

Rear lid lock and handle mechanism, assembly overview

The following list pertains to see scheme 19.

  1. Rear lid lock To remove, unclip and remove operating rod from swivelling bush. Remove hex nuts -3- and detach rear lid lock.
  2. Swivelling bush After installing rear lid lock, hook in operating rod and secure.
  3. Nut 8 Nm
  4. Operating rod
  5. Bowden cable
  6. Lock cylinder Removing: Disconnect connectors. Unhook Bowden cable -6- from lock cylinder. Remove combi bolt -7-. Turn lock cylinder 90°. Remove lock cylinder from handle mechanism.
  7. Combination bolt 8 Nm
  8. Engine Removing and installing, see «REMOTE CONTROL MOTOR (COUNTRY VERSIONS), REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet)
  9. Handle strip Removing: Rear lid lining removed. Lock cylinder removed. Remove collared hex bolts -10-. Press in tabs -arrows- Remove handle strip.
  10. Collared hex nut 8 Nm
  1. Unclip and unhook operating rod -3-.
  2. Remove bolt -2- (2x). Tightening torque 2 Nm
  3. Remove remote control motor.
  4. Disconnect connector of remote control motor -1-.
  1. Install in reverse order.
  1. Removing and installing gas-filled strut, see «REMOVING AND INSTALLING GAS-FILLED STRUT»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet)

Cover of rear lid hinge

  1. Insert electric cable or central locking wire -2- in lower catch of cable guide on cover -1-.
  2. Insert trim -1- of rear lid hinge at bottom of long hinge lever and clip upward audibly onto hinge lever.
  3. Snap clip -3- into trim in hinge lever.
  1. Install in reverse order.

Note. Rear lid hinges can be moved to adjust the rear lid more clearly with the aid of scales on the hinges.

  1. Remove nut -1-. Tightening torque 21 Nm.
  2. Remove nut -2-. Tightening torque 21 Nm.
  3. Lift up rear lid from hinge.
  4. Remove bolts -3- and -4-. Tightening torque 21 Nm.
  5. Middle bolt -5- should only be loosened. Tightening torque 21 Nm.
  6. Detach hinge -6-.
  1. Install in reverse order.

Note. For removing or installing gas-filled strut, gently push rear lid slightly beyond its end point, taking care not to damage components.

  1. Lift retaining springs at both ends one after the other with a screwdriver and detach gas-filled strut.
  1. Clip in first bottom then top of gas-filled strut.
  2. Gas-filled strut cylinder is secured at rear lid end.
  1. Clamp gas-filled strut in vice in area x = 50 mm.
  2. Saw open cylinder of gas-filled strut in first third of overall cylinder length - starting from reference edge on piston rod end.
WARNINGOnly clamp in the area indicated above so as to avoid danger of accidents.

Note. Wear protective goggles while sawing. It is also appropriate to cover sawing location with a cloth to absorb any oil spray.

  1. Butt joint -item A- of rear lid seal must be aligned with ball socket of left hinge.
  2. Press on seal.

Removal is reverse of installation.

Buffer stop, adjusting

  1. Open rear lid.
  2. Take off rubber cap.
  3. Screw in buffer stop as far as it will go.
  4. Remove buffer stop again gradually.
  5. Press on rubber cap.
  6. When correctly adjusted, buffer stop must lie gently against load sill when rear lid is closed.
  1. Remove tailgate trim. See «REAR LID TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .
  2. Disconnect or remove electrical harness connectors and hose for rear window washer system.
  3. Prop up and secure tailgate in open position.
  4. Using screwdriver, lift retaining spring -3- as shown and remove gas-filled strut -1- from upper ball stud -2-.
  5. Remove cover -1- for rear lid hinge and cable guide -2- from rear lid hinge -arrows-.
  6. Remove bolts -arrows- on left and right sides.
  7. Second person is needed to support and lift hood during removal.
  8. Remove rear lid.

Installation is reverse of removal, noting the following

  1. Installation tightening torque: 21 Nm
  2. Adjusting rear lid, see «REAR LID»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet)

Insulation mat to rear lid, adhering

On a new rear lid, insulation mats must be adhered to surfaces depicted in the illustration after painting

  1. Cut the insulation mats from self-adhering insulation Part No. 323 863 950 to the following dimensions: Insulation mat 100 x 150 mm (2x) Insulation mat 30 x 100 mm (2x)

Tailgate, adjusting

Note. The gas-filled struts must be attached before installing a new rear lid.

Scheme 4

Scheme 4: Tailgate, adjusting
Scheme 4: Tailgate, adjusting
  1. Remove rear cross panel trim. See «REAR CROSS PANEL TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .
  2. Loosen combination nuts -1- and -3-, striker -2- must be adjustable. NOTE: When installing a striker, make sure it is in the proper installed position, for this the tab -arrow- must point to the rear.
  3. Unclip cover -1- at rear lid stop.
  4. Turn adjustment screw -2- counter-clockwise into position "0".
  5. Tighten nuts -1- and -3- hand tight.
  6. Close tailgate.
  7. Press lid by hand into chassis approx. 2 mm.
  8. Open tailgate in this position and tighten nuts -1- and -3- to 21 Nm.
  9. Check whether tailgate closes easily and without play at lock. Repeat adjustment if necessary.
  10. Check whether lid sits without play by pressing on the side edge of tailgate below rear window.
  11. Pre-tension stop by turning adjustment screw -2- clockwise if necessary.
  12. Check whether tailgate still closes easily, repeat adjustment if necessary.
  13. Checking adjustment dimensions, see «REAR LID, ADJUSTMENT DIMENSIONS»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet__rear-lid-adjustment-dimensions) .
  1. Remove cover -1- for rear lid hinge and cable guide -2- from rear lid hinge -arrows-.
  2. Remove outer roof frame trim -1-, for this purpose lift trim from retaining clips -2- after unclipping and guide tabs -arrows- around the hinge.
  3. Remove D-pillar trim. See «D-PILLAR TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) . NOTE: To prevent damage to paint, support and secure rear lid.
  4. Unthread nuts -arrows-.
  5. Remove bolts -arrows- on left and right sides.
  6. Remove hinge.

Installation is reverse of removal, noting the following

  1. Installation tightening torque: 21 Nm.
  2. Adjusting rear lid, see «REAR LID»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet) .
  1. Prop up and secure tailgate in open position.
  2. Using screwdriver, lift retaining spring -3- as shown and remove gas-filled strut -1- from upper ball stud -2-.

Note. Following complete removal of the gas-filled strut, check for correct positioning during installation. Sound insulation components must be installed on the body side.

Installation is reverse of removal, noting the following

  1. To install, press gas-filled strut onto ball studs so that it engages in position.
  2. Ball stud tightening torque: 15 Nm - 1 Nm.
  1. Open tailgate and pull out seal.
  1. When installing, insert seal in lower left and right corners first.
  2. Press seal -1- onto body as shown.

Rear lid, adjustment dimensions

  1. Position rear lid in chassis cut-out just so that the gap measurement on the right equals the gap measurement on the left.
  2. Check whether chassis surface below rear window stands flush with chassis surface of lower side panel -arrows A-.
  3. Check whether rear lid is flush with roof (and projects slightly upward). Dimension -b- = 0 to 0.5 mm
  1. Remove tailgate trim. See «REAR LID TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .
  2. Disconnect electrical harness connector -2-.
  3. Disengage actuating link -3- to tailgate lock.
  4. Remove bolt -1-.
  5. Tightening torque: 8 Nm
  6. Turn lock cylinder 90° around its own shaft and remove lock cylinder.

Installation is the reverse of removal.

  1. Remove lock cylinder for rear lid lock, see «LOCK CYLINDER FOR REAR LID, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#hood-lids-except-cabriolet) .
  2. Disconnect inner electrical harness connector at grip piece.
  3. Remove 4 nuts -1- and -2- (different versions; mark for reinstallation).
  4. Tightening torque: 8 Nm
  5. Press both catches -arrows- down and remove grip piece -3-.

Installation is the reverse of removal.

  1. Remove lower tailgate trim. See «REAR LID TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .
  2. Disengage actuating link -6-, for this purpose press expanding clip -5-from operating lever.
  3. Disengage operating rod -1- to actuator, for this purpose turn hinge arm -7- clockwise and remove operating rod.
  4. Unthread nuts -2- and -4- and remove tailgate lock -3-.
  5. Tightening torque: 21 Nm.

Installation is the reverse of removal.

  1. Remove lower tailgate trim. See «REAR LID TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet) .
  2. Disengage operating rod -3- at tailgate lock, for this purpose turn hinge arm -4- clockwise and remove operating rod.
  3. Disengage operating rod at actuator -1-, for this purpose slide operating rod to actuator and turn approx. 90° out of mount -arrow-.
  4. Loosen bolts -2- approx. 2 rotations and disengage actuator at tailgate.
  5. Disconnect electrical harness connector.
  6. Remove bolts -3-.
  7. Tightening torque 2 Nm
  8. Remove adapter plate -2- from actuator -1-.

Installation is the reverse of removal.

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