Body Exterior Audi A4 B7

Lock carrier, service position

Note. Do not remove noise insulation, only loosen front quick release screws --> Noise insulation panel - assembly overview . Bumper removed.

Scheme 1

1 - Lock carrier

1. Service position
2. Unscrew intake air duct between lock carrier and air cleaner housing at lock carrier and remove.
3. On the left side, screw in special tool 3369 in threaded hole «Screw in special tool 3369»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
4. On the right side, screw in special tool 3369.

1. Unscrew mounting bolts - 5 - at left and right.
2. Unscrew mounting bolts - 4 - and pull lock carrier - 1 - toward front.
3. Secure lock carrier «Secure lock carrier»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

2 - Left engine cover

3 - Right engine cover

4 - Combination bolt

1. 10 Nm

5 - Combination bolt

1. 50 Nm
2. For service position, screw in special tool 3369.

Note. After assembly of lock carrier, check headlight positioning and adjust if necessary.

Scheme 2

1. Screw in special tool 3369 left and right as shown.
2. Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender flange.

Scheme 3

1. Secure lock carrier at left and right with bolts.

Lock carrier with attachments, removing and installing

1 - Lock carrier

1. Removing
2. Remove bumper --> «Front bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__front-bumper-removing-and-installing) .
3. Remove noise insulation --> «Noise insulation panel - assembly overview»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Disengage Bowden cable for hood lock --> «Hood lock cable, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove engine cover - 2 - and - 3 -.
2. Remove intake air duct between lock carrier and air cleaner housing at lock carrier.
3. Disconnect electrical connectors.
4. Drain engine coolant and disconnect coolant pipes «Disconnect upper coolant hose»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) and «Disconnect lower coolant hose»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove condenser from water cooler only (do not disconnect lines)
2. Secure A/C system condenser using wire e.g. to front wheel. Refer to «87 AIR CONDITIONING»(/audi/a4/b7-2004-2009/remont/ac-compressor/#heating-air-conditioning)

Note. Do not hang condenser on lines. Condenser lines should not be pinched under any circumstances. Disconnect hoses to hydraulic oil cooler. Remove hydraulic oil cooler --> Disconnect hydraulic oil cooler , 48 - STEERING

Note. Hydraulic oil cooler line should not be pinched under any circumstances. For cars with automatic transmission, disconnect lines to ATF-cooler. Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V 37 CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J On vehicles with an intercooler, remove air conduction hose. Remove gasket for left and right front flap at juncture of fender at lock carrier - 1 -. Unscrew bolts - 5 -. A second mechanic is needed to hold the lock carrier - 1 -. Unscrew bolts - 4 -. Pull lock carrier toward front. Installation: Reverse order of removal. Headlights must be adjusted anew. Adjusting: Lock carrier - 1 - must be aligned between the fenders. If the fenders and the front flap are also to be changed, then adjust these to each other first.

2 - Left engine cover

3 - Right engine cover

4 - Combination bolt

1. 10 Nm

5 - Combination bolt

1. 50 Nm

Scheme 4

1. Pull out retainer for coolant line connecting flange at top of radiator and remove connecting flange.

Scheme 5

1. Pull out retainer for coolant line connecting flange at bottom of radiator and remove connecting flange.
2. Bleed cooling system. Refer to 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/blowers-superchargers-turbochargers/#20l-4-cyl-4v-turbo-engine-mechanical-engine-codes-bpg-bwt) for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN «19 - ENGINE - COOLING SYSTEM»(/audi/a4/b7-2004-2009/remont/cooling-fan/#32l-v6-4v-engine-mechanical-engine-codes-bkh) for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH «19 - ENGINE - COOLING SYSTEM»(ref-278885-S21797592792008020700000) for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS «19 - ENGINE - COOLING SYSTEM»(ref-278884-S12212760292008020700000) for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF

Scheme 6

1. Disconnect hoses from hydraulic oil line.
2. Unscrew hydraulic line for power-assisted steering on lock carrier.

Scheme 7

1. On vehicles with charge air cooler, loosen bolts on hose clamps - arrows -.
2. Disconnect hoses.

Scheme 8

1 - Cowl trim

1. Windshield wiper arms removed.
2. Plenum chamber cover removed.
3. Pull out securing pins - 4 -.
4. Remove trim from retaining strip at windshield, bottom.

1. Remove trim upward.
2. When installing, make sure that the trim engages completely into retaining strip.

2 - Support

3 - Windshield

4 - Securing pin

5 - Plenum chamber cover

1. Remove gasket - 6 - and remove cover from cowl panel trim

6 - Gasket

Scheme 9

1. Remove bolts - 2 - and - 3 -.
2. Remove transverse support - 1 - from mount - 4 -.
3. Transverse support - 5 - only with Right Hand Drive

Fender, removing and installing

Note. Bolts and washers are micro-encapsulated and must be replaced after loosening or after removing the fender.

Up to Vehicle Identification Number (VIN) 400 000

Scheme 10

1 - Fender

1. Remove bumper --> «Front bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove wheelhousing liner --> «Wheelhousing liner, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove end plate --> «Removing and installing end plate»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Remove headlight. Refer to «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET ; Headlights, repairing

1. Disconnect electrical connectors for the side blinkers.

2 - Combination bolt

1. 8 Nm

3 - Combination bolt

1. 10 Nm

4 - Combination bolt

1. 10 Nm

5 - Combination bolt

1. 10 Nm

6 - Combination bolt

1. 10 Nm

7 - Bracket

8 - Combination bolt

1. 10 Nm

As of Vehicle Identification Number (VIN) 400 001

Scheme 11

1 - Brace for wheelhousing liner

2 - Combination bolt

1. 10 Nm

3 - Brace for fender

4 - Combination bolt

1. 10 Nm

5 - Torx screw

1. 10 Nm

6 - Combination bolt

1. 8 Nm

7 - Wheelhousing liner

1. Removed

8 - Combination bolt

1. 10 Nm

9 - Fender

1. Remove bumper --> «Front bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove wheelhousing liner --> «Wheelhousing liner, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Remove end plate --> «Removing and installing end plate»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Remove headlight. Refer to «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET ; Headlights, repairing

1. Disconnect electrical connectors for the side blinkers.
2. Remove bolts - 5 - ; - 6 - and - 8 - and remove fender.

Scheme 12

1. Front wheel removed.
2. Wheelhousing liner removed.
3. Unscrew bolts - 1 - from expanding clip - 3 - and remove end plate - 2 - from fender - 4 -.
4. Tightening torque 2 Nm

Scheme 13

1 - Quick release screw

1. Remove only these quick release screws for service position of lock carrier.
2. 3 pieces

2 - Noise insulation, front

3 - Wheel spoiler

4 - Quick release screw

1. 3 pieces

5 - Noise insulation panel rear

1. Only installed for certain motor types

6 - Quick release screw

1. Two pieces

7 - Noise insulation panel mount

1. Marking (recess) must point to left vehicle side.

8 - Bolt

1. Two pieces
2. 7 Nm

9 - Speed nut

1. 3 pieces

10 - Speed nut

1. Two pieces

11 - Clamping pin

1. Six pieces

12 - Wheelhousing liner

13 - Bumper

14 - Lock carrier with attachments

Hood, removing, installing and adjusting

Up to Vehicle Identification Number (VIN) 400 000

Scheme 14

1 - Hood

1. Removing
2. Disconnect line to windshield washer system and unclip line.
3. Second technician is needed to support and lift hood during removal.
4. Remove gas-filled strut - 5 - from hood - 1 - «Gas-filled strut, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__gas-filled-strut-removing-and-installing) .

1. Remove nuts - 4 -.
2. Remove hood.
3. Installing
4. Install in reverse order of removal.

1. Adjusting
2. Align hood - 1 - between fenders.
3. Adjust height of hood at hood lock «Removing and installing lower part of hood lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Hood can be adjusted for height relative to fenders by adjusting buffer stops --> «Buffer stop for height adjustment»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Panel gap dimensions --> «Hood gap dimensions»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__hood-gap-dimensions) .

2 - Hood hinge

1. Hood - 1 - must be removed or propped up securely.
2. To remove, remove bolts - 3 - and nuts - 4 -.

3 - Combination bolt

1. 21 Nm

4 - Hex nut

1. 21 Nm

5 - Gas-filled strut

1. Removing and installing «Gas-filled strut, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__gas-filled-strut-removing-and-installing)

As of Vehicle Identification Number (VIN) 400 001

Scheme 15

1 - Hood

1. Removing
2. Disconnect line to windshield washer system and unclip line.
3. Second technician is needed to support and lift hood during removal.
4. Remove gas-filled strut - 5 - from hood - 1 - «Gas-filled strut, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__gas-filled-strut-removing-and-installing) .

1. Remove nuts - 4 -.
2. Remove hood.
3. Installing
4. Install in reverse order of removal.

1. Adjusting
2. Align hood - 1 - between fenders.
3. Adjust height of hood at hood lock «Removing and installing lower part of hood lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

2 - Hood hinge

1. Hood - 1 - must be removed or propped up securely.
2. To remove, remove bolts - 3 - and nuts - 4 -.

3 - Combination bolt

1. 21 Nm

4

1. 21 Nm

5 - Gas-filled strut

1. Tube of gas-filled strut must be installed on body side

Scheme 16

1. Support hood or secure it from falling down.
2. Gently lift retaining springs at both ends of gas-filled strut using a screwdriver and unclip gas-filled strut.
3. To install, press gas-filled strut onto ball stud and engage.
4. Install with tube end of strut at body.

Scheme 17

1. Clamp gas-filled strut in vice area x. Dimension of - x - = 50 mm (2 in.).

1. Cover area of sawn portion with a rag to absorb oil spraying out.

1. Using saw, cut into cylindrical part of strut at point within first third of cylinders length (measured from cover edge at piston rod end of cylinder).

Scheme 18

1. Buffer stops - 1 - and - 2 - must make contact lightly against lock carrier when hood is closed.

Scheme 19

As of Vehicle Identification Number (VIN) 400 001

1. Impact guard - 1 - for hood inserted
2. During installation, screw buffer - 3 - for height adjustment into hood until it stops.
3. For height adjustment, screw out far enough until contour aligns with fender.
4. Buffer must make contact on lock carrier after adjustment.

1. Buffers - 2 - for strike guard are inserted.

Note. The buffer stops can be used for adjusting the height of the hood.

Scheme 20

1. To remove, disengage locking mechanisms - arrows -.
2. Swivel out radiator grille at top, then pull off downward.

Note. To ease installation, coat PU seal with lubricant.

1. To install, insert centered at bottom (note middle centering) and swivel in - direction of arrow -.
2. Dimension - a - = 1.5 ± 0.5 mm
3. Dimension - b - =0.7 ± 0.5 mm
4. When installing, make sure radiator grille engage completely (audibly).

Scheme 21

Up to Vehicle Identification Number (VIN) 400 000

1. To remove, unscrew cap nuts - 2 - and remove catch hook - 1 -.
2. When installing, tighten cap nuts to 11 Nm.

Scheme 22

As of Vehicle Identification Number (VIN) 400 001

1. To remove, unscrew cap nuts - 2 - and remove catch hook - 1 - from hood - 3 -.
2. When installing, tighten cap nuts to 11 Nm.

Scheme 23

1. Disengage Bowden cable for hood --> «Hood lock cable, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove bolts - 2 - (4x). Tightening torque: 14 Nm
3. Remove lower part of lock - 1 -.
4. To adjust hood, move lower section of lock up or down as required.

Scheme 24

1. Buffer stop must make contact lightly on inner plate when hood is closed.
2. When adjusting headlights, re-position buffer stop only for fine adjustment. Tightening torque: 15 Nm

Hood gap dimensions

Special tools, testers and auxiliary items required

Scheme 25

1. Adjusting gauge 3371

Scheme 26

1. Dimension - A - = 4.5 mm ± 0.5 mm
2. Dimension - B - = 4.5 mm ± 0.5 mm
3. Dimension - C - = 4.5 mm ± 0.5 mm
4. Dimension - D - = 3 mm ± 0.5 mm

Hood lining, removing and installing

Removing

Scheme 27

1. Unclip clips - 2 -.
2. Remove cover - 1 -.

Installing

1. Installation is reverse of removal.

Hood seal, assembly overview

Assembly overview

Scheme 28

1 - Seal for lock carrier

1. Apply gasket at left and right on foam piece.
2. When doing this, make sure it is applied without gaps.
3. Compress excess length of gasket along lock carrier.

2 - Left sealing profile

1. Self-adhering, adhesion surfaces must be free of dust and grease.

3 - Seal for plenum chamber

1. Apply gasket at left and right on foam piece.
2. When doing this, make sure it is applied without gaps.
3. Compress excess length of gasket along front panel of plenum chamber.

Impact guard, installing

Note. When installing impact guard, drain holes must not be covered.

Scheme 29

1. Insert profile and align at drain holes.
2. Press on impact guard evenly.

Scheme 30

1 - Hood lock cable

1. Removing
2. Raise vehicle.
3. Remove front wheelhousing liner --> «Wheelhousing liner, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Remove drivers side storage compartment --> «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

1. Remove retaining clamp - 4 -.
2. Unclip cable for lower part of hood lock and disengage attachment lug arrow - A -.
3. Installing
4. Install in reverse order of removal.

1. Bring ball on cable for lower part of hood lock into installation position.

2 - Actuating lever

3 - Bolt

1. 2.4 Nm

4 - Retaining clip

5 - Lower part of hood lock

1. Removing and installing «Removing and installing lower part of hood lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
2. Can be used to adjust height of hood.

6 - Retaining clip

Scheme 31

1 - Rear lid

1. Removing
2. Remove warning triangle with bracket - 5
3. Remove rear lid lining.
4. Disconnect electrical harness connectors and pull out of lid.

1. Remove the nuts that connect both lid hinges to rear lid.
2. Second technician is needed to support and lift hood during removal.
3. Installing
4. Install in reverse order of removal.

2 - Buffer stop

1. Adjusting --> «Adjusting buffer stops»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

3 - Expanding nut

4 - Bolt

5 - Bracket

6 - Striker

1. Removing and installing «Striker, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__striker-removing-and-installing)
2. Adjusting «Adjusting rear lid»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

7 - Nut

1. 8 Nm

Striker, removing and installing

1. Remove trim for rear panel. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 32

1. Unscrew nuts - 1 -. Tightening torque 8 Nm
2. Installation is performed in the reverse order of removal.

Scheme 33

1. Remove trim for rear panel. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

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

1. Loosen nuts - 1 - , striker - 2 - must be able to be moved.

1. Carefully close rear lid until lid is flush with side panels.
2. Carefully open lid and tighten nuts - 1 - to 8 Nm.

Gap dimensions for rear lid

Special tools, testers and auxiliary items required

1. Adjusting gauge 3371

Scheme 34

1. Dimension - A - = 4.0 mm ± 0.5 mm
2. Dimension - B - = 2.0 mm ± 0.5 mm
3. Dimension - C - = 2.0 mm ± 0.5 mm

Gap dimensions for fuel filler flap

1. Removing and installing fuel filler flap --> «Fuel filler flap»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__fuel-filler-flap)

1. Dimension - D - = 3 mm
2. Dimension - E - = 3 mm
3. Dimension - F - = 3.5 mm
4. Dimension - G - = 3 mm

Scheme 35

1 - Rear lid lock

1. To remove, unclip operating rod from swivelling bush and disengage.
2. Unscrew hex nuts - 3 - and remove rear lid lock.

2 - Swivelling bushing

1. After installing rear lid lock, engage operating rod and secure.

3 - Nut

1. 8 Nm

4 - Operating rod

5 - Bowden cable

6 - Lock cylinder

1. Removing
2. Disconnect electrical harness connectors.
3. Disengage Bowden cable - 6 - from lock cylinder.
4. Remove combination bolt - 7 -.

1. Twist lock cylinder 90°.
2. Remove lock cylinder from handle mechanism.

7 - Combination bolt

1. 8 Nm

8 - Engine

1. Removing and installing --> «Remote control motor, removing and installing (country versions)»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

9 - Grip piece

1. Removing
2. Rear lid trim removed.
3. Lock cylinder removed.
4. Remove hex head collar nuts - 10 -.

1. Press in catches - arrows -.
2. Remove grip piece.

10 - Hex head collar nut

1. 8 Nm

Scheme 36

1. Unclip operating rod - 3 - and disengage.
2. Remove bolt - 2 - (Qty. 2). Tightening torque: 2 Nm
3. Remove remote control motor.
4. Disconnect connector from remote control motor - 1 -.

1. Installation is performed in the reverse order of removal.

Rear lid hinge, removing and installing

Comfort hinge

Scheme 37

1 - Gas-filled strut

1. Engage tube end of strut at lid.
2. Insert cover with angled retractors in hinge lever.
3. Only then press cover at top over hinge lever until it engages audibly.
4. Press stop into hinge eye.

2 - Cover

1. Slide in cover from below between gas-filled strut and long hinge lever.

3 - Spring

1. Before removing, remove gas-filled strut and cover.
2. To remove, press off spring over ball stud.
3. While installing, plastic shells of spring must engage cleanly over ball stud.

4 - Comfort hinge

5 - Ball stud

1. No replacement part, belongs to delivery casing

1. Gas-filled strut, removing and installing «Gas-filled strut, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

Cover for rear lid hinge

Scheme 38

1. Place electric wiring or wiring for central locking system - 2 - into lower retainer of cable guide at cover - 1 -.
2. Insert trim - 1 - for lid hinge on long hinge lever at bottom and clip in audibly toward top onto hinge lever.
3. Engage clip - 3 - on trim into hinge lever.

Removing and installing rear lid hinges

Note. For easier adjustment of the rear lid hinges, use gradations marked on the hinges.

Removing

Scheme 39

1. Loosen nut - 1 -. Tightening torque 21 Nm
2. Unscrew nut - 2 -. Tightening torque: 21 Nm
3. Lift off lid from hinge.
4. Remove bolts - 3 - and - 4 -. Tightening torque: 21 Nm

1. Only loosen center bolt - 5 -. Tightening torque: 21 Nm
2. Remove hinge - 6 -.
3. Installation is performed in the reverse order of removal.

Gas-filled strut, removing and installing

Note. When removing or installing the gas-filled strut, push back the opened rear lid only slightly so as to avoid damaging components.

Scheme 40

1. Lift retaining springs in succession on both ends using screwdriver and remove gas-filled strut.

Installation

1. Clip in gas-filled strut at bottom first, then at top.
2. Install with tube end of strut at rear lid.

Releasing gas from gas-filled strut

1. Clamp gas-filled strut in vice area x. Dimension of - x - = 50 mm (2 in.).

1. Cover area of sawn portion with a rag to absorb oil spraying out.
2. Using saw, cut into cylindrical part of strut at point within first third of cylinders length (measured from cover edge at piston rod end of cylinder).

Scheme 41

1. The butt joint - position A - of the rear lid seal must be aligned with the ball socket of the left hinge.
2. Press seal on.

Scheme 42

1. Open lid.
2. Remove rubber cap.
3. Screw in buffer stops until they reach stop.
4. Unscrew stop again in steps.

1. Press rubber cap on.
2. When adjusted correctly and with lid closed, buffer stops must make contact lightly on luggage compartment edge.

Fuel filler flap

Assembly overview

Scheme 43

1 - Sheet-metal screw

1. 1.5 Nm

2 - Fuel filler flap

1. Panel gap dimensions «Gap dimensions for fuel filler flap»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__gap-dimensions-for-fuel-filler-flap)

3 - Fuel filler flap cup

1. Coat with soap solution to assist assembly.

4 - Ring for fuel filler flap cup.

Rear lid, removing and installing

Removing

1. Remove rear lid trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Disconnect or remove electrical harness connectors and hose for rear window washer system.
3. Prop up and secure rear lid in open position.

Scheme 44

1. Using screwdriver, lift retaining spring - 3 - as shown and remove gas-filled strut - 1 - from upper ball stud - 2 -.

Scheme 45

1. Remove cover - 1 - for rear lid hinge and cable guide - 2 - from rear lid hinge - arrows -.

Scheme 46

1. Remove bolts - arrows - at left and right.
2. Second technician is needed to support and lift hood during removal.
3. Remove rear lid.

Installing

Installation is the reverse of removal, noting the following

1. When installing, tightening torque 21 Nm.
2. Adjusting rear lid --> «Rear lid, adjusting»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__rear-lid-adjusting) .

Scheme 47

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

1 - Insulation mat 100 x 150 mm (2x)

2 - Insulation mat 30 x 100 mm (2x)

Rear lid, adjusting

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

1. Remove rear cross panel trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 48

1. Loosen combination nuts - 1 - and - 3 - , striker - 2 - must be adjustable.

Note. When installing a striker, make sure it is in the proper installation position, for this the tab - arrow - must point to the rear.

Scheme 49

1. Unclip cover - 1 - at rear lid stop.
2. Screw the adjustment screw - 2 - counterclockwise into position "0".

1. Tighten nuts - 1 - and - 3 - hand tight.
2. Close rear lid.
3. Press lid by hand into chassis approx. 2 mm.
4. Open rear lid in this position and tighten nuts - 1 - and - 3 - to 21 Nm.

1. Check whether rear lid closes easily and without play at lock. Repeat adjustment if necessary.
2. Check whether lid sits without play by pressing on the side edge of rear lid below rear window.

1. Pre-tension stop by turning adjustment screw - 2 - clockwise if necessary.
2. Check whether rear lid still closes easily, repeat adjustment if necessary.
3. Checking adjustment dimensions --> «Adjustment dimensions for rear lid»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__adjustment-dimensions-for-rear-lid) .

Removing

1. Remove cover - 1 - for rear lid hinge and cable guide - 2 - from rear lid hinge - arrows -.

Scheme 50

1. Remove outer roof frame trim - 1 - , for this purpose lift trim from retaining clips - 2 - after unclipping and guide tabs - arrows - around the hinge.
2. Remove D-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Note. To prevent damage to paint, support and secure rear lid.

Scheme 51

1. Remove nuts - arrows -.

1. Remove bolts - arrows - at left and right.
2. Remove hinge.

Installing

Installation is the reverse of removal, noting the following

1. When installing, tightening torque 21 Nm.
2. Adjusting rear lid --> «Rear lid, adjusting»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__rear-lid-adjusting) .

Gas-filled strut for rear lid, removing and installing

Removing

1. Prop up and secure rear lid in open position.

1. 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 component must be installed on the body side.

Installing

Installation is the 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

Scheme 52

1. Open rear lid and pull out seal.
2. When installing, insert seal in lower left and right corners first.
3. Press seal - 1 - onto body as shown.

Adjustment dimensions for rear lid

Special tools, testers and auxiliary items required

1. Adjusting gauge 3371

Scheme 53

1. Dimension - A - = 4 mm
2. Dimension - B - = 4.5 mm
3. Dimension - C - = 1.75 mm

1. Dimension - D - = 3 mm
2. Dimension - E - = 3 mm
3. Dimension - F - = 3.5 mm
4. Dimension - G - = 3 mm

Scheme 54

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).

1. Dimension - b - = 0 to 0.5 mm

Lock cylinder for rear lid, removing and installing

Removing

1. Remove rear lid trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 55

1. Disconnect electrical harness connector - 2 -.
2. Disengage actuating link - 3 - to rear lid lock.
3. Remove bolt - 1 -.
4. Tightening torque: 8 Nm

1. Turn lock cylinder 90° around its own shaft and remove lock cylinder.

Installing

Installation is performed in the reverse order of removal.

Handle mechanism for rear lid, removing and installing

Removing

1. Remove lock cylinder for rear lid --> «Lock cylinder for rear lid, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__lock-cylinder-for-rear-lid-removing) .
2. Disconnect inner electrical harness connector at grip piece.

Scheme 56

1. Remove nuts (Qty. 4) - 1 - and - 2 - (different versions; mark for re-installation).
2. Tightening torque: 8 Nm
3. Press both catches - arrows - down and remove grip piece - 3 -.

Installing

Installation is performed in the reverse order of removal.

Rear lid lock, removing and installing

Assembly overview

As of Vehicle Identification Number (VIN) 400 001

Scheme 57

1 - Rear lid

2 - Lid lock

1. Removing «Removing lid lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__removing-lid-lock)

3 - Hex nut

1. 21 Nm

4 - Cover

1. Connected to lid lock as anti-theft device.

5 - Cover for lid lock

1. Slide on lid lock before installing rear lid trim.

Removing lid lock

1. Remove lower rear lid trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 58

1. Disengage actuating link - 6 - , for this purpose press expanding clip - 5 - from operating lever.
2. Disengage operating rod - 1 - to actuator, for this purpose turn hinge arm - 7 - clockwise and remove operating rod.
3. Remove nuts - 2 - and - 4 - and remove rear lid lock - 3 -.
4. Tightening torque: 21 Nm

Installing

Installation is performed in the reverse order of removal.

Rear lid lock actuator, removing and installing

Removing

1. Remove lower rear lid trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 59

1. Disengage operating rod - 3 - at rear lid lock, for this purpose turn hinge arm - 4 - clockwise and remove operating rod.
2. Disengage operating rod at actuator - 1 - , for this purpose slide operating rod to actuator and turn approx. 90° out of mount - arrow -.
3. Loosen bolts - 2 - approx. 2 rotations and disengage actuator at rear lid.
4. Disconnect electrical harness connector.

Scheme 60

1. Remove bolts - 3 -.
2. Tightening torque 2 Nm
3. Remove adapter plate - 2 - from actuator - 1 -.

Installing

Installation is performed in the reverse order of removal.

Assembly overview

1 - Sheet-metal screw

1. 1.5 Nm

2 - Fuel filler flap

1. Panel gap dimensions «Gap dimensions for fuel filler flap»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

3 - Fuel filler flap cup

1. Coat with soap solution to assist assembly.

4 - Ring for fuel filler flap cup

Scheme 61

1 - Window frame

1. Removing
2. Remove door trim. Refer to «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET ; front door trim
3. Disconnect electrical harness connectors.
4. Remove window regulator motor «Window regulator motor, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__window-regulator-motor-removing-and-installing) .

1. Remove bolts - 7 -.
2. Remove bolts - 4 - , - 8 - and - 10 -.
3. Remove bolts - 6 - and - 9 - and lift window frame with window regulator upward and out of door.
4. Installation

1. Drive window into window frame half way before installing.
2. Insert window frame and window regulator into door from above.
3. Knock in the upper profile halves of door-side gasket into window frame at top.
4. Loosely screw in mounting bolts in the sequence - 6 - ; - 9 - ; - 3 - ; - 8 - and - 10 -.

1. Tighten collared shoulder bolts - 6 - and - 9 - hand tight.
2. Lightly press window frame - 1 - inward at top.
3. Tighten bolts - 4 - and - 8 - to 32 Nm.
4. Tighten collared shoulder bolts - 6 - and - 9 - to 32 Nm.

1. Tighten bolt - 10 - to 10 Nm.
2. Tighten locating bolt - arrows - in window frame to 32 Nm.

2 - Window regulator

1. Bolted to window frame for installing in door.

3 - Front door

4 - Torx screw

1. 32Nm

5 - Concealment cap

6 - Collared shoulder bolt

1. 32Nm

7 - Collar bolt

1. 6Nm

8 - Torx screw

1. 10Nm

9 - Collared shoulder bolt

1. 32Nm

Scheme 62

1. To remove, unscrew bolts - 2 - and remove window regulator motor.
2. Install window regulator motor --> «Motor for window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__motor-for-window-regulator-removing-and) .

Scheme 63

Upper door hinge

1. Torx bolt T45 - 1 - (installed from inside of vehicle) 32 Nm.
2. Top door hinge - 2 -.
3. Cover cap - 3 -.
4. Torx bolt T45 - 4 - 32 Nm.

1. Install bolt - 5 - T45 32 Nm.

Scheme 64

Lower door hinge

1. Torx bolt T45 - 1 - 32Nm bolted to B-pillar from interior of vehicle.
2. Lower door hinge - 2 -.
3. Cover cap - 3 -.
4. Torx bolt T45 - 4 - 32Nm.

1. Collared shoulder bolt T45 - 5 - 32Nm.
2. Re-grease lubrication points - arrows - in service interval.
3. Front door - 6 -.

Scheme 65

1 - Window frame

1. Removing
2. Remove door trim. «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET ; front door trim
3. Window frame with window regulator removed from front door --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Door window - 4 - removed

1. To remove, unscrew countersunk screws - 3 - and remove window regulator from window frame.
2. Installation
3. When installing, make sure that both guide rails, - arrows A - , run parallel to guide - arrow B -.
4. Tighten bolts - 3 - to 6 Nm.

2 - Window regulator

1. Window frame with window regulator removed from front door --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Door window removed.
3. To remove, unscrew countersunk screws - 3 - and remove window regulator from window frame.

3 - Countersunk screw

1. 6Nm

4 - Window

1. Removing
2. Drive down door window fully.
3. Unscrew bolts - 5 - and remove door windows from window regulator.
4. Installing

1. Insert window into window regulator.
2. Screw bolts - 5 - into window regulator, but do not tighten yet.
3. Drive door window upward into window frame.
4. Pull door window toward rear into window guide on window frame at B-pillar and tighten bolts - 5 - to 4Nm.

5 - Socket head bolt

1. 4 Nm

Motor for window regulator, removing and installing

Removing

1. Door trim removed. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Note. Motor for window regulator can be removed or installed in every position of motor or side window. Before removing motor, disconnect electrical harness connectors.

Scheme 66

1. Remove Torx bolts - 2 - T30 and remove motor.

Installing

1. When installing, make sure that threaded pins - arrows - are engaged in inner door plate.
2. Slide on window regulator motor -1- and secure with bolts - 2 -.
3. Tightening torque 3.5 Nm

Note. Only switch ignition on and off after installing motor and connected wires. Then move door window upward to stop and keep pressing switch for window regulator for approx. 2 seconds longer. This position is the base position and the high- and low-running function is activated.

Front door, adjusting

Special tools and equipment

Special tools, testers and auxiliary items required

Scheme 67

1. T40038/01

Note. To adjust door exactly in relation to height, inclination and door recess, use the special tool T40 038/1 as described on --> Adjusting using door adjustment template T40038/1 .

Scheme 68

Panel gap dimensions

Note. Rear door must be adjusted. Panel gap dimensions can be checked using 3371 adjustment gauge.

1. Dimension - A - = 3.5 mm ± * .5mm .
2. Dimension - B - = 4.5 mm ± * .5mm .
3. Flush dimension - C - =approx. * mm+1mm in parallel position to chassis.

Adjustment in longitudinal direction

Scheme 69

1. Adjustment in longitudinal direction is performed by loosening hinge bolts - arrow A - of A-pillar at top of door hinge or/and bottom and sliding doors - 2 - (over-sized holes in hinge or in A-pillar)
2. Tightening torque 32 Nm
3. Door hinge - 1 -.
4. A - pillar - 3

1. Door - 2

Note. Illustration shows lower door hinge.

Adjustment to center of vehicle

Note. A collared shoulder bolt is installed at each upper and lower door hinge (door side). When repairing, an adjustment is therefore not necessary under normal circumstances. If an adjustment should become necessary anyway, bolts can be replaced with bolts of the same size, length and toughness .

1. The adjustment to vehicle center occurs by loosening hinge bolts - arrow B - at top and/or at bottom of door and shifting the doors (elongated holes in hinge).
2. Tightening torque 32 Nm

Note. In rear portion of door, adjust door depth (relative to vehicle center) via striker.

Adjusting via striker

Scheme 70

1. Loosen bolts - 2 -.
2. Use the markings (- arrows a - and - arrows c -) for side adjustment.
3. Slide striker - 1 - until the door is flush with the contour of the chassis.

Note. Door may only be adjusted for depth (towards car interior) and not for height.

1. Use the markings (- arrows b - and - arrows d -) for height adjustment.
2. Striker must align in door lock center for correct adjustment.
3. Tighten bolts to 25 Nm.

Scheme 71

1. Use the door adjustment template T40 038/1 as described in the following for testing (e.g. for wind noises) and for adjusting door.
2. For testing contact pressure of sealing lips on roof trim molding, use a standard bank card - 1 - or similar means.

Scheme 72

Testing sealing lip/roof trim molding contact

1. Using a standard bank card, drive off contact area of sealing lip to roof trim molding with light pressure.
2. When doing this, card must not sink in between sealing lip - 1 - and roof trim molding - 2 -.

Scheme 73

1. Template has points of different lengths at - arrows a - and - arrows b - so that side adjustment of door can be tested.
2. The upper point - arrow a - on the side with the cut-out - arrow c - at bottom is the longer side (max. marking).
3. This side is used to check whether the window frame is located too far outward in relation to the chassis.

Scheme 74

1. Position template at dimension - a - = 200mm and with cut-out - arrow - facing door window
2. Make sure that points - 1 - and - 3 - make contact.
3. At point - 2 - of template, there must be a gap.
4. In this position (max), doors are adjusted to farthest outward point within tolerance range.

1. If there is no gap at point - 2 - , or there is a gap at point - 1 - , the window frame is set too far outward and must be adjusted --> «Window frame, adjusting»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

1. The upper point - arrow b - opposite the side with cut-out - arrow c - at bottom is the shorter side (min. marking).
2. This side is used to check whether the window frame is located too far inward in relation to the chassis.
3. Position template at dimension - a - = 200mm and with cut-out - arrow - turned away from door window as depicted in magnified areas of illustration.

Scheme 75

1. Make sure that points - 2 - and - 3 - make contact on door window.
2. At point - 1 - of template, there must be a gap.
3. In this position (min), doors are adjusted to farthest inward point within tolerance range.
4. If point - 1 - has no gap, or if template cannot be brought into contact at point - 2 - , window frame is set too far inward and must be adjusted.

Panel gap dimensions

Special tools, testers and auxiliary items required

1. Adjusting gauge 3371

1. Dimension - E - = 3.5 mm ± 0.5 mm
2. Dimension - F - = 4.5 mm ± 0.5 mm
3. Flush adjustment of front door to fender must be in the range of 0 mm to 1 mm recess.
4. Flush adjustment of front door to rear door must be in the range of 0 mm to 1 mm projection.

Scheme 76

1 - Insulation for door trim

1. Must not be removed for the adjustment.

2 - Front door

1. For correct adjustment of window frame, door trim and loudspeaker must be removed.

3 - Spacer

1. Place underneath at bolt point - B - if necessary.
2. By loosening mounting bolts - arrow A - and removing or adding spacers at bolt point - B - , --> «Inclination adjustment at A-pillar»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) , the position (inclination) of window frame in A-pillar region can be adapted to roof molding.
3. Different sizes (0.5 mm and 1 mm thick) are available.

Scheme 77

1. By loosening bolt - arrow - and placing underneath or removing spacers, the contact pressure of seal in A-pillar region can be adjusted.
2. Spacers up to a maximum of 3 mm can be inserted underneath, depending on technical assessment.
3. Spacers in sizes of 0.5 mm and 1 mm are available.

Adjustment for B-pillar region

Note. If height adjustment dimensions are not within tolerance range of the adjusting template, collared shoulder bolts must be replaced by two standard-type bolts. After that, the window frame height can be adjusted.

Scheme 78

1 - Front collared shoulder bolt

1. Replace with standard-type bolt for height adjustment if necessary.
2. 32 Nm.

2 - Rear collared shoulder bolt

1. Replace with standard-type bolt for height adjustment if necessary.
2. 32 Nm.

3 - Bolt for longitudinal compensation (X compensation)

1. 32 Nm.

4 - Rear mounting bolt

1. 32 Nm.

5 - Front mounting bolt

1. 32 Nm.

6 - Door seal

Note. After installing or adjusting window frame, mounting bolts must be screwed in and tightened in the sequence described in the following. Door window must be lowered to half-way before installing window frame. Insert door frame into door base carrier. Screw in bolts - 1 - and - 2 - "hand tight". Loosen bolt - 3 -. Install door seal - 6 - in window frame. Screw in bolt - 4 - and tighten it to 32 Nm. Close door and check inclination of window frame using adjusting template --> Adjusting using door adjustment template T40038/1 . If necessary, the inclination can be adjusted further by loosening bolt - 4 -. Check contact area of seal in A-pillar region Inclination adjustment at A-pillar Tighten bolt - 5 - to 32 Nm.

Scheme 79

1. If height of window frame must be adjusted, then the corresponding collared shoulder bolt -arrow- must be replaced with a standard bolt.
2. Now, the window frame height can be adjusted.
3. Position adjusting template as shown on roof, or on upper edge of rain channel.

Scheme 80

1. For a correct adjustment, lower edge of window frame must be located between markings - a - , (line on template - arrow -) or - b -.
2. Check/adjust inclination of window frame --> «Adjusting using door adjustment template T40038/1»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__adjusting-using-door-adjustment-template-t400381) .

Scheme 81

1. Door position can be assessed using lower side of template T40038.
2. No recess of front door - 1 - at rear door - 2 - is permitted.
3. Recess of front door - 1 - at rear door - 2 - is not permitted (wind noise).

Scheme 82

1. Projection (maximum 0.8 mm) of front door at rear door must be in range of template cut-out - arrow -.

Window frame installation

Note. If window frame must be removed or installed for a repair, observe the following points and the bolting sequence described afterward. The adjusting element is self-adjusting, meaning it can compensate bearing tolerances.

Scheme 83

1. First check basic setting of adjusting element.
2. Before installing window frame, adjusting element must always be in the basic position.
3. Adjusting element is in basic position in position - a -.
4. Adjusting element is in end position in position - b -.

Scheme 84

1. In area of mirror base on A-pillar, a sealing strip is applied flush along window shaft strip under trim as shown.
2. When removing mirror base, sealing strip must always be replaced.
3. Pull off protective foil from sealing strip.
4. Affix sealing strip starting from - arrow b - up to cut at front and shorten strip using scissors - arrow a -.

1. Insert window frame with door window lowered to half-way into door shell.

Scheme 85

1. Screw in bolts - arrow 1 - and - arrow 2 - by hand.
2. Loosen bolt - arrow 3 -.
3. Install door seal into window frame.
4. Screw in rear bolt through door shell and secure window frame.

1. Tighten bolt to 32 Nm.
2. Close door and check inclination of window frame using adjusting template in B- pillar region and adjust if necessary.

1. Screw in bolt - arrow - and check adjustment in A-pillar region.
2. If necessary, adjust window frame at A-pillar «Inclination adjustment at A-pillar»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
3. Spacers can be slid in between window frame and door shell up to a maximum of 3mm, depending on technical assessment.
4. Tighten bolt - arrow - to 32 Nm.

1. Tighten collared shoulder bolts - arrow 2 - and - arrow 3 - to 32Nm.
2. Also tighten bolt - arrow 3 - to 32 Nm.
3. Insert bolt into adjusting element as shown in magnified area of illustration.
4. Slowly screw bolt into adjusting element.

1. While doing this, upper part of adjusting element unscrews and fits automatically

Note. If upper part of adjusting element does not unscrew on its own, adjusting element must be replaced.

Scheme 86

Replacing adjusting element

1. To remove, pull adjusting element - 2 - out of door shell - 1 -.
2. To install, press adjusting element in basic position with retaining pins completely into door shell at top.

Scheme 87

1. While screwing the adjusting element, place a finger on window frame and door plate as a check.
2. The reason for this is the distance must not change while screwing the adjusting element.

Scheme 88

1. Tighten bolts of window regulator rails at bottom to 6Nm.

Scheme 89

1. Clip pins - arrows a - for window regulator cable reel completely into door shell.
2. Clip cable - 1 - into door shell - arrow b - , otherwise rattling noises will result.

Scheme 90

1. Also secure door insulation mat using water resistant webbed band (e.g. D 004 350 A2) - arrow - on upper side as shown.
2. This measure can prevent insulation mat from loosening from door during periods of operation and thus preventing drafts.

Scheme 91

Function of adjusting element

1. While screwing in bolt - 5 - , the upper part - 3 - of adjusting element screws itself out of the lower part - 2 - and compensates a gap between window frame - 4 - and door shell - 1 -.

Scheme 92

1 - Window frame

1. For correct door adjustment, sealing lip must make clean contact to contours at roof frame and at B- pillar, see - arrows -.

2 - Window

1. Adjust door until the result is dimension - d - = 4 mm in area - c - = 365 mm.
2. Dimension - d - can be checked further using door adjusting template T40038.
3. Dimension - b - of rear door edge starting at B- pillar = 200 mm.

3 - Window frame

1. Door window - 2 - must drive as far as dimension - a - = 7.5 mm -1mm into window frame at B- pillar.

Scheme 93

1 - Mount for door handle.

1. Releasing «Disengage mount for door handle»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__disengage-mount-for-door-handle) .

2 - Door lock

1. Removing
2. Door trim removed.
3. Window frame and window regulator removed --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. To remove, unscrew multi-point bolts - 4 - and remove door lock downward.

3 - Operating rod

1. Clip into door lock «Engaging operating rod in door lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__engaging-operating-rod-in-door-lock)

4 - Socket-head bolt

1. 20 Nm

5 - Lock cylinder cover

1. Lock cylinder removed and cover unclipped

6 - Lock cylinder

1. Removal «Locking cylinder, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

7 - Door handle

1. Before disassembling, remove window frame and window regulator.
2. Removal --> «Door handle, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__door-handle-removing) .

8 - Actuating lever

9 - Clip

1. Engage operating rod in clip, swivel clip 90° and engage at operating rod.

Scheme 94

1. Open driver-side door.
2. Remove cover cap - 2 -.
3. Turn Torx bolt arrow counter-clockwise until it stops.
4. This moves the arm - 1 - toward rear and releases lock cylinder.

1. Remove lock cylinder from door handle.

Scheme 95

1 - Door handle

2 - Clip

1. When disassembling door handle - 1 - , unclip operating rod - 3 - here.

3 - Operating rod

1. Before removing door handle, disengage at clip - 2 -.
2. After installing a new door lock, first insert operating rod into casing and engage.
3. Only then pull securing pin - 5 - from door lock.

4 - Casing

1. To engage operating rod - 3 - , slide casing - 4 - upward.

5 - Securing pin

1. Only available as replacement part.
2. Pull out after installing operating rod - 3 -.

6 - Door lock

1. Removal --> «Door handle and door lock - front, assembly overview»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 96

1. Door trim as well as window frame and window regulator removed.
2. Insert screwdriver through door plate and release slider - 2 - from door handle - 1 - in direction of arrow.

Scheme 97

1. To remove, pull up door handle - 1 - , slide out locking mechanism - 3 - in longitudinal direction using small screwdriver.
2. Disengage trim - 2 - at top on the sides and remove downward from door handle.
3. Installation is the reverse order of removal.

Scheme 98

1 - Socket head bolt M8

1. 20 Nm

2 - Base plate

3 - Door lock

1. Door trim removed.
2. Window frame and window regulator removed.
3. Disconnect electrical harness connector at door lock.
4. If the same door lock is installed again, disengage operating rod at door handle.

1. If door lock is being replaced, disengage operating rod at door lock «Engaging operating rod in door lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__engaging-operating-rod-in-door-lock) .
2. Unclip operating rod at casing from door lock.
3. Unscrew multi-point bolts - 1 - and remove door lock.

4 - Release lever

5 - Bowden cable for interior door mechanism

1. To install, first insert vertically into release lever as shown in the magnified area of illustration, then swivel 90° and clip into door lock to secure.

Scheme 99

1. When installing a new door lock, clip operating rod - 1 - into casing.
2. Move slide - 2 - of casing upward to engage operating rod.
3. Pull securing pin - 3 - out of door lock.

Scheme 100

1 - Front Passengers Door Control Module J387

1. Integrated in window regulator.

2 - Right Rear Door Control Module J389

1. Integrated in window regulator.

3 - Fuel Tank Lid Unlock Motor V155

1. Removal «Removing Fuel Tank Lid Unlock Motor V155»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

4 - Rear Lid Unlock Motor V139

5 - Left Rear Door Control Module J388

1. Integrated in window regulator.

6 - Drivers Door Control Module J386

1. Integrated in window regulator.

7 - Comfort System Central Control Module J393

1. Before removing, disassemble left front seat
2. Remove lower A-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
3. Remove lower A-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
4. Removal «Removing Comfort System Central Control Module J393»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

8 - Front Hood Switch F266

1. Component location in lock carrier

Scheme 101

1. Left front seat and lower A- pillar trim removed.
2. Ignition switched off.
3. Open box - 1 - for control module.
4. Disconnect harness connector from control module - 2 - and remove it.

Scheme 102

1. Disconnect electrical connector.
2. Loosen bolts - arrows - using special tool T10010, slide actuator - 1 - toward front and remove.
3. Before installing actuator, emergency release - 3 - must be slid over the locking pin.
4. Locking pin of actuator must move cleanly into closed fuel filler flap - 2 -.

Scheme 103

1 - Front Passengers Door Control Module J387

1. Integrated in window regulator.

2 - Right Rear Door Control Module J389

1. Integrated in window regulator.

3 - Fuel Tank Lid Unlock Motor V155

1. Removal «Removing Fuel Tank Lid Unlock Motor V155»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

4 - Rear Lid Unlock Motor V139

5 - Left Rear Door Control Module J388

1. Integrated in window regulator.

6 - Drivers Door Control Module J386

1. Integrated in window regulator.

7 - Comfort System Central Control Module J393

1. Before removing, disassemble left front seat
2. Remove lower A-pillar trim. --> «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «72 - SEAT - FRAMES»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
3. Remove lower A-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
4. Removal «Removing Comfort System Central Control Module J393»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

8 - Front Hood Switch F266

1. Component location in lock carrier

Repairing the central locking system

1. Central locking system in the A4 operates electrically instead of pneumatically as before.
2. Actuators in doors are integrated in the door lock and have 2 motors.
3. Actuators cannot be replaced separately.
4. The first motor locks the door and the second motor locks the interior door mechanism (Safe function).

1. Now, doors also can no longer be opened from the interior.
2. Actuators of fuel filler flap and rear lid have one motor each and cannot be replaced individually.
3. After an accident in which the airbag deploys, the central locking system control module opens any doors which were locked.
4. Central locking system control module is located in front of drivers seat, at left, under floor mat.

Scheme 104

1 - Window frame

1. Removing
2. Remove door trim. «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET ; front door trim
3. Remove window regulator motor «Window regulator motor, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) or manual window regulator «Manual window regulators, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__manual-window-regulators-removing-and-installing) .
4. Disconnect electrical harness connectors.

1. Remove bolts - 7 - and - 8 -.
2. Remove bolts - 3 - - 4 - ; - 6 - and - 10 - and lift window frame with window regulator upward and out of door.
3. Installation
4. Insert window frame and window regulator into door from above.

1. Knock in the upper profile halves of door-side gasket into window frame at top.
2. Loosely screw in mounting bolts - 4 - at front and rear.
3. Then, loosely screw in bolts in the sequence - 3 - ; - 10 - ; - 8 -.
4. Tighten collared shoulder bolts - 4 - hand tight.

1. Lightly press window frame - 1 - inward at top.
2. Tighten bolts - 3 - and - 10 - to 32 Nm.
3. Tighten collared shoulder bolts - 4 - to 32 Nm.
4. Tighten bolt - 8 - to 10 Nm.

1. Tighten locating bolt - arrows - in window frame to 32 Nm.
2. Knock in lower half of door seal into inner door plate.
3. Secure window regulator rail with bolt - 7 - to inner door plate.
4. Press threaded pin of window regulator reel through inner door plate until it engages «Window regulator motor, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Window regulator motor, removing and installing

1. To remove, unscrew bolts - 2 - and remove window regulator motor.
2. Install window regulator motor --> «Motor for window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 105

1. Unthread bolts - 2 - and remove manual window regulator from inner door plate.
2. Install manual window regulator --> «Manual window regulators, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Upper door hinge

1. Torx bolt T45 - 1 - (installed from interior of vehicle) 32 Nm.
2. Top door hinge - 2 -.
3. Cover cap - 3 -.
4. Torx bolt T45 - 4 - 32 Nm.

1. Fitting bolt - 5 - T45 32 Nm.

Scheme 106

Lower door hinge

1. B-pillar trim removed.
2. Torx bolts T45 - 1 - 32Nm bolted to B-pillar from interior of vehicle.
3. Lower door hinge - 2 -.
4. Cover cap - 3 -.

1. Torx bolt T45 - 4 - 32Nm.
2. Fitting bolt T45 - 5 - 32Nm.
3. Re-grease lubrication points - arrows - in service interval.
4. Front door - 6 -.

Scheme 107

1 - Window frame

1. Removing
2. Remove door trim. «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET ; front door trim
3. Window frame removed together with window regulator from door --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. Door window - 4 - removed

1. To remove, unscrew countersunk screw - 7 - and remove window regulator from window frame.
2. Installation
3. When installing, make sure that guide rail, arrow - A - , runs parallel to guide arrow - B -.
4. Tighten bolts - 7 - to 6 Nm.

2 - Triangular panel

1. Before removing, disassemble window frame and window regulator.
2. Unscrew bolt - 3 - and remove panel sideways.

3 - Countersunk screw

1. 5Nm

4 - Window

1. Removing
2. Drive down door window fully.
3. Unscrew bolts - 5 - and remove door windows from window regulator.
4. Installation

1. Insert window into window regulator.
2. Screw bolts - 5 - into window regulator, but do not tighten yet.
3. Drive door window upward into window frame.
4. Pull door window toward front into window guide on window frame at B-pillar and tighten bolts - 5 - to 4Nm.

5 - Socket head bolt

1. 4Nm -0.5Nm

6 - Window regulator

1. Window frame removed together with window regulator from door --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Door window removed.
3. To remove, unscrew countersunk screw - 7 - and remove window regulator from window frame.

Removing

1. Door trim removed. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Note. Motor for window regulator can be removed or installed in every position of motor or side window. Before removing motor, disconnect electrical harness connectors.

1. Remove Torx bolts - 2 - T30 and remove motor.

Installing

1. When installing, make sure that threaded pins - arrows - are engaged in inner door plate.
2. Slide on window regulator motor -1- and secure with bolts - 2 -.
3. Tightening torque 3.5 Nm

Note. Only switch ignition on and off after installing motor and connected wires. Then move door window upward to stop and keep pressing switch for window regulator for approx. 2 seconds longer. This position is the base position and the high- and low-running function is activated.

Manual window regulators, removing and installing

1. Door trim removed. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

1. Unthread bolts - 2 - and remove manual window regulator from inner door plate.
2. When installing, tighten bolts to 3.5 Nm.

Rear door, adjusting

Adjustment in longitudinal direction

1. Adjustment in longitudinal direction is performed by loosening hinge bolts - arrow A - of B-pillar at top of door hinge or/and bottom and sliding doors - 2 - (over-sized holes in hinge or in B-pillar).
2. Tightening torque: 32 Nm
3. Door hinge - 1 -.
4. A-pillar - 3 -.

1. Door - 2 -.

Note. Illustration shows lower door hinge.

Adjustment to center of vehicle

Note. A fitting bolt is installed at each upper and lower door hinge (door side). When repairing, an adjustment is therefore not necessary under normal circumstances. If an adjustment should become necessary anyway, fitting bolts can be replaced with bolts of the same size, length and toughness .

1. The adjustment to vehicle center occurs by loosening hinge bolts (arrow -B-) at top and/or at bottom of door and shifting the doors (elongated holes in hinge).
2. Tightening torque: 32 Nm

Note. In rear portion of door, adjust door depth (relative to vehicle center) via striker.

Adjusting via striker

1. Loosen bolts - 2 -.
2. Use the markings (- arrows a - and - arrows c -) for side adjustment.
3. Slide striker - 1 - until the door is flush with the contour of the chassis.

Note. Door may only be adjusted for depth (towards car interior) and not for height.

1. Use the markings (- arrows b - and - arrows d -) for height adjustment.
2. Striker must align in door lock center for correct adjustment.
3. Tighten bolts to 25 Nm.

Scheme 108

1 - Window frame

1. For correct door adjustment, sealing lip must make clean contact to contours at roof frame and at A-pillar, see - arrows -.

2 - Window

1. Adjust door until the result is dimension - c - = 4 mm in area - b - = 300 mm.
2. Dimension - c - can be tested further using a gauge.
3. Dimension - a - of front door edge starting at B-pillar = 200 mm.

3 - Window frame

1. Door window - 2 - must drive as far as dimension - d - = 7.5mm -1mm into window frame at B-pillar.

Adjusting using Door adjustment template T40038/1

Special tools, testers and auxiliary items required

1. Template T40038

1. Use the door adjustment Template T40038 as described in the following for testing (e.g. for wind noises) and for adjusting door.

Testing sealing lip/roof trim molding contact

1. Using a standard bank card, drive off contact area of sealing lip to roof trim molding with light pressure.
2. When doing this, card must not sink in between sealing lip - 1 - and roof trim molding - 2 -.

1. Template has points of different lengths at - arrows a - and - arrows b - so that side adjustment of door can be tested.
2. The upper point - arrow a - on the side with the cut-out - arrow c - at bottom is the longer side (max. marking).
3. This side is used to check whether the window frame is located too far outward in relation to the chassis.

1. Position template at dimension - a - = 200 mm and with cut-out - arrow - facing door window
2. Make sure that points - 1 - and - 3 - make contact.
3. At point - 2 - of template, there must be a gap.
4. In this position (max), doors are adjusted to farthest outward point within tolerance range.

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

1. The upper point - arrow b - opposite the side with cut-out - arrow c - at bottom is the shorter side (min. marking).
2. This side is used to check whether the window frame is located too far inward in relation to the chassis.
3. Position template at dimension - a - = 200 mm and with cut-out - arrow - turned away from door window as depicted in magnified areas of illustration.

1. Make sure that points - 2 - and - 3 - make contact on door window.
2. At point - 1 - of template, there must be a gap.
3. In this position (min), doors are adjusted to farthest inward point within tolerance range.
4. If point - 1 - has no gap, or if template cannot be brought into contact at point - 2 - , window frame is set too far inward and must be adjusted.

Special tools, testers and auxiliary items required

1. Adjusting gauge 3371

1. Dimension - E - = 3.5 mm ± 0.5 mm
2. Dimension - F - = 4.5 mm ± 0.5 mm
3. Flush adjustment of rear door to front door must be in the range of 0 mm to 1 mm recess
4. Flush adjustment of rear door to side panel must be in the range of 0 mm to 1 mm projection

Scheme 109

1 - Mount for door handle

1. Releasing «Disengage mount for door handle»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

2 - Door handle

1. Before disassembling, remove window frame and window regulator.
2. Removal --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

3 - Operating rod

1. Clip into door lock «Engaging operating rod in door lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

4 - Clip

1. Engage operating rod in clip, swivel clip 90° and engage at operating rod.

5 - Socket-head bolt

1. 20 Nm

6 - Door lock

1. Removing
2. Door trim removed.
3. Window frame and window regulator removed --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
4. To remove, unscrew multi-point bolts - 5 - and remove door lock downward.

Scheme 110

1. When installing a new door lock, clip operating rod - 1 - into casing - 2 -.
2. Move slide - 3 - of casing - 2 - upward to engage operating rod.
3. Pull securing pin - 4 - out of door lock.

Door handle, removing

1 - Door handle

2 - Clip

1. When disassembling door handle - 1 - , unclip operating rod - 3 - here.

3 - Operating rod

1. Before removing door handle, disengage at clip - 2 -.
2. After installing a new door lock, first insert operating rod into casing and engage.
3. Only then pull securing pin - 5 - from door lock.

4 - Casing

1. To engage operating rod - 3 - , slide casing - 4 - upward.

5 - Securing pin

1. Only available as replacement part.
2. Pull out after installing operating rod - 3 -.

6 - Door lock

1. Removal --> «Door handle and door lock - rear, assembly overview»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Disengage mount for door handle

1. Door trim as well as window frame and window regulator removed.
2. Insert screwdriver through door plate and release slider - 2 - from door handle - 1 - in direction of arrow.

Removing trim

1. To remove, pull up door handle - 1 - , slide out locking mechanism - 3 - in longitudinal direction using small screwdriver.
2. Disengage trim - 2 - at top on the sides and remove downward from door handle.
3. Installation is the reverse order of removal.

Scheme 111

1 - Rear doors

2 - Grommet

3 - Base plate

4 - Door lock

1. Door trim removed.
2. Window frame and window regulator removed.
3. Disconnect electrical harness connector at door lock.
4. If the same door lock is installed again, disengage operating rod at door handle.

1. If door lock is being replaced, disengage operating rod at door lock «Engaging operating rod in door lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Unscrew multi-point bolts - 6 - and remove door lock.

5 - Bowden cable for interior door mechanism

1. Installing «Engaging Bowden cable in door lock»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

6 - Socket head bolt M8

1. 20 Nm

Scheme 112

1. To install, first insert Bowden cable - 2 - vertically into release lever - 3 - as shown in the magnified area of illustration, then swivel 90° and clip into door lock - 1 - to secure.

Engaging operating rod in door lock

1. When installing a new door lock, clip operating rod - 1 - into casing.
2. Move slide - 2 - of casing upward to engage operating rod.
3. Pull securing pin - 3 - out of door lock.

Scheme 113

1 - Combination bolt (T 25)

1. 3Nm

2 - Sunroof motor

1. The sunroof motor casing must be removed at molded headliner before removing motor --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

3 - Frame

1. Detach headliner before removing
2. Removing and installing is described in --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

4 - Wind deflector

1. Removal --> «Wind deflector, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__wind-deflector-removing-and-installing)

5 - Extension spring for wind deflector

Wind deflector, removing and installing

Removing

1. Slide sunroof completely open

Scheme 114

1. Press wind deflector - 2 - out of bracket - 3 - in - direction of arrow -.
2. Lift wind deflector towards rear and out of sunroof opening.

Installation

Scheme 115

1. Lay spring - 3 - around retaining pins on wind deflector - 2 -.
2. Also place spring in groove on wind deflector.

Note. Bracket - 1 - is shown in detached condition for the sake of diagram clarity.

1. Slide in stop - 1 - of wind deflector - 2 - toward front under roof cut-out.
2. Insert a wind deflector retaining pin into bracket - 3 -.
3. Push opposite side of wind deflector slightly towards center of vehicle to snap second retaining pin into bracket.

Scheme 116

1 - Sliding headliner

1. Only for vehicles with glass panel
2. For vehicles with solar panel, slide into sunroof toward rear
3. Detach headliner before removing
4. Removal --> «Sunroof headliner, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__sunroof-headliner-removing-and-installing) .

2 - Spring for sliding headliner

1. Detach cover frame for molded headliner before removal. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. To remove, remove countersunk screw - 7 - at front and rear.
3. Push front spring - 2 - forward and rear spring rearward, remove both from sliding headliner.
4. Pull sliding headliner on opposite guide track out of side and lift out.

3 - Lower trim

1. Removal --> «Trim, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__trim-removing-and-installing) .

4 - Upper trim

1. Removal --> «Trim, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__trim-removing-and-installing) .

Note. For vehicles as of calendar week 27/2002, a boot is installed in place of upper/lower panel. Removal and installation is described on --> Boot, removing and installing (vehicles as of CW 27/2002 >) .

5 - Sunroof panel

1. To remove, detach headliner
2. Remove left and right panels --> «Trim, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__trim-removing-and-installing) .
3. Remove Torx bolts (T 25) left and right at sunroof panel and lift out panel --> «Sunroof panel, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__sunroof-panel-removing) .
4. Adjusting --> «Sunroof panel, adjusting»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

6 - Panel seal

1. Removal --> «Panel seal, replacing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__panel-seal-replacing) .

7 - Countersunk screw

1. 1.5Nm.

Sunroof headliner, removing and installing

1. Sunroof panel removed

Scheme 117

1. Remove bolt of spring clip - 1 -.
2. In vehicles with solar sunroof, unscrew bolt and remove guide.

Scheme 118

1. Slide headliner back slightly and remove spring clip - 1 - toward front.
2. Slide out rear spring clip toward rear.
3. Remove headliner upward.

Trim, removing and installing

Removing

1. Tilt sunroof open
2. Push sliding headliner fully back

Scheme 119

1. Unclip lower panel -1- at rear in direction of arrow - A - from locking mechanism and slide toward front - arrow B -.
2. Remove lower trim from guide track by pulling towards center of vehicle.
3. Unclip front and center of trim - 2 - and remove in direction of arrow.

Installing

Scheme 120

1. Press on lower panel - 1 - onto upper edge - arrows - of retaining rail - 2 -.

Scheme 121

1. Slide lower panel - 1 - toward rear in - direction of arrow - far enough until hook catches in coupling plate - 2 -.
2. Press in upper trim in link guide.

Boot, removing and installing (vehicles as of CW 27/2002 >)

Removing

1. Tilt sunroof open
2. Slide sunroof headliner completely toward rear.

Scheme 122

1. Pull off boot starting at top from glass sunroof panel and from frame - arrows -.

Installing

Installation is the reverse of removal, noting the following

1. Press on lower panel - 1 - onto upper edge - arrows - of retaining rail - 2 -.
2. Press on lower panel - 1 - onto upper edge - arrows - of retaining rail - 2 -.

Note. Make sure especially that boot is seated correctly in rear mounts on glass sunroof panel.

Sunroof panel, removing

1. Trims removed

Scheme 123

1. Remove Torx bolts (T 25) - arrows - on both sides and lift panel upward and out.
2. When installing, tightening torque 4.5) 0.5 Nm.

Scheme 124

1. Perform height adjustment at front and rear according to illustration to prevent wind noise.
2. Check height adjustment at each point, left and right, where rounded portion of roof cut-out merges with straight portion.
3. Sunroof panel should not be higher than roof at any point at front or lower than roof at any point at rear.
4. When adjusting sunroof panel height, start by running sunroof from open position (not tilted open) into closed position.

Panel seal, replacing

1. Sunroof panel - 3 - removed.
2. Remove panel seal - 2 - from sunroof panel - 3 -.

Scheme 125

1. Push new panel seal into sunroof panel - 3 - starting at rear of panel edge in center.

Note. Coat edge of panel with soapy water to facilitate installation of seal.

"Zero" position (link guide), adjusting

1. Motor is removed, electrical harness connections connected.
2. Move rotary control to "roof closed" position.
3. Sunroof motor runs to "zero" position and cuts out automatically
4. Install motor in this position with sunroof closed

"Zero" position of sunroof motor (link guide), checking and adjusting

Checking

Zero position can only be checked when sunroof panel is installed.

1. Trims removed
2. Slide sunroof back and into closed position.
3. On vehicles with glass panel, slide sliding headliner completely toward rear.
4. In vehicles with solar panel, drive back sunroof panel.

Scheme 126

1. Pull sunroof headliner slightly toward rear in - direction of arrow - and slide in headliner toward rear.
2. Close sunroof.

Scheme 127

1. For a correct "zero" position, guide pins - 1 - in center on tilting mechanism must align with marking - arrow - on link guide - 2 -.
2. In vehicles with solar panel, slide headliner with panel closed from rear toward front until it engages.

Scheme 128

1. When doing this, coupling plate must be slid into guide on sunroof headliner at rear.
2. When sunroof is tilted open, headliner is also tilted open.

Cleaning water drain hoses

Note. For cleaning, it is recommended that you create your own assisting tool out of a speedometer inner cable, approx. 2300 mm (90.5 in.) long.

Scheme 129

1 - Front water drain hose

1. Front water drain hoses - 1 - are routed in A-pillar and end between door and A-pillar. Cleaning is performed at cut out for sunroof.

2 - Rear water drain hose

1. Rear water drain hoses - 2 - are routed in C-pillars and end at sides behind bumper cover. Cleaning is performed from lower hose end. To do this, bumper cover must be removed --> «Bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__bumper-removing-and-installing) .

Front bumper, removing and installing

Special tools, testers and auxiliary items required

Scheme 130

1. Socket 40078
2. Use socket 40078 to screw in cap nuts on fender bolts.

Up to Vehicle Identification Number (VIN) 400 000

Scheme 131

1 - Socket head bolt

1. 26 Nm

2 - Air intake grille

1. S4, removing «Air intake grille for S4»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

3 - Clamping pin

1. To disassemble, rotate 180°.

4 - Side impact molding

1. Replace
2. Side impact moldings are secured to bumper with double-sided adhesive tape.
3. It is not possible to remove without destroying.
4. To remove, pull side impact molding away from bumper.

1. Remove any residual adhesive on bumper.
2. Installation on same bumper
3. Bumper must be free of dust and grease in adhesion area
4. Clean bumper using petroleum spirits or cleaning solution D 009 401 04.

Note. Centering holes for centering pins for the exact installation of side impact moldings are already present in bumper Position centering pins with double-sided adhesive tape onto markings of side impact molding Adhering centering pins on side impact molding . Remove protective foil from double-sided adhesive tape for side impact molding. Press side impact molding with attached centering pins firmly onto bumper over the entire surface. Installing on new bumper

Note. Centering holes for side impact molding must be drilled on the new bumper before painting. Position centering holes for side impact moldings on bumper --> Centering holes for side impact moldings . Apply side impact moldings to bumper as described above.

5 - Bumper

1. With crossmember
2. Bumper, removing and installing --> «Front bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
3. Removing and installing crossmember --> «Crossmember, removing from cover and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__crossmember-removing-from-cover-and-installing)
4. Separating two-piece bumper cover --> «Two-piece bumper cover, separating»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__two-piece-bumper-cover-separating)

1. Positioning license plate mounting holes «Positioning license plate mounting holes»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

6 - Guide piece

1. Removing and installing --> «Guide piece, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__guide-piece-removing-and-installing)

7 - Expanding clip

1. 6x
2. Must be inserted into fender before installing bumper cover

8 - Grommet

1. 2x
2. Must be inserted into fender before installing bumper cover

9 - Shock absorber

1. self-aligns to correct height in crossmember --> «Bumper, mounting to shock absorber»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__bumper-mounting-to-shock-absorber)

10 - Fender

11 - Special nut

1. 4 Nm

12 - Wheelhousing liner

13 - Bolt

1. 1 Nm
2. 2x

As of Vehicle Identification Number (VIN) 400 001

Scheme 132

1 - Combination bolt

1. 6 Nm

2 - Socket head bolt

1. 23 Nm

3 - Bumper

1. Bumper cover removed.
2. To remove, unscrew socket head bolts - 2 -.
3. Disconnect harness connectors to signal horns and remove bumper from shock absorbers toward front.

4 - Pop rivet

5 - Signal horn

1. To remove, drill off rivet heads.

6 - Support piece

1. Before assembling bumper cover, adjustment screw for support piece must be adjusted «Adjusting support piece»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
2. To disassemble, drill off pop rivet heads.

7 - Pop rivet

8 - Signal horn

9 - Brace for fender

10 - Guide piece

1. Side piece of bumper cover must be clipped in between fender and guide piece «Removing guide piece»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

11 - Torx screw

1. 1 Nm

12 - Bumper cover

Note. While installing, the following sequence described for assembling/bolting must be observed for correct assembly.

1. Set cover onto vehicle and first clip the left and right side piece into guide parts - 10 -.
2. Tighten cap nuts on fender bolts to 4 Nm «Fender bolts»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Tighten bolts - 12 - to wheelhousing liner.
4. Loosely thread in bolts - 1 -.

1. Close hood and check cover for projection and recess.
2. If necessary, correct the cover position and tighten bolts - 12 - to 6 Nm.
3. Tighten bolt on support piece to 2 Nm.
4. Bumper, removing and installing --> «Front bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

1. Removing and installing crossmember --> «Crossmember, removing from cover and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__crossmember-removing-from-cover-and-installing)

Scheme 133

1. Make sure when installing that the clips - 2 - are inserted onto threaded pins.
2. Tighten cap nuts - 4 - to 4 Nm after inserting bumper cover - 1 - into fender - 3 -.

Scheme 134

1. Before installing bumper cover - 1 - , adjust adjustment screw - 3 - for support piece - 5 - to dimension - a - = 21 mm +1 mm.
2. Mounting bracket - 4 - must be screwed on completely (left-hand thread) for this.
3. Adjustment screw - 3 - and mounting bracket - 4 - belong to delivery casing for support piece - 5 - , there are no replacement parts.
4. While screwing in bolt - 3 - , mounting bracket - 4 - screws out and holds the carrier part - 2 - of bumper cover - 1 - in the designated position.

1. Support piece - 5 - is secured to bumper - 6 - with pop rivets.

Scheme 135

1. When removing bumper cover - 1 - , rotate clamping pins - 2 - 180° and pull out of speed nuts - 4 - of noise insulation - 3 -.

Scheme 136

1. Bumper cover removed
2. Unscrew bolts - 3 - and pull guide piece - 2 - downward out of fender - 1 -.
3. When installing, cover - 4 - for bumper must engage cleanly in guide piece.

Scheme 137

1. For mounting front wheelhousing liner - 3 -.
2. When installing brace - 1 - , tighten bolt - 2 - to 10 Nm.

Scheme 138

1. Remove phillips head bolt - arrow -.
2. Press air intake grille - 2 - on the inside of bumper cover - 2 - as shown toward rear out of locking mechanism.
3. Remove air intake grille toward front out of bumper cover.

Radiator grill, removing and installing

Assembly overview

Scheme 139

1 - Bumper cover

2 - Radiator grille

1. Bumper cover removed

3 - Trim for radiator grille

4 - License plate holder

1. To disassemble from rear side, unclip from radiator grille

Scheme 140

Removing radiator grille

1. Bumper cover removed
2. Unscrew bolts - arrows - around edge and pull radiator grille from bumper cover.
3. When installing, tighten bolts to 1.5 Nm.

Scheme 141

Removing panel for fog lights

1. Disengage locking mechanisms - arrows - and pull off panel toward vehicle interior.

Scheme 142

Fog lights removed.

1. Disengage locking mechanisms - arrows - and pull off panel toward outside.

Scheme 143

Covers are divided into two parts.

Disengage locking mechanisms - arrows - and pull off cover toward outside.

Centering holes for side impact moldings

Up to Vehicle Identification Number (VIN) 400 000

Scheme 144

1 - Front bumper

1. Position hole to vehicle outside - arrow B - according to marking on bumper.

Note. If there is no marking in this position, the long hole (as depicted in illustration) must be manufactured at upper/outer edge, according to the lines on bumper Positioning centering holes . Position hole to vehicle center - arrow A - according to marking on bumper.

Scheme 145

1. Position of long holes is indicated by markings on bumper.
2. Long hole must be aligned to dimensions - a - = 8.5 mm and b = 15.5 mm as shown
3. If there is no marking in this area, the long hole must be aligned according to the indicated lines on bumper as shown, with upper edge to horizontal line and with outer edge to vertical line.
4. Dimension - a - = 8.5 mm.

1. Dimension - b - = 15.5 mm.

Scheme 146

Note. Adhesive and centering pin are in delivery casing of side impact molding.

1. Remove protective foil from the double-sided adhesive - 3 - and adhere it onto centering pin - 4 -.
2. Remove second protective foil and position centering pin onto marking - arrow - on side impact molding.
3. Remove protective foils from double-sided adhesive strips - 2 - and press side impact molding - 1 - onto bumper.

Scheme 147

There are four centering punch marks on license plate area of bumper cover which must be drilled through for securing a license plate (dimensions 115 x 520 mm).

If centering punch marks are not visible, proceed as follows

1. Determine vertical bisecting line from Audi emblem to center of grill on bumper.
2. Determine horizontal bisecting line

1. Dimension - a - = dimension - a

1. Determine mounting points for license plate symmetrically as follows

1. Dimension - x - = 139 mm
2. Dimension - y - = 62 mm

Removing

1. To ease repair work, remove front noise insulation completely.

Scheme 148

1. For this purpose, remove bolts and quick release screws - 1 - and - 2 -. Rear noise insulation (quick release screws - 3 -) remains installed.
2. Remove left and right front wheels.

Scheme 149

1. Loosen left and right wheelhousing liners in front area - arrows -.

Scheme 150

1. Pull back wheelhousing liner - arrow A -.
2. Remove bolt - 2 - and nuts - 1 -.
3. Unclip bumper rear edge from catch - arrow B -.
4. Repeat procedure on opposite side of the vehicle.

Scheme 151

1. Release catches - 1 - to - 4 - using a screwdriver - arrow - and remove air intake grille on left and right on bottom part of bumper.

Scheme 152

1. Unthread left and right retaining bolts for bumper approx. 15 rotations - arrow -.
2. Pull lock carrier slightly toward front.

Scheme 153

1. If installed, disconnect hose - 1 - to headlight cleaning system and reserve washer fluid in a clean container for re-use.
2. Disconnect harness connector(s) - 2 - to bumper.

Installing

Installation is the reverse of removal, noting the following

Note. Before installing bumper, check for the presence of threaded pins at bumper rear edge as well as expanding clips and sleeves in the fenders.

1. Slide bumper onto shock absorber and re-connect hose - 1 - of headlight cleaning system and electrical harness connectors - 2 -.
2. Move bumper into installation position. Make sure that the threaded pins in bumper side edges engage into holes at the fenders.

Scheme 154

1. Pull back wheelhousing liner - arrow A -.
2. Engage bumper rear edge into catch - arrow B -.
3. Tighten nuts - 1 - to 4 Nm and bolt - 2 - to 1 Nm.
4. Repeat procedure on opposite side of the vehicle.

1. Tighten left and right retaining bolts for bumper to 23 Nm - arrow -.
2. Install left and right air intake grille on bumper.

Rest of installation is performed in the reverse order of removal.

Bumper, mounting to shock absorber

Up to Vehicle Identification Number (VIN) 400 000

Note. Shock absorber is self-adjusting, meaning it can compensate bearing tolerances in height between bumper and shock absorber when screwing in the socket head bolt. This holds and secures the front bumper automatically in the previously adjusted position when screwing in the socket head bolt - 1 -. In vehicles as of Vehicle Identification Number (VIN) 400 001, the self-adjusting height compensation has been discontinued.

Scheme 155

1 - Socket head bolt

1. 23 Nm

2 - Lower carrier bushing

1. Plastic part pressed into adjusting screw.
2. No replacement part available

3 - Lower adjusting screw

1. Before assembling bumper, screw in completely but do not tighten.
2. Left-hand thread
3. No replacement part available

4 - Lower threaded bushing

1. Secured against falling out with securing pin.
2. No replacement part available

5 - Securing pin

1. No replacement part available

6 - Shock absorber

1. Removing and installing --> «Shock absorber, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__shock-absorber-removing-and-installing) .

7 - Upper threaded bushing

1. Secured against falling out with securing pin.
2. No replacement part available

8 - Upper adjusting screw

1. Screw in completely before assembling bumper.
2. Right-hand thread
3. No replacement part available

9 - Cover

1. Removing and installing --> «Front bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__front-bumper-removing-and-installing) .

10 - Nut

1. Belongs to crossmember delivery casing.

11 - Upper carrier bushing

1. Plastic part pressed into adjusting screw.
2. No replacement part available

12 - Cross member

1. Removing from cover and installing --> «Crossmember, removing from cover and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__crossmember-removing-from-cover-and-installing)

Guide piece, removing and installing

Up to Vehicle Identification Number (VIN) 400 000

Scheme 156

1 - Guide piece

1. Bumper removed.
2. To remove, remove bolts - 2 -.

2 - Bolt

1. 1.5 Nm

3 - Clip

4 - Cover

1. Removal --> «Front bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__front-bumper-removing-and-installing)
2. When installing, cover must engage cleanly in guide piece - 1 -.

5 - Special nut

1. 4 Nm
2. Only accessible after loosening front half of wheelhousing liner.

Crossmember, removing from cover and installing

1. Bumper removed.
2. Remove signal horn - 4 -.

Scheme 157

1. Disconnect hose - 5 - of headlamp cleaning system on both sides (press release buttons).
2. Unscrew bolts - 3 - of right spray jet for headlamp cleaning system - spray jet remains installed.
3. Remove bolts - 1 - (qty. 5).
4. Pry off retaining clips - 2 - (qty. 3).

1. Swivel spray jet for headlamp cleaning system to the side and remove crossmember from bumper cover.

Two-piece bumper cover, separating

1. Bumper removed.

Scheme 158

1. Unscrew bolt - 2 - on both sides.
2. Release catches for center part of air intake grille and remove it.
3. Release catches - arrows - and remove lower part - 1 - of bumper cover.

Shock absorber, removing and installing

1. Bumper removed.

Scheme 159

1. Remove combination bolts - 2 -.
2. Unscrew nut - 3 - and pull shock absorber - 1 - from longmember.
3. When installing, tighten combination bolts - 2 - to 50 Nm and hex nut - 3 - to 4 Nm.

Bumper, removing and installing

Up to Vehicle Identification Number (VIN) 400 000

Scheme 160

1 - Combination bolt

1. 18 Nm

2 - Bumper

1. Bumper cover removed.

Remove combination bolts - 1 - and pull out bumper toward rear.

3 - Cover

1. Two-piece version
2. One-piece version (for USA)
3. Removing
4. Remove side luggage compartment trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

1. Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
2. Remove cap nuts - 9 - and - 10 -.
3. Remove combination bolts - 4 -.
4. Unscrew wheel housing liners - 8 - in rear area.

1. Remove bolts left and right on guide piece - 6
2. Unscrew bolts - 7 - from wheelhousing liner
3. Unclip cover side-pieces on guide piece.
4. Remove cover.

1. Separating two-piece cover
2. Drill off rivet heads from pop rivets at left and right.
3. Disengage locking tabs and pull spoiler out of cover.

4 - Combination bolts

1. 4 Nm

5 - Grommet

1. Grommets must be pressed in before assembling cover.

6 - Guide piece

1. Removing and installing --> «Guide piece, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

7 - Sheet-metal screw

1. 2 Nm

8 - Wheelhousing liner

9 - Cap nut

1. 4 Nm

10 - Cap nuts

1. 4 Nm

As of Vehicle Identification Number (VIN) 400 001

Scheme 161

1 - Cover

1. Removing

1. Remove side luggage compartment trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
3. Remove special nuts - (accessible from luggage compartment).
4. Remove special nuts - «Cap nuts»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) - (accessible from luggage compartment).

1. Unscrew wheel housing liners in rear area.
2. Remove bolts left and right on guide piece - 3
3. Unclip cover side-pieces on guide piece.
4. Remove cover.

1. Separating two-piece cover
2. Drill off rivet heads from pop rivets at left and right.
3. Disengage locking tabs and separate both pieces of cover.

2 - Grommet

1. Grommets must be installed before assembling cover.

3 - Guide piece

4 - Combination bolts

1. 1.5 Nm

5 - Expanding rivet

1. Pressed into side panel at bottom

6 - Combination bolt

1. 18 Nm

7 - Base plate

1. Must always be installed.

8 - Combination bolt

1. 18 Nm

9 - Right holder for bumper

1. Bumper removed
2. Remove combination bolt - 8 - and pull shock absorber out of bumper.

10 - Hex nut

1. 18 Nm
2. Counterhold when tightening combination bolt - 8 -.

11 - Bracket

1. Riveted to bumper.

12 - Pop rivet

13 - Left holder for bumper

1. Bumper removed
2. Remove combination bolt - 8 - and pull shock absorber out of bumper.

14 - Bumper

1. Cover - 1 - removed.
2. Remove combination bolts - 6 - and pull bumper toward rear out of longmembers.

Country version

Scheme 162

1 - Cover

1. Removing

1. Remove side luggage compartment trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
3. Remove special nuts - (accessible from luggage compartment).
4. Remove special nuts - «Cap nuts»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) - (accessible from luggage compartment).

1. Unscrew wheel housing liners in rear area.
2. Remove bolts left and right on guide piece - 3
3. Unclip cover side-pieces on guide piece.
4. Remove cover.

1. Separating two-piece cover
2. Drill off rivet heads from pop rivets at left and right.
3. Disengage locking tabs and separate both pieces of cover.

2 - Special nut

1. 4 Nm

3 - Guide piece

4 - Combination bolts

1. 1.5 Nm

5 - Expanding rivet

1. Pressed into side panel at bottom

6 - Combination bolt

1. 18 Nm

7 - Base plate

1. Must always be installed.

8 - Combination bolt

1. 30 Nm

9 - Right shock absorber

1. Bumper removed
2. Remove combination bolt - 8 - and pull shock absorber out of bumper.

10 - Hex nut

1. 30 Nm
2. Counterhold when tightening combination bolt - 8 -.

11 - Bracket

1. Riveted to bumper.

12 - Pop rivet

13 - Left shock absorber

1. Remove combination bolt - 8 - and pull shock absorber out of bumper.

14 - Bumper

1. Cover - 1 - removed.
2. Remove combination bolts - 6 - and pull bumper toward rear out of longmembers.

Scheme 163

1. Remove cap nuts - 1 - and - 2 - for bumper cover disassembly.
2. Cap nut - 2 - only installed in Avant models.
3. When installing, tighten cap nuts to 4 Nm.

Side impact moldings, replacing

Assembly overview

Scheme 164

1 - Bolt

1. 1 Nm

2 - Wheelhousing liner

3 - Cap nut

1. 4 Nm

4 - Cap nut

1. 4 Nm

5 - Guide piece

6 - Grommet

1. Must be pressed in before assembling cover - 9 -.

7 - Trim molding

8 - Bolt

1. 2 Nm

9 - Cover

1. Removal «Bumper, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__bumper-removing-and-installing)

10 - Side impact molding

1. Replace
2. Side impact moldings are secured to bumper with double-sided adhesive tape.
3. It is not possible to remove without destroying.
4. To remove, pull side impact molding away from bumper.

1. Remove any residual adhesive on bumper.
2. Installation on same bumper
3. Bumper must be free of dust and grease in adhesion area
4. Clean bumper using petroleum spirits or cleaning solution D 009 401 04.

1. Position centering pins with double-sided adhesive tape onto markings of side impact molding «Adhering centering pins on side impact molding»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove protective foil from double-sided adhesive tape for side impact molding.
3. Press side impact molding with attached centering pins firmly onto bumper over the entire surface.

Note. Centering holes for side impact molding must be drilled on a new bumper before painting.

Scheme 165

1 - Rear bumper

1. Markings for centering holes are positioned on the inside of the cover - arrows - as shown.
2. Drill through cover at these locations (3x) using a drill bit 8.5mm before painting.

Adhering centering pins on side impact molding

Note. Adhesive - 3 - and centering pin - 4 - (3x each) are in delivery casing of side impact molding - 1 -.

1. Remove protective foil from the double-sided adhesive - 3 - and adhere it onto centering pin - 4 -.
2. Remove second protective foil and position centering pin onto marking - arrow - on side impact molding.
3. Remove protective foils from double-sided adhesive strips - 2 - and press side impact molding - 1 - onto bumper.

Up to Vehicle Identification Number (VIN) 400 000

Scheme 166

1 - Bolt

1. 1 Nm

2 - Wheelhousing liner

3 - Combination nut

1. 4 Nm

4 - Cap nut

1. 4 Nm

5 - Guide piece

1. Removing and installing --> «Guide piece, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

6 - Grommet

1. Grommets must be pressed in before assembling cover.

7 - Supporting strip

8 - Sheet-metal screw

1. 2 Nm

9 - Sealing strip

1. Clipped in cover - 12

10 - Trim molding

1. Clipped in cover - 12

11 - Side sealing strip

1. Clipped in cover - 12

12 - Cover

1. Two-piece version
2. One-piece version (for USA)
3. Removing
4. Remove side luggage compartment trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

1. Remove bass loudspeaker. --> «91 - COMMUNICATION»(/audi/a4/b7-2004-2009/remont/accessories-control-systems/#communication) «91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER»(/audi/a4/b7-2004-2009/remont/accessories-control-systems/#communication-cabriolet) for COMMUNICATION, CABRIOLET
2. Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
3. Remove combination nuts - 3 - and special nuts - 4 - (accessible from luggage compartment).
4. Unscrew bolts - 13 -.

1. Unscrew wheel housing liners - 2 - in rear area.
2. Remove bolts - 1 - at left and right on guide piece - 6
3. Unclip cover side-pieces on guide piece.
4. Remove cover.

1. Separating two-piece cover
2. Drill off rivet heads from pop rivets at left and right.
3. Disengage locking tabs and separate both pieces of cover.
4. Installing

1. Install in reverse order of removal.
2. When installing a new bumper cover, insert a new support piece - 14 - into cover.
3. Disengage support piece only when bumper cover is completely installed «Disengaging support piece»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

13 - Bolt

14 - Support piece

1. Replace when installing a new bumper cover
2. Disengage only when bumper cover is completely installed «Disengaging support piece»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

15 - Side impact molding

1. Replace
2. Side impact moldings are secured to bumper with double-sided adhesive tape.
3. It is not possible to remove without destroying.
4. To remove, pull side impact molding away from bumper.

1. Remove any residual adhesive on bumper.
2. Installing on new bumper

Note. Centering holes for side impact molding must be drilled on a new bumper before painting. Position centering holes for side impact moldings on bumper --> Centering holes for side impact moldings .

As of Vehicle Identification Number (VIN) 400 001

Scheme 167

1 - Cover

1. Removing

1. Remove side luggage compartment trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
3. Remove special nuts - (accessible from luggage compartment).
4. Remove special nuts - «Cap nuts»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) - (accessible from luggage compartment).

1. Unscrew wheel housing liners in rear area.
2. Remove bolts left and right on guide piece - 3
3. Unclip cover side-pieces on guide piece.
4. Remove cover.

1. Separating two-piece cover
2. Disengage locking tabs and separate both pieces of cover.

2 - Guide piece

3 - Combination bolts

4 - Expanding rivet

1. Pressed into side panel at bottom

5 - Cap nut

1. 4 Nm

6 - Base plate

1. Must always be installed.

7 - Combination bolt

1. 18 Nm

8 - Base plate

1. Must always be installed.

9 - Expanding clip

1. Qty. 5 inserted in rear cross panel.

10 - Supporting strip

11 - Sheet-metal screw

1. 2.5 Nm

12 - Combination bolt

1. 18 Nm

13 - Right holder for bumper

1. Bumper removed
2. Remove combination bolt - 12 - and pull shock absorber out of bumper.

14 - Hex nut

1. 18 Nm
2. Counterhold when tightening combination bolt - 8 -.

15 - Bracket

1. Riveted to bumper.

16 - Pop rivet

17 - Left holder for bumper

1. Remove combination bolt - 8 - and pull shock absorber out of bumper.

18 - Bumper

1. Cover - 1 - removed.
2. Remove combination bolts - 6 - at left and right and pull out bumper toward rear.

19 - Support piece

1. Replace when installing a new bumper cover
2. Disengage only when bumper cover is completely installed «Disengaging support piece»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

Country version

Scheme 168

1 - Cover

1. Removing

1. Remove side luggage compartment trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side).
3. Remove special nuts - (accessible from luggage compartment).
4. Remove special nuts - «Cap nuts»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) - (accessible from luggage compartment).

1. Unscrew wheel housing liners in rear area.
2. Remove bolts left and right on guide piece - 3
3. Unclip cover side-pieces on guide piece.
4. Remove cover.

1. Separating two-piece cover
2. Disengage locking tabs and separate both pieces of cover.

2 - Guide piece

3 - Combination bolts

4 - Expanding rivet

1. Pressed into side panel at bottom

5 - Cap nut

1. 4 Nm

6 - Base plate

1. Must always be installed.

7 - Combination bolt

1. 18 Nm

8 - Base plate

1. Must always be installed.

9 - Expanding clip

1. Qty. 5 inserted in rear cross panel.

10 - Supporting strip

11 - Sheet-metal screw

1. 2.5 Nm

12 - Combination bolt

1. 30 Nm

13 - Right shock absorber for bumper

1. Bumper removed
2. Remove combination bolt - 12 - and pull shock absorber out of bumper.

14 - Hex nut

1. 30 Nm
2. Counterhold when tightening combination bolt - 8 -.

15 - Bracket

1. Riveted to bumper.

16 - Pop rivet

17 - Left shock absorber for bumper

1. Remove combination bolt - 8 - and pull shock absorber out of bumper.

18 - Bumper

1. Cover - 1 - removed.
2. Remove combination bolts - 6 - at left and right and pull out bumper toward rear.

19 - Support piece

1. Replace when installing a new bumper cover
2. Disengage only when bumper cover is completely installed «Disengaging support piece»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

Up to Vehicle Identification Number (VIN) 400 000

Note. Centering holes for side impact molding must be drilled on a new bumper before painting.

1 - Rear bumper

1. Markings for centering holes are positioned on the inside of the cover - arrows - as shown.
2. Drill through cover at these locations (3x) using a drill bit 8.5 mm before painting.

Adhering centering pins on side impact molding

Note. Adhesive - 3 - and centering pin - 4 - (3x each) are in delivery casing of side impact molding - 1 -.

1. Remove protective foil from the double-sided adhesive - 3 - and adhere it onto centering pin - 4 -.
2. Remove second protective foil and position centering pin onto marking - arrow - on side impact molding.
3. Remove protective foils from double-sided adhesive strips - 2 - and press side impact molding - 1 - onto bumper.

Scheme 169

Installing support piece

Note. Support piece must be installed only with a new bumper cover.

1. To remove, press catch - arrow - to the side and pull support piece downward out of cover - 1 -.
2. Insert support piece - 2 - into cover as shown and let engage inside.
3. Disengaging cord must be removed only when the cover is installed completely.

Scheme 170

When re-installing the old bumper cover, the old support piece remains installed.

1. When replacing the bumper cover, a new support piece must be clipped into the bumper cover from below.
2. After completely installing bumper cover, disengage support piece by pulling on disengaging cord - arrow -.

Note. By pulling disengaging cord, tension is released from support piece and reinforces the bumper cover against the crossmember.

Up to Vehicle Identification Number (VIN) 400 000

1. Bumper removed.

Scheme 171

1. Remove bolts - 1 - and remove guide piece - 2 -.
2. Tightening torque: 1.5 Nm
3. Clip - 3 - pressed into side panel.

As of Vehicle Identification Number (VIN) 400 001

Scheme 172

1. Bumper removed.
2. Remove bolts - 1 - and remove guide piece - 2 -.
3. Expanding clip - 3 - pressed into side panel.

Crossmember for bumper, removing and installing

Note. Bumper cover removed.

Scheme 173

1 - Shock absorber

2 - Bolt

1. 10 Nm
2. 4x

3 - Bolt

1. 20 Nm
2. 2x

4 - Nut

1. 20 Nm
2. 2x

5 - Cross member

USA version

Note. Bumper cover removed.

Scheme 174

1 - Shock absorber

2 - Bolt

1. 10 Nm
2. 4x

3 - Bolt

1. 20 Nm
2. 2x

4 - Nut

1. 20 Nm
2. 2x

5 - Cross member

Crossmember for bumper (vehicles with trailer hitch), removing and installing

Note. Bumper cover removed.

Scheme 175

1 - Trailer hitch carrier

2 - Bolt

1. 60 Nm
2. 4x

3 - Nut

1. 23 Nm
2. 2x

4 - Mounting clamps

1. 4x

5 - Spacer

1. 2x

6 - Bolt

1. 23 Nm
2. 2x

7 - Cross member

Scheme 176

Note. Note the various mounting points for the threaded plate. - Arrow A - as of Vehicle Identification Number (VIN) 400 001 - Arrow B - up to Vehicle Identification Number (VIN) 400 000

1. Contact surface of threaded plate must be clean and even.
2. Mount threaded plate - 1 - with pop rivets - 2 - starting from outside working toward inside.

Scheme 177

Special tools, testers and auxiliary items required

1. Suction lifter V.A.G 1344
2. Electric cutter V.A.G 1561 A
3. Universal cutting blade V.A.G 1561/11
4. Cartridge gun V.A.G 1628

1. Window removing kit V.A.G 1755
2. Cutting tools for glass V.A.G 1351
3. Cutting tool kit V.A.G 1474 B
4. Cartridge heater V.A.G 1939 A

1. Cutting cord 357 853 999

Scheme 178

1. Spooling tool V.A.G 1654 A

Scheme 179

Double cartridge gun VAS 5237

Servicing windows using special tool

Note. Windshields damaged by flying rocks can be repaired using the repair kit for windshields VAS 6092. These damaged areas must not exceed a certain dimension or lie within the drivers field of sight. For further details on use, refer to Users Manual enclosed with each kit.

Materials

* Observe minimum curing time --> Minimum curing times!

* Double cartridge pistol VAS 5237 must be used to process this material

* Heat according to manufacturers instructions using cartridge heater V.A.G 1939 A

* Small cartridge (110 ml) for sealing and/or when a 400 ml double cartridge is not sufficient.

Minimum curing times!

Cleaning when soiled by adhesive sealing material

Adhesive removal solution D 002 000 10 is the recommended cleaning solution. Observe safety precautions when processing.

Paint surfaces

1. First, clean paint surfaces with a dry cloth. Remove further material using adhesive removal solution D 002 000 10.

Plastic trim

1. Allow adhesive sealing material to harden (about 1 hour) and then peel off.

Scheme 180

1 - Windshield

1. Removing --> «Removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__removing)
2. Installing --> «Preparing for window installation»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__preparing-for-window-installation)
3. Distance to roof dimension - a - = 6 mm + 0. 5 mm
4. Align distance - d - at sides.

Note. Stickers on windshield (e.g. for airbag) must be replaced in same position on new windshield.

2 - Adhesive bead

1. Observe curing times --> «Minimum curing times!»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__minimum-curing-times)
2. Note varying spacing dimensions to window edge.
3. Distances of top and side window edge dimension - b - and dimension - d - = 4 mm
4. Distance at lower window edge measured from inner side of clip dimension - c - = 10 mm.

1. Bead cross section
2. Bead width = 8 ± 2 mm
3. Bead height = 13.5 +1.5 mm

3 - Spacers

1. 5x
2. Affix in regular intervals to retaining strip

4 - Protective piping

1. Only installed as new part.
2. Only remove after installing windshield and before installing plenum chamber cover

5 - Plenum chamber cover

1. Pull protective piping - 4 - from retaining strip before installing plenum chamber cover.
2. Press into fastening strip only after window adhesive curing time has elapsed.

Removing

Necessary tools and materials --> Flush-bonded windows, removing and installing - general information .

1. Remove wiper arms. «92 WINDSHIELD WIPER WASHER SYSTEM»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET
2. Remove cowl panel trim.
3. Pull left and right drip rails out from retaining strips (from bottom upward).
4. Remove sun visors on left, center and right. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

1. Remove interior rear-view mirror. --> «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «68 - INTERIOR EQUIPMENT»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Remove upper trim panels of A-pillars --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 181

1. Pierce hole in adhesive sealing material from inside of vehicle using awl V.A.G 1755 or awl V.A.G 1351 at bottom-left of windshield.
2. Pull cutting cord through adhesive sealing material into inside of vehicle using awl.

Scheme 182

1. Lay cutting cord underneath and all around inside of windshield.

Scheme 183

1. Secure end of cutting cord at bolt - arrow - for securing window wiper frame.
2. Insert protective foil V.A.G 1474/13 between windshield and instrument panel.

1. Secure beginning of cutting cord in winding device and cut out first area of adhesive (up to about center of windshield).

Scheme 184

1. Move spooling tool as shown in diagram and continue cutting.

Scheme 185

1. Move spooling tool as shown in diagram and attach relay pulley.

1. Route cutting cord as shown.

1. Cut adhesive up to point where cord no longer runs in relay pulley.

Scheme 186

1. Remove relay pulley and continue to cut adhesive.

Scheme 187

1. Move spooling tool as shown in diagram and attach relay pulley in upper corner of window.

1. Route cutting cord as shown.

1. Insert protective foil V.A.G 1474/11 between windshield and molded headliner.
2. Cut adhesive up to point where cord no longer runs in relay pulley.
3. Remove relay pulley and continue to cut adhesive.
4. Repeat these steps in top left and bottom left corners of windshield.

1. Cut window completely free.
2. Remove window using two double suction cups.

Preparing for window installation

Note. If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

1. When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter V.A.G 1561A and scraper V.A.G 1561/10; do not remove completely!
2. Residual material acts as a base for the new adhesive sealing material.

New window, installing

1. Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

Applying primer

Scheme 188

1. Apply primer - 2 - along circumference evenly and in one motion using applicator - 1 -.
2. Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

1. Primer dimensions: Dimension - a - = approx. 20 mm

1. Apply primer in center of adhesive bead.

Scheme 189

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

1. Bead width - a - = 8 ± 2 mm
2. Bead height - b - = 12 + 3 mm
3. Dimension - c - = note varying spacing dimensions to window edge --> «Windshield, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

Windshield, installing

1. After preparatory work has been performed, apply the adhesive.

Scheme 190

1. Position complete surface of nozzle - 2 - onto window.
2. Arrow - indicates direction of application

Note. Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

Scheme 191

1. Apply adhesive sealing material all around, as shown in illustration.
2. Note varying spacing dimensions to window edge --> «Windshield, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
3. Using two suction lifters, install windshield in windshield opening.

1. Align windshield at sides.
2. Spacing between edge of window and roof frame must be 6 mm + 0.5 mm.

Scheme 192

1. Press drip rail - 1 - into retaining clips - 2 - until it stops only after curing time has elapsed.
2. When pressing in drip rail, make sure sealing lip - arrow - lies flat against windshield and does not slip behind edge of windshield.

Scheme 193

1. Affix stickers on windshield (e.g. for airbag) in same position on new windshield. "Caution- Safety information" sticker

1. Dimension - a - = 25 mm
2. Dimension - b - = 10 mm

Scheme 194

1 - Side window

1. Removal --> «Undamaged side window, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__undamaged-side-window-removing) .
2. Note varying spacing dimensions of adhesive bead to window edge.
3. When inserting window, make sure that retaining tabs on molding at D-pillar, or at joint of D-pillar to side panel, are slide behind roof trim molding.

2 - Roof trim molding

Scheme 195

1 - Side window

1. Removal --> «Undamaged side window, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__undamaged-side-window-removing) .
2. Note varying spacing dimensions of adhesive bead to window edge.
3. When installing, set window first on side panel at bottom.
4. Press in window up to lower stop - arrow - and into window cut-out.

1. After curing time has elapsed, install roof trim molding and trim to D-pillar

2 - Roof trim molding D-pillar

1. C-pillar trim removed.
2. To remove, pry carefully out of retaining clips beginning first at bottom on C-pillar.
3. Then pry out of retaining clips at D-pillar and pull downward out of roof trim molding.

3 - C- pillar trim

1. To remove, pull trim panel out of clips - 4 - toward rear.
2. When installing, insert trim panel first at top on roof trim molding and press completely into clips - 4 -.
3. Dimension - a - = 0.5 ± 0.1 mm

4 - Retaining clips

1. Riveted to C- pillar.

Undamaged side window, removing

Side window with molding

Scheme 196

1. Apply fabric reinforced adhesive tape - 6 - to area of window edges along circumference to protect paint from damage.
2. Using awl from V.A.G 1755, pierce through adhesive bead on window glass - 1 - at top in direction of B-pillar from inside vehicle toward outside.
3. Pull cutting cord - 4 - through toward inside and secure it in grab handle - 3 -.
4. Secure the other end in pull handle - 5 -.

1. Second technician pierces adhesive bead at bottom using grab handle as shown.
2. Pull cutting cord on the outside through adhesive bead - 2 - downward.

Note. At the corners, move cutting cord in sawing motions to cut through the adhesive more easily.

Scheme 197

1. Pull cutting cord - 4 - toward inside and insert grab handle - 3 - into adhesive bead - 2 - at D-pillar at rear.
2. Pull cutting cord - 4 - toward rear through adhesive bead using pull handle.

Scheme 198

1. Pull cutting cord - 4 - toward inside and insert grab handle - 3 - into adhesive bead - 2 - at D-pillar at top.
2. Pull cutting cord - 4 - upward through adhesive bead using pull handle.
3. Remove window from cut-out.

Side window with gloss package

1. Remove C-/D-pillar trim --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET .

Scheme 199

1. Apply adhesive tape - 3 - to C-/D-pillar trim as well as side panel to protect paint from damage.
2. Pull off trim molding - 1 - from retaining clips - 2 - toward front.

Scheme 200

1. Carefully pull roof trim molding - 1 - from below, beginning at C-pillar, out of retaining clips using a plastic wedge.
2. Pry out roof trim molding at D-pillar in the same manner out of retaining clips and pull off downward.
3. Insert cutting cord around the side window as depicted in the illustration.

Scheme 201

1. Secure ends X and Y in two pull grips from special tool V.A.G 1351.
2. Pull cutting cord in - direction of arrow A - using light sawing motions and cut through lower adhesive sealing material at side panel and at roof frame.
3. Then pull cutting cord through in - direction of arrow B - downward through adhesive sealing material.
4. Remove window from window opening.

Note. If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

1. When reusing an undamaged window, cut remaining adhesive sealing material on window and flange using a carpet knife so that it is even, but do not remove completely!
2. Residual material acts as a base for the new adhesive sealing material.

1. Apply adhesive onto residual adhesive bead

1. Bead width = 8 ± 2 mm
2. Bead height = 13.5 ± 1.5 mm

Note. Adhesive sealing material DH 009 100 03 (small cartridge) is recommended when bonding a single window; D 004 300 05 (2K- adhesive) is recommended when bonding more than one window.

New window, installing

1. Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.
2. Ensure an air drying time of 10 minutes for primer.
3. Apply adhesive

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

1. Bead width - a - = 8 ± 2 mm
2. Bead height = 13.5 ± 1.5 mm
3. Dimension - c - = note varying spacing dimensions to window edge

Side window, installing

Vehicles with molded side window

1. Place window onto lower D-pillar and press into window opening.
2. Side window molding must engage behind roof trim molding --> «Side window (Sedan), removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)
3. Secure window in opening using adhesive tape.
4. Observe curing time.

Vehicles with gloss package

1. Press roof trim molding into retaining clips at D-pillar.

1. Press trim - 1 - into retaining clips - 2 - at D-pillar and lower side panel.
2. Position window at lower side panel and press into opening.
3. Secure window in opening using adhesive tape.

1. Position upper B-pillar trim at roof trim molding and slide trim - 1 - into side retaining clips.
2. Observe curing time.

Scheme 202

1 - Side window

2 - Adhesive bead

1. Note varying spacing dimensions to window edge.
2. Dimension - a - = 8 mm behind window molding
3. Dimension - b - = 25 mm
4. Bead cross section

1. Bead width = 8 mm ± 2 mm
2. Bead height = 13.5 ± 1.5 mm

3 - Spacers

1. Height 8 mm

4 - Double sided adhesive

1. D 004 400

5 - Securing pin

1. 2x

6 - Trim for side panel

1. When installing, first insert into roof trim molding at bottom, then press at sides into retaining clips on side panel.

Remove the following trim pieces

1. Side luggage compartment trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. D-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
3. Trim above rear side window. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
4. C-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

Scheme 203

1. Remove C-pillar trim from rear side window toward front - arrows -.

Side window with gloss package

Scheme 204

1. Beginning at C-pillar, pull lower trim molding - 1 - from retaining springs - 2 -.
2. Disengage lower trim molding from roof trim molding.

All vehicles

Scheme 205

1. Pierce through adhesive sealing material using a guide needle with handle from V.A.G 1755 window removing kit.
2. Remove handle and thread cutting cord through eye of the guide needle.

Scheme 206

1. Pull cutting cord end - A - inward (use pliers and protective gloves) to opposite window side with guide needle from V.A.G 1755 window removing kit.

Scheme 207

1. Pull cutting cord - B - with small tube from V.A.G 1755 window removing kit under polyurethane molding of side window.

Scheme 208

1. Insert cutting cord completely around window.
2. Pierce through adhesive sealing material using a guide needle with handle from V.A.G 1755 window removing kit.
3. Remove handle and thread end of cutting cord - B - through eye of the guide needle.
4. Pull through cutting cord end - B - with guide needle inward (use pliers and protective gloves).

1. Secure cutting cord end - B - to belt guide console.

Scheme 209

1. Attach spooling tool V.A.G 1654 as shown together with cutting cord.

Scheme 210

1. Cut first area at C-pillar and window bottom.

Note. Press cutting cord in direction of chassis during cutting procedure.

Scheme 211

1. Position V.A.G 1474/1 roller as depicted in the illustration.
2. Move spooling tool V.A.G 1654 and continue cutting.

Scheme 212

1. Position V.A.G 1474/1 roller as depicted in the illustration.
2. Move spooling tool V.A.G 1654 and continue cutting.

Scheme 213

1. Remove side window using V.A.G 1344 double suction cups.

Note. If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

1. When reusing an undamaged window, cut remaining adhesive sealing material on window and flange using a carpet knife so that it is even, but do not remove completely!
2. Residual material acts as a base for the new adhesive sealing material.

1. Apply adhesive onto residual adhesive bead

1. Bead width = 8 ± 2 mm
2. Bead height = 13.5 ± 1.5 mm

Note. Adhesive sealing material DH 009 100 03 (small cartridge) is recommended when bonding a single window; D 004 300 05 (2K- adhesive) is recommended when bonding more than one window.

New window, installing

1. Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.
2. Ensure an air drying time of 10 minutes for primer.
3. Apply adhesive

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

1. Bead width - a - = 8 ± 2 mm
2. Bead height = 13.5 ± 1.5 mm
3. Dimension - c - = note varying spacing dimensions to window edge --> «Side window (Avant), removing and installing - assembly overview»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

1. Adhere spacer onto side window.
2. Apply double sided adhesive tape D 004 400 on window gasket, rear.

Vehicles with gloss package

1. Install lower trim molding - 1 - into retaining clips - 2 -.

1. Press side window into window opening using V.A.G 1344 double suction cups and align it according to window opening.
2. Secure window in opening using adhesive tape.
3. Observe curing time.

Scheme 214

1. On vehicles with trim attached, press it into retaining clips at C-pillar - arrows -.

Scheme 215

1 - Rear window

1. Removal --> «Undamaged rear window, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__undamaged-rear-window-removing)
2. When installing, note direction of joint - arrow - in magnified area of illustration.
3. After inserting window, pull up to dimension - a - = 6.5 mm at roof.
4. Align window at sides.

2 - Adhesive end profile

1. Adhere next to vertical rear window defrosting strips
2. Adhesive must not touch distributing wire for rear window defroster.

3 - Adhesive bead

1. Note varying spacing dimensions to window edge.
2. The dimensions - b - and - c - are achieved when you allow the application nozzle to touch each inner edge of the molding.
3. The distance to lower window edge dimension - d - is 15mm.
4. Bead cross section

1. Bead width = 8 ± 2 mm
2. Bead height = 13.5 ± 1.5 mm

4 - Spacers

1. Note different heights for standard glass and tinted glass.
2. Place spacers at distance of 3mm to lower window edge onto markings applied in ceramic screen printed area.

Undamaged rear window, removing

Note. Always wear protective glasses and leather gloves when removing a window.

1. Unclip rear shelf. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Disconnect connections for rear window defrost and window antenna.
3. Press connections at window towards center of vehicle.

Scheme 216

1. Press awl through adhesive sealing material in lower window corner, until eye of awl is visible outside of vehicle.
2. Thread beginning of cutting cord through eye and pull into vehicle interior.

Scheme 217

1. Thread cutting cord through spooling tool and clamp securely.
2. Place cutting cord around window as shown.
3. Cutting cord must be pressed under gap covers on upper window edge and side window edges.

Scheme 218

1. Lay end of cutting cord around buffer stop - arrow - and tighten with bolt for rear lid hinge.

1. Cut first section.

Scheme 219

1. Move winding device as shown and attach relay pulley in lower window radius.

1. Route cutting cord as shown.

1. Cut adhesive up to point where cord no longer runs in relay pulley.

Scheme 220

1. Remove relay pulley and continue to cut adhesive.

Scheme 221

1. Move winding device as shown and attach relay pulley in lower window radius.

1. Route cutting cord as shown.

1. Cut adhesive up to point where cord no longer runs in relay pulley.
2. Insert 1474/12 protective foil between molded headliner and rear window.

1. Remove relay pulley and continue to cut adhesive.
2. Repeat these steps in top right and bottom right corners of windshield.
3. Cut glass completely free in this manner.
4. Remove window using double suction cups.

Damaged rear window, removing

1. Remove glass pieces up to adhesive material.

Scheme 222

1. Disconnect connector - 1 - for antenna and amplifier.
2. Remove harness connectors for glass defroster.
3. Mask flange all around with fabric reinforced adhesive tape.

Scheme 223

1. Remove adhesive sealing material (with glass residue) - 1 - from window opening using electric cutter and knife V.A.G 1561/11 (with stopper roll).

Note. If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

1. Observe different spacers for tinted glass and standard glass.
2. Adhere lower spacer onto rear window according to the markings.

Scheme 224

1. Adhesive stopper profile - 2 - must be adhered onto left side, centered on antenna wire next to distributing wire for rear window heater.
2. On the right side, adhere inner edge of profile onto outer edge of distributing wire for rear window heater.

Note. If adhesive sealing material leaks out at lower window edge during installation, this must be removed immediately.

For undamaged removed windshield

1. When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter V.A.G 1561A and scraper V.A .G 1561/10; do not remove completely!
2. Residual material acts as a base for the new adhesive sealing material.

New window, installing

1. Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

Applying primer

1. Apply primer - 2 - along circumference evenly and in one motion using applicator - 1 -.
2. Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

1. Primer dimensions: Dimension - a - + approx. 20 mm

1. Apply primer in center of adhesive bead.

Note. Do not touch up primer strip until after primer has thoroughly dried.

Dimensions for application of adhesive

1 - Adhesive bead

2 - Primer

3 - Washer

1. Bead width - a - = 8 ± 2 mm
2. Bead height - b - = 12 + 3 mm
3. Dimension - c - = note varying spacing dimensions to window edge --> «Rear window (Sedan), removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

Installing rear window

1. After preparatory work has been performed, apply the adhesive.

1. Position complete surface of nozzle - 2 - onto window.
2. Arrow - indicates direction of application

Note. Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

1. Apply adhesive sealing material all around, as shown in illustration.
2. Note varying spacing dimensions to window edge --> «Rear window (Sedan), removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Using two double suction cups, install rear window in window opening.

1. Align windshield at sides.
2. Spacing between edge of window and roof frame must be 6.5 mm.
3. Observe curing time.

Assembly overview

Note. The printed gap covers on window edges have been discontinued in vehicles as of Vehicle Identification Number (VIN) 400 001. New windows without gap covers can be installed retroactively in older vehicles.

Scheme 225

1 - Rear window

1. Undamaged side window, removing --> «Undamaged rear window, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Removing damaged rear window --> «Damaged rear window, removing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Dimension - a - even out when installing.

2 - Adhesive bead

1. Observe curing times --> «Minimum curing times!»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__minimum-curing-times)
2. Note varying spacing dimensions to window edge.
3. Dimension - b - = 6 mm
4. Dimension - c - = 38 mm

1. Dimension - d - = 6 mm
2. Bead cross section
3. Bead width = 8 +2 mm
4. Bead height = 13.5 +1.5 mm

3 - High-mount brake light

1. Removed before removing rear window. Refer to «94 LIGHTS, SWITCHES - EXTERIOR»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 94 LIGHTS, SWITCHES - EXTERIOR for ELECTRICAL EQUIPMENT, CABRIOLET

4 - Sealing strips

1. Pull off before removing rear window.

5 - Seal for rear window wiper

1. Remove rear lid trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Remove rear window wiper motor. --> «92 WINDSHIELD WIPER WASHER SYSTEM»(/audi/a4/b7-2004-2009/remont/cruise-control-systems/#electrical-equipment) 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET
3. Disconnect electrical harness connectors for heated rear window and antennas.
4. Pull off side sealing strip at rear window.

Scheme 226

1. Open rear lid.
2. Pierce through adhesive sealing material using a guide needle with handle - 1 - from V.A.G 1755 window removing kit.
3. Remove handle and thread end of cutting cord through eye of the guide needle.

Scheme 227

1. Pull cutting cord end - A - inward (use pliers and protective gloves) to opposite window side with guide needle from V.A.G 1755 window removing kit.

Scheme 228

1. Using plastic wedge, loose sealing lip from glass flange and spray with D009 401 04 cleaning solution (lubricant replacement).
2. Insert cutting cord end - B - around rear window using small tube from V.A.G 1755 window removing kit.

Scheme 229

1. Using needle and handle, pull second cutting cord end - B - inward as shown.

Note. Cutting cord ends - A - and - B - may not be pulled diagonally.

1. Thread in cutting cord end - A - into spooling tool V.A.G 1654 and secure.

1. Remove cover - 1 - for rear lid hinge and cable guide - 2 - from rear lid hinge - arrows -.

Scheme 230

1. Fasten cutting cord end - B - to lid hinge.

Scheme 231

1. Fasten V.A.G 1654 spooling tool as shown to rear window.
2. When cutting side area, press cutting cord in - direction of arrow -.
3. Cut glass free at bottom.

Scheme 232

1. Move winding device as shown, and continue to cut window free.
2. When cutting lower area, press cutting cord in - direction of arrow -.
3. Cut glass free at side.
4. Move winding device as shown, and continue to cut window free.

Scheme 233

1. When cutting side area, press cutting cord in - direction of arrow -.
2. Cut glass free at top.
3. Move winding device as shown, and continue to cut window free.

Scheme 234

1. When cutting upper area, press cutting cord in - direction of arrow -.
2. Cut window away completely and lift out from rear lid.

1. Remove glass pieces up to adhesive material.
2. Disconnect connections for heated rear window and antennas.
3. Bond flange all around with fabric reinforced adhesive tape.
4. Remove adhesive sealing material (with glass residue) from window opening using electric cutter and knife V.A.G 1561/10 (with stopper roll).

Note. If windshield flange was damaged during removal, paint structure should be repaired according to specifications in article, "Vehicle-Paint" and if necessary, corrosion repair measures should be taken according to guidelines in "Surface Technology/Chemical Materials Folder".

For undamaged removed windshield

1. When reusing an undamaged window, cut back smoothly residual adhesive sealing material on window and flange using electric cutter V.A.G 1561A and scraper V.A.G 1561/8; do not remove completely!
2. Residual material acts as a base for the new adhesive sealing material.

New window, installing

1. Clean windshield in adhering area using D 009 401 04 and prime using D 009 200 02 glass/paint primer.

Applying primer

1. Apply primer - 2 - D 009 200 02 uniformly all around on window, centering by markings, using applicator - 1 - , Part No. D 009 500 25 (felt ball with wire).
2. This determines the distance to window edge - dimension b -.
3. Primer width - dimension a - is determined by the markings on window.
4. Begin application with a fully saturated felt. Air drying time approx. 10 minutes.

Note. Do not touch up primer strip until after primer has thoroughly dried.

Adhesive bead cross section

1 - Adhesive bead

2 - Primer

3 - Washer

1. Dimension - a - = 8 ± 2 mm.
2. Dimension - b - =13.5 ± 1.5 mm.
3. Dimension c is determined by markings on window

1. After preparatory work has been performed, apply the adhesive.

1. Position complete surface of nozzle - 2 - onto window.
2. Arrow - indicates direction of application

Note. Cross-section thickness of adhesive bead - 1 - is determined by dimension of opening in nozzle tip and rate of application.

1. Apply adhesive sealing material all around, as shown in illustration.
2. Note varying spacing dimensions to window edge --> «Rear window (Avant), removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Using two double suction cups, install rear window in window opening.

1. Align windshield at sides.
2. Secure window glass in windshield opening using adhesive tape during curing process.
3. Observe curing time.

Scheme 235

1 - Roof joint strip

1. Removing
2. Carefully pry out of roof joint starting from rear.
3. Installing
4. Install seal profile - 2 - onto roof joint strip - 1 -.

1. Coat seal profile with lubricant (e.g. soap).
2. Slide in roof joint strip under gap cover starting at windshield - 3 - and press into roof joint in sections up to half way.
3. Also slide in roof joint strip under gap cover at rear window and press completely into roof joint.

2 - Seal profile

1. Coat with lubricant before installing.

3 - Windshield

Scheme 236

1 - Windshield

2 - Seal profile

1. Coat with lubricant before installing.

3 - Roof joint strip

1. Removing
2. Removing roof rail --> «Roof rail, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
3. Carefully pry out of roof joint starting from rear.
4. Installing

1. Install seal profile - 2 - onto roof joint strip.
2. Coat seal profile with lubricant (e.g. soap).
3. Slide on roof joint strip starting at windshield - 3 - below gap cover and press completely into roof joint by sections from front toward rear.

Roof trim molding (Sedan), removing and installing

Note. To remove roof trim molding, it is not necessary to remove the side window.

Scheme 237

1 - Roof trim molding

1. B-pillar trim removed --> «B-pillar trim panel, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Door seals in area of roof trim molding pulled off.
3. Pry out cover strip - 2 - from roof trim molding.
4. Drill off rivet heads of pop rivets - 3 - , strike rivet shafts through and remove roof trim molding.

2 - Cover strip

1. To ease installation, coat edges with lubricant.
2. Press into roof trim molding from front toward rear.

3 - Pop rivet

4 - Retaining clip

1. 5x

5 - C- pillar trim

1. Pull off in direction of travel.

6 - Roof trim molding, side window

1. Pry off carefully using plastic wedge starting from bottom and pull off in - direction of arrow -.

Roof trim molding, removing and installing (Avant)

Note. To remove roof trim molding, it is not necessary to remove the side window.

Scheme 238

1 - Roof trim molding

1. B-pillar trim removed --> «B-pillar trim panel, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Remove door seals in area of roof trim molding
3. Pry out cover strip - 3 - from roof trim molding.
4. Drill off rivet heads of pop rivets - 3 - , strike rivet shafts through and remove roof trim molding.

1. Carefully pry out roof trim molding from retaining clips - 2 - (7x) starting at A-pillar.
2. On vehicles with gloss package, disengage roof trim molding from lower trim molding «Disengaging roof trim molding from trim molding under side window»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__disengaging-roof-trim-molding-from-trim)

2 - Retaining clip

1. 7x

3 - Cover strip

1. To ease installation, coat edges with lubricant.
2. Press into roof trim molding from front toward rear.

4 - Pop rivet

Disengaging roof trim molding from trim molding under side window

1. Carefully disengage loose roof trim molding from lower trim molding.

Scheme 239

1 - Special nut

1. 18 Nm

2 - Gaskets with glued seal

1. Check for proper seating

3 - Roof rail

1. Removing
2. Remove upper A-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
3. Remove D-pillar trim. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
4. Remove trim above rear door. --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET

1. Unthread nuts - 1 - and remove roof rail.
2. Installing
3. Check for correct seating of seals on threaded points of roof rail.
4. Tighten nuts - 1 - to 18 Nm.

Replacing side protective moldings

Note. Protective moldings cannot be removed without destroying them.

Scheme 240

1. To remove protective moldings - 1 - and - 2 - , heat using a hot air blower and pull off from door.
2. Adhesion surface must be free of dust and grease.
3. Clean outer panel with mineral spirits, treat with silicone remover and rub dry.

1. Protective moldings must be affixed only at room temperature.
2. For this purpose, bring vehicle and protective moldings to room temperature at least 2 hours before processing.
3. Protective moldings must be adhered within 90 minutes after protective foil has been removed.

1. Pull protective foil - 3 - from double-sided adhesive tape - 4 - shortly before installation.
2. Apply protective molding to be adhered at front and adhere working toward rear.
3. Heat protective molding to approx. 40°C using heat gun and forcefully press on or roll on.

1. After adhering strip, leave vehicle 4 hours in room temperature.

Scheme 241

1 - Front trim cover

1. To remove, remove bolt - 3 - , slide trim cover with clip - 4 - toward rear and out of locking mechanism.
2. Remove trim cover sideways.
3. To install, insert trim cover in door, slide into locking mechanism toward front and secure with bolt - 3 -.

2 - Rear trim cover

1. Removal as for front trim cover.

3 - Bolt

1. 1 Nm

4 - Clip

Scheme 242

1. To remove, remove bolts - 2 -.
2. Pull trim cover - 3 - toward rear out of retainers.
3. Remove trim cover sideways from door - 1 -.
4. When installing trim cover, tighten bolts - 2 - to 1Nm.

Scheme 243

1. To remove, remove bolts - 2 -.
2. Pull trim cover - 3 - toward rear out of retainers.
3. Remove trim cover sideways from door - 1 -.
4. When installing trim cover, tighten bolts - 2 - to 1Nm.

Scheme 244

1 - B pillar trim panel

Removing

1. Unclip cover - 7 -.
2. Remove bolts - 6 - pull trim panel off outward.

Installation

1. With rear door opened, guide trim panel into retaining bracket.
2. With rear door closed, position at top and bottom according to magnified area in illustration.
3. Screw in front bolt - 6 -.
4. Outer lip of rear door window seal must make contact cleanly over entire range of trim panel.

Note. Excessive pressure on seal at trim panel must be prevented, otherwise the projecting lip may cause wind noise. With door opened, screw in rear bolt - 6 -. Press grommet - 5 - into trim panel. Slide cover - 7 - on from below.

2 - Bolt

1. 1.5 Nm

3 - Retaining bracket

4 - Clip

5 - Grommet

6 - Combination bolt

1. 5 Nm

7 - Cover

Window weatherstrips for front door (standard vehicle), removing and installing

1. Remove door trim --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Remove window frame and window regulator --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 245

1. Remove clips - 2 -.
2. Remove window shaft strip - 1 -.
3. Installation is performed in the reverse order of removal.

Front window weatherstrips (vehicles with gloss package), removing and installing

Note. Illustrations show window weatherstrips for rear door

Scheme 246

1. Cover area below window weatherstrips - 1 - with adhesive tape - 2 -.

Scheme 247

1. Carefully bend up window weatherstrip - 1 - slightly at rear - arrow -.

Scheme 248

1. Using a plastic wedge, pry off window weatherstrip - 1 - from carrier part at sides.

Scheme 249

1. Carefully widen slightly the lower edge on inside of new window weatherstrip - 1 - using a plastic wedge - 2 -.
2. Coat this edge and carrier part with e.g. soap solution to assist installation.

Scheme 250

1. Insert window weatherstrip - 1 - from above and carefully press window weatherstrip completely onto carrier part by hand.

Window weatherstrips for rear door (standard vehicle), removing and installing

1. Remove door trim --> «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior) «70 - INTERIOR TRIM»(/audi/a4/b7-2004-2009/remont/gauges-instrument-panels/#body-interior-cabriolet) for BODY INTERIOR - CABRIOLET
2. Remove window frame and window regulator --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

Scheme 251

1. Remove clips - 2 -.
2. Remove window weatherstrips - 1 -.
3. Installation is performed in the reverse order of removal.

Rear window weatherstrips (vehicles with gloss package), removing and installing

1. Cover area below weatherstrips - 1 - with adhesive tape - 2 -.

1. Carefully bend up weatherstrips - 1 - slightly at rear - arrow -.

1. Using a plastic wedge, pry off weatherstrips - 1 - from carrier part at sides.

1. Carefully widen slightly the lower edge on inside of new weatherstrips - 1 - using a plastic wedge - 2 -.
2. Coat this edge and carrier part with e.g. soap solution to assist installation.

1. Insert weatherstrips - 1 - from above and carefully press weatherstrips completely onto carrier part by hand.

Outside rear view mirror, removing and installing

Special tools, testers and auxiliary items required

Scheme 252

1. Lever 80-200

Assembly overview

Scheme 253

1 - Mirror housing

1. May be removed from door without removing entire rearview mirror --> «Outside rear view mirror housing, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

2 - Adjusting motor

1. Removal --> «Outside rear view mirror adjusting motor, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior__outside-rear-view-mirror-adjusting-motor)

3 - Mirror adjusting unit

1. Before replacing, window frame must be removed --> «Window frame and window regulator, removing and installing»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Before removing, remove rearview mirror from door
3. To remove, pry off mirror lens, disconnect electrical harness connectors for mirror heater, remove phillips-head screws - 6 - and remove mirror adjusting unit from mirror housing - 1 -.

4 - Mirror lens

1. Use special tool Lever 80-200 to unclip.
2. Protect mirror housing against damage using textile tape above and below.
3. Press mirror lens first downward, then upward.
4. To install mirror lens into guide pins and friction finger, insert into friction spring and press on.

1. Apply pressure only on center of glass, wear protective gloves while doing so.

5 - Front door

6 - Electrical harness connector

7 - Combination bolt

1. 12 Nm

8 - Seal

1. Ensure correct seating when installing.

9 - Mirror base

Scheme 254

1. Install mirror lens - 3 - with locking tabs onto mirror lens base - 2 - in - direction of arrow -.
2. Friction finger must be inserted into friction spring - arrow - of housing - 1 - while doing so.
3. Apply pressure only on center of glass, wear protective gloves while doing so.

Outside rear view mirror adjusting motor, removing and installing

1. Mirror lens removed.

Scheme 255

1. Remove bolts - arrows - from mirror adjusting unit.
2. Remove motor - 2 - from mirror adjusting unit and disconnect electrical harness connector.
3. When installing, tighten bolts to 1 Nm.

Scheme 256

1 - Mirror housing

1. Removing
2. Remove bolts - 4 - from cover trim - 3 - and remove them downward.
3. Release housing from locking tabs on mirror adjusting unit and remove it upward.
4. Installing

1. Position mirror housing onto mirror adjusting unit - 2 - from above.
2. While doing so, locking tabs - arrows - in mirror adjusting unit must engage above and below «Lower mirror locking tab»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

2 - Mirror adjusting unit

3 - Lower trim strip.

4 - Combination bolts

1. 1Nm

Scheme 257

1. When installing, locking tab (- arrow A -) of mirror adjusting unit - 2 - must be inserted into mirror housing catches - 1 - in - direction of arrow -.

Outer sill panel trim, replacing

Note. Outer sill panel trim cannot be removed without destroying it.

Scheme 258

1. Heat door sill panel trim using a hot air gun and carefully pull upward and off.
2. Clean adhesion surface with mineral spirits, treat with silicone remover and rub dry.

1. Door sill moldings must be affixed only at room temperature.
2. For this purpose, bring vehicle and door sill moldings to room temperature at least 2 hours before processing.
3. Protective moldings must be adhered within 90 minutes after protective foil has been removed.

1. Heat adhesion surface to approx. 40°C using a hot air gun.

1. Pull protective foil from double-sided adhesive tape shortly before installation.
2. Clip in door sill molding and press on.

1. After adhering strip, leave vehicle 4 hours in room temperature.

Scheme 259

1 - Bracket for sill panel cover

1. Removing and installing «Removing bracket for sill panel cover»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

2 - Bolt

1. 1 Nm

3 - Bolt

1. 2 Nm

4 - Sill panel cover

1. Removing
2. Then pull out of rear cover in - direction of arrow - and remove.
3. Installing
4. Insert sill panel cover into rear cover.

1. Then secure to bracket - 1 - «Removing bracket for sill panel cover»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Screw in bolts - 3 -.
3. Screw in bolts - 2 -.

5 - Cover strip

6 - Rear sill panel cover

1. Removing and installing «Rear sill panel cover»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior)

7 - Bolt

1. 2 Nm

8 - Bolt

1. 1 Nm

9 - Wheelhousing liner

Scheme 260

1. Sill panel cover removed.
2. Remove bolts at wheelhousing liner.
3. Remove bolts - 2 - and remove bracket - 1 -.
4. Expanding nut - 3 -.

1. When installing, engage sill panel cover - 4 - completely into bracket - 1 -.

Scheme 261

1. Sill panel cover - 1 - removed.
2. Remove bolts - 1 - and remove rear sill panel cover - 2 -.
3. Wheelhousing liner - 5 -.
4. Rear wheel spoiler - 4 -.

Underbody covers

Front underbody cover

Scheme 262

1 - Cd cover, right, front

2 - Cap for Cd cover

3 - Hex nut

1. 2.3 Nm

4 - Expanding rivet

5 - Cd cover, left, front

6 - Right underbody cover

7 - Hex nut

1. 2.3 Nm

8 - Left underbody cover

Rear underbody cover for Front Wheel Drive (FWD)

Scheme 263

1 - Blind rivet bolt

2 - Underbody cover for fuel tank

3 - Hex nut

1. 1.7 Nm

4 - Hex nut

1. 2.3 Nm

5 - Sheet-metal screw

1. 1.7 Nm

6 - Sheet-metal screw

1. 1.7 Nm

7 - Underbody cover, left, rear

Rear underbody cover for All Wheel Drive (AWD)

Scheme 264

1 - Underbody cover for fuel tank

2 - Hex nut

1. 2.3 Nm

3 - Expanding rivet

4 - Sheet-metal screw

5 - Spring nut

1. 2.3 Nm

6 - Underbody cover, left, rear

Underbody cover for rough terrain package

Scheme 265

1 - Underbody cover for fuel tank

2 - Hex nut

1. 2.3 Nm

3 - Expanding rivet

4 - Washer

5 - Hex bolt

1. 5 Nm

6 - Stone impact protection plate

7 - Underbody cover, right, rear

Scheme 266

1. Underbody cover removed.
2. Front tunnel brace - 2
3. When installing, tighten hex bolts - 1 - to 55 Nm.
4. Rear tunnel brace - 3

1. When installing, tighten hex bolts - 4 - to 60Nm.

Scheme 267

1 - Fender

2 - Bolt

1. 2.3 Nm

3 - Front wheelhousing liner

1. Remove front wheel before disassembly.
2. To disassemble, release quick-release screws - 6 -.
3. Unscrew bolts - 2 -.
4. Disengage wheelhousing liner from fender and pull downward and out.

4 - Expanding nut

5 - Sill panel cover

6 - Quick release screw

Scheme 268

1 - Rear wheelhousing liner

1. Remove rear wheel before disassembly.
2. Unscrew bolts - 2 -.
3. Remove wheelhousing liner downward.

2 - Bolt

1. 1.5 Nm

3 - Combination bolt

1. Inserted only on the right side of vehicle.

4 - Expanding nut

Wheel spoiler

Front wheel spoiler, removing and installing

Scheme 269

1 - Brace for fender

2 - Clamping pin

1. To loosen, rotate 180°.

3 - Front wheel spoiler

1. To remove, remove bolts - 8 - , rotate clamping pins 180°, pull out and pull out wheel spoiler under wheelhousing liner - 7 -.

4 - Speed nut

1. Slid onto noise insulation

5 - Noise insulation

6 - Guide piece for bumper

1. Secured to fender

7 - Front wheelhousing liner

8 - Sheet-metal screw

1. 1.5 Nm

Rear wheel spoiler, removing and installing

Scheme 270

1 - Rear wheel spoiler

1. Remove bolts - 2 - completely and pull out wheel spoiler downward under wheelhousing liner/underbody cover.

2 - Combination bolt

1. 2Nm

3 - Front underbody cover

Lettering on rear lid (Sedan)

Note. Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.

Installation

1. Warm vehicle and type designation to room temperature.
2. Bonding surfaces must be dry and free from dust and grease.
3. Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
4. Pull off backing paper and press on characters - 1 - , maintaining pressure for approx. 3 seconds.

Dimensional data for Front-Wheel Drive (FWD) vehicles

Scheme 271

1. a = 23 mm.
2. b = 28 mm
3. c = 2 mm
4. d = 28 mm

1. e = 11 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Scheme 272

1. a = 23 mm.
2. b = 28 mm
3. c = 4 mm
4. d = 12.5 mm

1. e = 28 mm
2. f = 0.11 mm

Lettering on rear lid (Avant)

Note. Outer edges of rear lid and lines extending from lower rear lights are used as reference edges.

Installation

1. Warm vehicle and type designation to room temperature.
2. Bonding surfaces must be dry and free from dust and grease.
3. Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
4. Pull off backing paper and press on characters - 1 - , maintaining pressure for approx. 3 seconds.

Dimensional data for Front-Wheel Drive (FWD) vehicles

Scheme 273

1. a = 95 mm
2. b = 33 mm
3. c = 38 mm
4. d = 28 mm

1. e = 95 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Scheme 274

1. a = 33 mm
2. b = 28 mm
3. c = 4 mm
4. d = 12.5 mm

1. e = 38 mm
2. f = 95 mm

Note. Lower edge of rear lid is used as a reference edge, outer edge at crossover point for the corresponding height dimension.

Installation

1. Warm vehicle and type designation to room temperature.
2. Bonding surfaces must be dry and free from dust and grease.
3. Clean outer panel with mineral spirits, treat with silicone remover and rub dry.
4. Pull off backing paper and press on characters - 1 - , maintaining pressure for approx. 3 seconds.

Dimensional data for Front-Wheel Drive (FWD) vehicles

Scheme 275

1. a = 25 mm
2. b = 30 mm
3. c = 63 mm
4. d = 25 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Scheme 276

1. a = 25 mm
2. b = 30 mm
3. c = 63 mm
4. d = 25 mm

1. e = 4 mm

Dimensional data for Front-Wheel Drive (FWD) vehicles

Scheme 277

1. a = 50 mm
2. b = 30 mm
3. c = 65 mm
4. d = 50 mm

Dimensional data for All Wheel Drive (AWD) vehicles

Scheme 278

1. a = 50 mm
2. b = 30 mm
3. c = 65 mm
4. d = 50 mm

1. e = 4 mm

Rear lid spoiler, removing and installing

Special tools, testers and auxiliary items required

Scheme 279

1. Heat gun V.A.G 1416

S4 sedan

Scheme 280

1 - Rear lid spoiler

Removing

1. Before removing spoiler, remove rear lid trim.
2. Remove nuts - 2 -.
3. Heat rear lid from inside using a hot air gun.
4. Carefully pull off spoiler from rear lid, beginning at sides.

1. Remove remaining adhesive tape from rear lid.

Installation

1. Rear lid must be free of dust and grease in adhesion area
2. Clean adhesion area of rear lid with cleaning solution D 009 401 04.
3. Before installing a new spoiler, pull backing paper - arrow - from adhesive tape.
4. Place spoiler onto rear lid, centered and in flush position.

1. Press spoiler firmly over entire length onto rear lid.
2. Tighten nuts - 2 - to 2 Nm.

1. Before reinstalling spoiler, remove remaining adhesive tape completely.
2. Before installing, adhesive tape - 3 - must be applied all around and sealing washers around threaded pins in spoiler as shown in «Apply adhesive tape on spoiler»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .

2 - Cap nut

1. 2Nm

3 - Adhesive tape

1. If a removed spoiler is to be reinstalled, first apply adhesive tape and sealing pieces for threaded pins in spoiler «Apply adhesive tape on spoiler»(/audi/a4/b7-2004-2009/remont/door-locks-anti-theft-systems/#body-exterior) .
2. Adhesive tape residue must be removed from spoiler before reinstalling.

Scheme 281

1. Heat rear lid in adhesion area for spoiler using hot air gun V.A.G 1416.
2. Carefully pull off spoiler upward from rear lid, beginning at sides.
3. If spoiler is re-used, adhesive tape residue must be removed completely.

Scheme 282

1. Pull off backing paper from sealing pieces - 5 - and press seal over thread onto spoiler - 1 -.
2. Pull off backing paper on one side from adhesive tape - 2 - or - 4 -.
3. Press adhesive tape along circumference on spoiler as shown.
4. In rear area, adhesive tape - 4 - must be pressed on in radius.

1. Tighten nuts to 2 Nm when installing.

S-Line Avant

Scheme 283

1 - Spoiler

1. Remove rear lid trim before removing

1. Remove bolts - 4 -.
2. Heat adhesion area on lid using hot air gun V.A.G 1416.

1. Pull spoiler from lid upward and off.
2. Before assembling a spoiler, clean adhesion area on lid with cleaning solution D 009 401 04.
3. Pull off backing paper from double-sided adhesive tape.
4. Place spoiler over holes onto closed lid.

1. Press on spoiler forcefully, starting at center and working outward over entire width.
2. Open lid and tighten bolts to 4 Nm.

2 - Rear lid

1. Lid must be free of dust and grease in adhesion area.
2. Before assembling a spoiler, clean adhesion area on lid with cleaning solution D 009 401 04.

3 - Adhesive tape

1. Remove protective paper before applying.

4 - Combination bolt

1. 4 Nm

See also:
• 87 AIR CONDITIONING
• 48 - STEERING
• 37 CONTROLS, HOUSING
• 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING
• 19 - ENGINE - COOLING SYSTEM
• 19 - ENGINE - COOLING SYSTEM
• 94 LIGHTS, SWITCHES - EXTERIOR
• 68 - INTERIOR EQUIPMENT
• 68 - INTERIOR EQUIPMENT
• 91 - COMMUNICATION
• 91 RADIO, TELEPHONE, NAVIGATION, TRIP COMPUTER
• Noise insulation panel - assembly overview
• Front bumper, removing and installing
• Gas-filled strut, removing and installing
• Hood gap dimensions
• Striker, removing and installing
• Fuel filler flap
• Gap dimensions for fuel filler flap
• Rear lid, adjusting
• Adjustment dimensions for rear lid
• Lock cylinder for rear lid, removing and installing
• Removing lid lock
• Window regulator motor, removing and installing
• Motor for window regulator, removing and installing
• Adjusting using door adjustment template T40038/1
• Disengage mount for door handle
• Engaging operating rod in door lock
• Door handle, removing
• Manual window regulators, removing and installing
• Wind deflector, removing and installing
• Sunroof headliner, removing and installing
• Trim, removing and installing
• Boot, removing and installing (vehicles as of CW 27/2002 >)
• Sunroof panel, removing
• Panel seal, replacing
• Bumper, removing and installing
• Adhering centering pins on side impact molding
• Centering holes for side impact moldings
• Crossmember, removing from cover and installing
• Two-piece bumper cover, separating
• Guide piece, removing and installing
• Bumper, mounting to shock absorber
• Shock absorber, removing and installing
• Minimum curing times!
• Removing
• Preparing for window installation
• Undamaged side window, removing
• Undamaged rear window, removing
• Disengaging roof trim molding from trim molding under side window
• Outside rear view mirror adjusting motor, removing and installing