Hood Lids Audi A6 C5

Contact corrosion!

With the extensive use of aluminum construction, corrosion caused by contact between dissimilar metals may result if the wrong fastening components (screws, bolts, nuts, washers, rivets, plugs, grommets, adhesives, etc.) are installed.

For this reason, the manufacturer only installs fastening components that have a special surface coating (Dachromet), recognized by its greenish color, and only uses rubber parts, plastic parts and adhesives that are electrically non-conductive.

These parts, compatible for use with aluminum, are also available as replacement parts.

Note. Use only Genuine Parts! If there is any doubt about whether the old parts are suitable for re-use, always install new replacement parts. All accessories must be approved by Audi of America, Inc. Damage from contact corrosion caused by improper assembly with unsuitable parts is NOT covered under warranty!

Hood, removing, installing and adjusting

Note. The hood is made of aluminum. Note contact corrosion information, see HOOD, FRONT .

The following list pertains to (Scheme 11).

1. Hood Removing: Second person is needed to support and lift hood during removal Disconnect hose to windshield washer system and unclip. Remove gas-filled strut -5- from hood -1- (Scheme 12) Remove nuts -4-. Remove hood. Installing: Install in reverse order of removal. Adjusting: Align hood -1- between fenders. Adjust height of hood at hood lock, see «REMOVING AND INSTALLING LOWER SECTION OF HOOD LOCK»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__removing-and-installing-lower-section-of). Hood can be adjusted for height relative to fenders by adjusting stop buffers. See «ADJUSTING HEIGHT OF STOP BUFFERS»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__adjusting-height-of-stop-buffers). Panel gap dimensions, see «PANEL GAP DIMENSIONS»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__panel-gap-dimensions)
2. Hood hinge Hood -1- must be removed or propped up securely To remove, remove bolts -3- and nuts -4
3. Torx (R) bolt 15 Nm (11 ft lb)
4. Nut 15 Nm (11 ft lb)
5. Gas-filled strut Removing (Scheme 12)To install, press gas-filled strut onto ball stud Install with tube end of strut at body of vehicle

Removing

1. Prop up and secure hood in open position.
2. Lift retaining spring (arrow) slightly using small screwdriver and pull gas-filled strut -1- off ball stud.
3. Detach strut at bottom ball stud.

Installing

1. To install, press gas-filled strut onto ball studs so that it engages in position. Install with tube end of strut at body of vehicle.

Releasing Gas From Strut

1. Clamp gas-filled strut in vice in area -x-. Dimension -x- = 50 mm (2 in.)
2. Using saw, cut into cylindrical part of strut at point within first third of cylinder's length (measured from piston rod end of cylinder).

Note. Always wear eye protection when performing this procedure. Cover the sawing area with a clean rag to contain any escaping fluid.

Scheme 11

Adjusting height of stop buffers

When hood is closed, stop buffers -1- and -2- must lightly contact hood at contact area.

Note. The stop buffers can be used for adjusting the height of the hood.

Scheme 12

1. Release catches (arrows).
2. Swing out radiator grill at top, then pull off at bottom.

Note. To ease assembly, apply lubricant to the PU seal.

1. Install radiator grill at bottom in center (make sure it is properly centered) and pivot it into place in direction shown in inset (arrow). Dimension -a- = 2 mm +/- 0.5 mm (0.079 in. +/- 0.019 in.) When installing, make sure radiator grill engages audibly in position

Removing and installing hood lock

1. To remove, remove nuts -2- and remove hood lock -1-. Nut tightening torque: 8 Nm (71 in. lb)

Removing and installing lower section of hood lock

1. Disengage hood lock cable. See «HOOD LOCK CABLE, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__hood-lock-cable-removing-and-installing) .
2. Remove bolts -2- (Qty. 4). Tightening torque: 10 Nm (7 ft lb)
3. Remove lower section of lock -1- from lock carrier -3-.
4. To adjust hood, move lower section of lock up or down as required.

Panel gap dimensions

Note. Gap dimensions can be checked using 3371 adjustment gauge.

Dimension -A- = 5.0 mm +1 / -0 mm (0.197 in. +0.039 / -0 in.)

Dimension -B- = 5.0 mm +1 / -0 mm (0.197 in. +0.039 / -0 in.)

Dimension -C- = 3.0 mm +1 / -0 mm (0.118 in. +0.039 / -0 in.)

Dimension -D- = 5.0 mm +1 / -0 mm (0.197 in. +0.039 / -0 in.)

Dimension -E- = 2.0 mm +/- 0.2 mm (0.079 in. +/- 0.008 in.)

Dimension -F- = 2.0 mm +/- 0.2 mm (0.079 in. +/- 0.008 in.)

Dimension -G- = 2.5 mm +/- 0.2 mm (0.098 in. +/- 0.008 in.)

Scheme 13

Hood lining, removing

1. Remove clips -2- (Qty. 18).
2. Remove lining -1-.

Scheme 14

Hood lock cable, removing and installing

The following list pertains to (Scheme 20).

1. Hood lock cable Removing: Remove storage compartment on driver's side. See «DRIVER'S STORAGE COMPARTMENT, REMOVING»(/audi/a6/c5-1997-2001/remont/mirrors/#interior-equipment__drivers-storage-compartment-removing) . Remove screws -3-. Detach cable at support (arrow -B-) and disengage end of cable (arrow -A-) at lower section of hood lock -5-. Remove securing clip -4-. Remove cable -1- from guide channel in seal -6- and pull cable through bulkhead into interior of vehicle. Installing: Install in reverse order of removal.
2. Hood lock release
3. Self-tapping screw 1.5 Nm (13 in. lb)
4. Securing clip
5. Lower section of hood lock Removing and installing, see «REMOVING AND INSTALLING LOWER SECTION OF HOOD LOCK»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__removing-and-installing-lower-section-of) . Can be moved to adjust hood height

Rear lid and rear lid lock, removing, installing and adjusting

The following list pertains to (Scheme 21).

1. Rear lid Removing: Remove warning triangle and holder -5-. Remove rear lid lining. Disconnect and unclip harness connectors. A second person is required to lift off rear lid during removal Remove nuts for rear lid hinges, see «REMOVING AND INSTALLING REAR LID HINGE»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__removing-and-installing-rear-lid-hinge) . Installing: Install in reverse order of removal. Adjusting: Rear lid can be centered and adjusted for height at rear lid hinges. See «REMOVING AND INSTALLING REAR LID HINGE»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__removing-and-installing-rear-lid-hinge) . Adjust stop buffers -2-. Adjust striker plate -6-. Align (center) rear lid to attain specified panel gap dimensions. See «PANEL GAP DIMENSIONS»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids) .
2. Stop buffers (2x) Rear lid can be adjusted in relation to side panels via striker plate Adjusting: Press in spring pin fully using Phillips-head screwdriver. Lock spring pin by turning counter-clockwise. Screw stop buffers into rear lid. Carefully close rear lid until flush with rear side panels. Unscrew stop buffers in stages. When correctly adjusted, stop buffers make light contact with rear loading sill when rear lid is closed Unlock spring pin by turning clockwise using Phillips-head screwdriver.
3. Expanding nuts
4. Self-tapping screws 1.5 Nm (13 in. lb)
5. Holder To remove, remove warning triangle, remove screws -4- and detach holder
6. Striker plate Remove nuts -7-. Adjusting: Tighten nuts -7- finger-tight (striker plate should still be movable). Carefully close rear lid until flush with rear side panels. Carefully open rear lid and tighten nuts -7- to 8 Nm (71 in. lb).
7. Nuts 8 Nm (71 in. lb)

Note. Gap dimensions can be checked using 3371 adjustment gauge.

Dimension -A- = 3 mm +1 / -0 mm (0.118 in. +0.039 / -0 in.)

Dimension -B- = 5 mm +1 / -0 mm (0.197 in. +0.039 / -0 in.)

Dimension -C- = 1.5 mm +/- 0.3 mm (0.059 in. +/- 0.012 in.)

Dimension -D- = flush with rear lid

Dimension -E- = 1.5 mm -0.5 / +0 mm (0.059 in. -0.019 / +0 in.)

Scheme 15

Rear lid lock and handle mechanism, removing and installing

The following list pertains to (Scheme 23).

1. Rear lid lock To remove, swing out hinge arm - 2 - from operating rod - 4 - and unhook from rear lid lock. Remove nuts - 3 - and remove rear lid lock.
2. Hinge arm After installing rear lid lock, swing it over operating rod
3. Nuts 8 Nm (71 in. lb)
4. Operating rod
5. Nut 8 Nm (71 in. lb)
6. Handle mechanism Removing: Remove rear lid trim. Unclip operating rod - 4 - from handle mechanism. Unscrew nuts-5- and remove handle mechanism.
7. Rear lid lock actuator Removing, see «REAR LID LOCK ACTUATOR, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__rear-lid-lock-actuator-removing-and) .
8. Lock cylinder Removing: Remove release handle. Remove operating rod, see «REAR LID LOCK ACTUATOR, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__rear-lid-lock-actuator-removing-and) . Remove lock cylinder out of handle mechanism.
9. Rear lid lock motor
10. Screws (2x) 1.2 Nm (11 in. lb)
11. Operating rod

Rear lid lock motor, removing and installing

1. Unclip operating rod -3-.
2. Remove screws -2- (2x). Tightening torque: 1.2 Nm (11 in. lb)
3. Disconnect harness connector from motor -1-.

Scheme 16

Note. Do not unclip operating rod -4- from fulcrum lever -5-. Make sure the harness connector is connected to the motor before installation.

Rear lid lock actuator, removing and installing

The following list pertains to (Scheme 25).

1. Release handle To remove, disengage locating hooks and pull out release handle.
2. Seal
3. Lock actuator Removing: Rear lid lining removed Locking system removed Using screwdriver, press in and disengage locating hooks on left release handle -1- in direction of arrows -A-. Pull left release handle -1- downward out of handle mechanism -4-. Remove Phillips-head screws -B- and remove lock actuator.
4. Handle mechanism Removing, see «REAR LID LOCK AND HANDLE MECHANISM, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__rear-lid-lock-and-handle-mechanism) .
5. Lock cylinder Sealant is sprayed on

Rear lid hinge cover

1. Place electric wiring or wiring for central locking system -2- into lower retainer of cable guide at cover -1-. (Scheme 26)
2. Attach cover -1- for rear lid hinge from below between gas-filled strut -3- and hinge lever, and clip onto hinge lever at top so it engages audibly.

1. 4 - Torx (R) bolt Tightening torque: 8 Nm (71 in. lb)
2. 5 - Stop
3. 6 - Pop rivet nut
4. 7 - Torx (R) bolt Tightening torque: 8 Nm (71 in. lb)
5. 8- Stop
6. 9 - Pop rivet nut

Removing and installing rear lid hinge

1. Loosen nuts -2- at top on left and right. see scheme 18 Tightening torque: 21 Nm (15 ft lb)
2. Remove nuts -2- at bottom on left and right. see scheme 18 Tightening torque: 21 Nm (15 ft lb)
3. Lift rear lid off hinge.
4. Remove bolts -7- at front and rear (2x). see scheme 18
5. Loosen, but do not remove center bolt. Tightening torque: 21 Nm (15 ft lb)
6. Remove hinge -4-. see scheme 18

Note. For easier adjustment of the rear lid hinge, use graduations (-8-) marked on the hinge and the rear lid.

Rear lid seal, installing

The butt joint (-A-) of the rear lid seal must be aligned with the ball socket of the left hinge (arrow).

1. Press seal into place.

Scheme 17

1. Using screwdriver, push back retaining springs slightly at both ends of gas-filled strut and unclip gas-filled strut.

Note. When removing or installing the gas-filled strut, push back the opened rear lid slightly without damaging the components.

Scheme 18

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

1. Clamp gas-filled strut in vice in area -x-. Dimension -x- = 50 mm (2 in.)
2. Using saw, cut into cylindrical part of strut at point within first third of cylinder's length (measured from piston rod end of cylinder).

Note. Always wear eye protection when performing this procedure. Cover the sawing area with a clean rag to contain any escaping fluid.

Scheme 19

Stop buffers, adjusting

1. Open rear lid.
2. Press in spring pin in direction of arrow using Phillips-head screwdriver.
3. Lock spring pin by turning counterclockwise (arrow -A-). see scheme 20
4. Screw in stop buffer (-1-) until fully home. see scheme 20
5. Unscrew stop buffer again in stages. When correctly adjusted, the stop buffers make light contact with the rear sill trim when the rear lid is closed.
6. Unlock spring pin by turning clockwise (arrow -B-). see scheme 20

Scheme 20

Tailgate, removing and installing

1. Remove tailgate trim. See «TAILGATE TRIM, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exteriorinterior-trim/#interior-trim__tailgate-trim-removing-and-installing).
2. Disconnect or remove harness connectors and hoses (i.e. for central locking and rear window washer system).
3. Prop up and secure tailgate in open position.
4. Lift retaining spring slightly using small screwdriver and pull gas-filled strut -1- off lower ball stud. see scheme 21
5. Using screwdriver, lift retaining spring -3- as shown and remove gas-filled strut spring -1- from upper ball stud -2-. see scheme 21

Scheme 21

Note. After completely removing the gas-filled strut, check to make sure it is correctly positioned when installed. Sound deadening components must be installed on the body side.

Scheme 22

1. To install, press gas-filled strut onto ball studs so that it engages in position. Ball stud tightening torque: 15 Nm +0 / -1 Nm (11 ft lb +0 / -9 in. lb)
2. Unscrew socket-head screws -1- (2x) from tailgate -5-. Tightening torque: 21 Nm (15 ft lb)
3. Remove tailgate.

Tailgate, adjusting

Note. Before installing a new tailgate the gas-filled struts must be installed.

1. Remove rear sill trim.
2. Unscrew nuts -1- and remove cover for panel -2-. see scheme 23
3. Loosen nuts -3- until striker -4- is moveable.

Note. When installing the striker, note the correct installation position (the tip (arrow) must point toward the back).

Scheme 23

Note. The stop on the body side is two-parts and slides into the basic position when installing the rear hatch.

1. Loosen screw -5- and completely remove upper part -4- of stop -3-. see scheme 24
2. Tighten screw -5- slightly. see scheme 24
3. Close tailgate and press approx. 2 mm (0.079 in.) below basic position.
4. Open tailgate and pull out upper part of stop three notches.
5. Tighten screw -5- to 8 Nm (71 in. lb).
6. When installing, fasten stop -3- with rivet -6-. see scheme 24
7. When installing stop -2-, tighten screw -1- to 8 Nm (71 in. lb).
8. Adjust tailgate with lock bracket -4- in basic position. see scheme 25
9. Tighten nuts -3- to 21 Nm (15 ft lb).
10. Check gap dimensions. See groove diagram in «GAP DIMENSION FOR TAILGATE»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__gap-dimension-for-tailgate).
11. Install cover for lock bracket -2- and tighten nuts -1- to 5 Nm (44 in. lb).

Tailgate hinge, removing and installing

1. Disassemble rear roof trim. See «TRIM PANELS (AVANT)»(/audi/a6/c5-1997-2001/remont/exteriorinterior-trim/#interior-trim).
2. Remove screws -1- and remove cover -2- for hinge -3-. see scheme 26 Tightening torque: 3 Nm +0/-1 Nm (27 in. lb +0/-9 in. lb).

When installing, the cover must first be centered in the notches (arrow) up in the roof flange.

Scheme 24

1. Remove nut -4-. see scheme 27
2. Remove bolts -1- and hinge -2-.
3. Replace seal -3-.

Scheme 25

Tailgate seal, removing and installing

1. Open tailgate and remove seal.
2. When installing, first place seal at left and right in corners.
3. Press seal -1- onto body as shown.

Gap dimension for tailgate

Note. Gap dimensions can be checked using 3371 adjustment gauge.

Dim. -A- = 4 mm +1/-0 mm (0.157 in. +0.039/-0 in.)

Dim. -B- = 4 mm +1/-0 mm (0.157 in. +0.039/-0 in.)

Dim. -C- = 4 mm +1/-0 mm (0.157 in. +0.039/-0 in.)

Dim. -D- = 5 mm +1/-0 mm (0.197 in. +0.039/-0 in.)

Dim. -E- = 2.5 mm +/-0.1 mm (0.098 in. +/-0.004 in.)

Dim. -F- = 3.3 mm +/-0.1 mm (0.130 in. +/-0.004 in.)

Dim. -G- = 3 mm +/-0.2 mm (0.118 in. +/-0.008 in.)

Dim. -H- = 2.5 mm +/-0.4 mm (0.098 in. +/-0.016 in.)

Dim. -I- = 0 to 1 mm (0 in. to 0.039 in.)

Scheme 26

Tailgate lock and handle mechanism, removing and installing

The following list pertains to see scheme 30.

1. Tailgate lock NOTE: The tailgate lock consists of two locks (two stage). For installation to be correct, the tailgate lock must lock in the second stage (main lock). To remove, swing out hinge arm -2- from operating rod -4- and unhook from tailgate lock. Remove nuts -3- and remove tailgate lock.
2. Hinge arm After installing tailgate lock move operating rod over.
3. Nuts 8 Nm (71 in. lb)
4. Operating rod Adjust operating rod so that there is no tension or play For installation to be correct, tailgate lock must lock in second stage (main lock)
5. Nuts 8 Nm (71 in. lb)
6. Handle mechanism Removing: Remove tailgate trim. Unclip operating rod -4- from handle mechanism. Remove nuts -5- and remove handle mechanism.
7. Actuator element Removing, see «REAR LID LOCK ACTUATOR, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__rear-lid-lock-actuator-removing-and) .
8. Lock cylinder Removing: Remove handle mechanism. Remove operating rod. See «REAR LID LOCK ACTUATOR, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__rear-lid-lock-actuator-removing-and) . Remove lock cylinder from handle mechanism.

Tailgate lock actuator, removing and installing

The following list pertains to see scheme 31.

1. Release handle To remove, loosen lock and remove handle
2. Seal
3. Lock actuator Removing Tailgate trim removed Lock system removed Using screwdriver, press in and disengage locating hooks on left release handle -1- in direction of arrow -A-. Pull left release handle -1- downward and out of handle mechanism -4-. Remove Phillips-head screws -B- and lock actuator.
4. Handle mechanism Removing, see «REAR LID LOCK AND HANDLE MECHANISM, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#hood-lids__rear-lid-lock-and-handle-mechanism) .
5. Lock cylinder Sealant is sprayed on

See also:
• DRIVER'S STORAGE COMPARTMENT, REMOVING
• TAILGATE TRIM, REMOVING AND INSTALLING
• TRIM PANELS (AVANT)
• HOOD, FRONT
• REMOVING AND INSTALLING LOWER SECTION OF HOOD LOCK
• ADJUSTING HEIGHT OF STOP BUFFERS
• PANEL GAP DIMENSIONS
• HOOD LOCK CABLE, REMOVING AND INSTALLING
• REMOVING AND INSTALLING REAR LID HINGE
• REAR LID LOCK ACTUATOR, REMOVING AND INSTALLING
• REAR LID LOCK AND HANDLE MECHANISM, REMOVING AND INSTALLING
• GAP DIMENSION FOR TAILGATE