Front Doors, Central Locking System — Audi A8 D3 (2002-2005)

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, 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.

Use only Genuine Parts!

If there is any doubt about whether the old parts are suitable for re-use, always install new replacement parts.

CAUTION

Use only genuine Audi A8 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!

Door shell and door component carrier, removing and installing

Front door trim removed See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) .

Note. The following list refers to (Scheme 1).

Hex bolt 30 Nm (22 ft lb) Note tightening sequence
Door shell Removing: Disconnect harness connectors. Disconnect line for central locking system and unclip. Upper and lower hinges for door shell. See «UPPER DOOR HINGE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__upper-door-hinge) and «LOWER DOOR HINGE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__lower-door-hinge) . Adjusting. See «FRONT DOOR, ADJUSTING (SEQUENCE OF OPERATIONS)»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system) . Removing and installing side impact bar. See «REMOVING AND INSTALLING SIDE IMPACT BAR»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-side-impact-bar) .
Door component carrier Removing: Unclip Bowden cable for interior door mechanism. Disconnect harness connector for window regulator motor. Remove hex bolt -1- and -5- and lift out door component carrier. Installing: Place door component carrier into door shell and loosely secure shorter hex bolts -1- and -5- at top. Insert adjusting plate -4- and tighten longer hex bolts -1- and -5- at bottom. Tighten hex bolts -1- and -5- in sequence a, b, c, d. Adjusting. See «II - DOOR COMPONENT CARRIER, ADJUSTING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__ii-door-component-carrier-adjusting) .
Adjusting plate Must always be installed To adjust tilt of door around B-pillar, shift adjusting plate. See «II - DOOR COMPONENT CARRIER, ADJUSTING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__ii-door-component-carrier-adjusting) .
Hex bolt 30 Nm (22 ft lb) Note tightening sequence

Upper door hinge

1 - Tightening torque: 30 Nm (22 ft lb)
3 - Tightening torque: 30 Nm (22 ft lb)

Lower door hinge

2 - Tightening torque: 30 Nm (22 ft lb)
3 - Tightening torque: 30 Nm (22 ft lb)

Scheme 1

Note. Grease points (arrows). See GREASING POINTS FOR LOWER DOOR HINGE .

Greasing points for lower door hinge

Grease door check only at illustrated greasing points (arrows). Grease: G 000 150

Removing and installing side impact bar

Pry off cover -2-.
Remove hex bolts -1- (3x) and remove side impact bar -4-.

Note. Top part -3- and bottom part -4- are caulked to each other and must not be separated. Butyl cord -5- must always be installed; replace if necessary.

Front window, removing and installing

Front door trim removed See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) .

Note. The following list refers to see scheme 6.

Bolt 2 Nm (18 in. lb)
Washer
Front window Removing and installing. See «REMOVING AND INSTALLING FRONT WINDOW»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-front-window) . Adjusting. See «ADJUSTING WINDOW»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjusting-window) .
Centering sleeve
Guide pin Removing and installing. See «REMOVING AND INSTALLING GUIDE PIN»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-guide-pin) .
Cap
Door component carrier Removing and installing. See item 3 in «DOOR SHELL AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-shell-and-door-component-carrier) .
Buffer plugs After installing window glass into guide of door component carrier
Locking plate
Backing plate
Damper washer

Removing and installing front window

Lightly pry locking plate -1- using small screwdriver and slide out of groove on guide pin -4-.
Remove backing plate -2-.
Lightly pry door window glass from guide pin and remove from vehicle downward. NOTE: Guide pin will simultaneously push buffer plugs out of door window guide.
Remove damper washer -3-.
When installing, align slot in door window so that it is centered relative to guide pin -4-. Pay attention to contact area on roof frame and at A-pillar. NOTE: The buffer plug helps seal window and minimize noise. It must be reinserted in the door window guide at the B-pillar after installing the door window.

Adjusting window

Adjust upper impact of window regulator -1- via external Torx(R) E6 (arrow).
Adjust door window upper edge to interior seal lip. See «ADJUSTING WINDOW»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system) . B- Area of door window at interior seal lip

Adjust door window -2- with door closed.
Adjust upper impact of window regulator so interior seal lip presses against door window seal -1- at upper window edge with pressure in entire area -B-. See «ADJUSTING WINDOW»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjusting-window) . Dimension - a- = at least 1.0 mm If door window is adjusted too high, greater force is required to shut door. NOTE: A good seal is only guaranteed if the seal presses against the door window with at least 1.0 mm preload.

Removing and installing guide pin

Remove window. See «REMOVING AND INSTALLING FRONT WINDOW»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-front-window) .
Drill bolt -1- in center using 5 mm diameter drill bit until guide pin -5- falls out.
Coat threads of new bolt with fluid securing material D 185 400 A2.
Bolt new guide pin to centering sleeve -4-, door window -3-, and washer -2-. Tightening torque: 2 Nm (18 in. lb)
Attach cap -6-.

Front window regulator, removing and installing

Front door trim removed See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) .

Note. The following list refers to see scheme 11.

Front window regulator To remove, drill off rivet heads -2- and knock out rivet shafts Securely rivet window at point designated by arrow first
Pop rivet (6x) To avoid contact corrosion, use only genuine Audi rivets
Door component carrier Removing and installing. See item 3 in «DOOR SHELL AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-shell-and-door-component-carrier) .
Window regulator motor After installing, run window up until impact. Activate all power window switches ("up") for at least one second to activate automatic window raising/lowering.
Bolts (3x) 10 Nm (7 ft lb)
Clip Engage window regulator -1- in clip and close clip (arrow)
Guide pin
Damper washer
Backing plate
Locking plate

Front door lock with operating components, removing and installing

Front door trim removed See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) .
Door component carrier removed. See item 3 in «DOOR SHELL AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-shell-and-door-component-carrier) .

Note. The following list refers to see scheme 12.

Locking rod Unclip at locking mechanism
Lock cylinder locking rod Installing. See «INSTALLING LOCK CYLINDER LOCKING ROD»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__installing-lock-cylinder-locking-rod) .
External end plate Removing lock cylinder. See item 11 in «FRONT DOOR HANDLE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__front-door-handle-removing-and-installing) .
Door handle Removing and installing. See item 2 in «FRONT DOOR HANDLE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__front-door-handle-removing-and-installing) .
Bolt 5 Nm (44 ft lb)
Rotating clamp To remove, swivel toward rear of car.
Lock operating rod Installing. See «INSTALLING LOCK CYLINDER LOCKING ROD»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__installing-lock-cylinder-locking-rod) .
Operating clip (2x) Disengage lock operating rod by sliding sleeve down
Door lock Removing: Disengage locking rod, lock operating rod and lock cylinder locking rod. Unscrew combination bolt -11-. Pull hose line from actuator for central locking system. Unclip Bowden cable for interior door mechanism. See «REMOVING AND INSTALLING BOWDEN CABLE FOR INSIDE DOOR MECHANISM»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-bowden-cable-for) .
Bowden cable for interior door mechanism Removing and installing. See «REMOVING AND INSTALLING BOWDEN CABLE FOR INSIDE DOOR MECHANISM»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-bowden-cable-for) .
Combination bolts (2x) 8 Nm (71 in. lb)
Intermediate plate for lock
Bolts (2x) 16 Nm (12 ft lb)
Striker Adjusting. See «ADJUSTING DOOR AT STRIKER PLATE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjusting-door-at-striker-plate) .

Installing lock cylinder locking rod

Snap hinged clip -2- into activation lever -1-.
Insert lock cylinder locking rod -3- into hinged clip and snap into place.
Swivel operating clip -4- 1/4 turn (90°), insert into lock activation lever -5- and swivel back toward top.
Clip lock cylinder locking rod into operating clip free of play without putting tension on door lock activation lever. Max. play: 1 mm
Slide sleeve up onto operating clip.

Removing and installing Bowden cable for inside door mechanism

Disengage hook -3- from activation lever -4-.
Turn end piece of Bowden cable 1/4 turn (90°) (tab -2- unclips) and pull out bottom of bracket -1-.
Note engagement direction of Bowden cable when installing.

Front door handle, removing and installing

Front door trim removed See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) .
Door component carrier removed. See «DOOR SHELL AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-shell-and-door-component-carrier) .

Note. The following list refers to see scheme 15.

Rotating clamp To remove, swivel toward rear of car.
Door handle Removing: Remove face plate for door handle to avoid paint damage. See «REMOVING TRIM PANEL FOR DOOR HANDLE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-trim-panel-for-door-handle) . Remove rotating clamp -1- and unscrew combination bolt -3-.
Bolt 5 Nm (44 in. lb)
Circlip For external profile keys Clip: for internal profile keys
Coupling plate Installation position. See «INSTALLED POSITION OF COUPLING PLATE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__installed-position-of-coupling-plate) . For internal profile keys, do not replace individually
Spring Not individually replaceable Installation position. See «INSTALLED POSITION OF SPRING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__installed-position-of-spring) .
Housing To remove, disassemble door handle -2- and lock cylinder -11
Base plate
Face plate
Seal
Lock cylinder For internal profile keys, do not replace individually Only remove with key inserted Pry circlip -4- from groove of lock cylinder. Pull out coupling plate -5- together with spring -6-. Pull out lock cylinder using key.

Installed position of spring

Ends of spring must lie to left and right of operating lever when stretched.
Operating lever and lock cylinder are always returned to intermediate position by preload.

Removing trim panel for door handle

Lift door handle.
Pry mounting unit off door handle using small screwdriver in direction of arrow and remove.
Remove face plate for door handle.

Installed position of coupling plate

In order for the central locking system and the anti-theft device to work properly, the partially closed groove on the coupling plate must align with the half tooth on the microswitch wheel.

Scheme 2

Scheme 2: Installed position of coupling plate

Door lock, removing and installing

Note. The following list refers to see scheme 19.

Bolts (2x) Tightening torque: 9.5 Nm
Door handle Removing and installing. See «DOOR HANDLE, REMOVING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-handle-removing) .
Door lock Removing: Remove door trim. See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) . Remove door component carrier. Remove cover for door lock. See «DOOR LOCK COVER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-lock-cover-removing-and-installing) . Unclip securing rod and operating rod. See «REMOVING AND INSTALLING SECURING ROD FOR LOCK CYLINDER»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-securing-rod-for) . Detach connection hose from actuator for central locking. Remove bolts -1- Remove door lock and intermediate plate for lock -2-. Installing: Install in reverse order of removal.
Clip Installing. See «REMOVING AND INSTALLING SECURING ROD FOR LOCK CYLINDER»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-securing-rod-for) .
Bowden cable for interior door mechanism Removing: Remove door component carrier. Remove cover for door lock. See «DOOR LOCK COVER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-lock-cover-removing-and-installing) . Unhook Bowden cable (Bowden cable shown in magnified area is unhooked), unclip downward and disengage from door lock. Installing: Install in reverse order of removal.
Intermediate plate for lock

Door lock cover, removing and installing

Note. The following list refers to see scheme 20.

Securing rod-lock cylinder Clip into socket at release lever
Door handle Removing and installing. See «DOOR HANDLE, REMOVING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-handle-removing) .
Operating rod-door lock Adjustment depth for securing rod in operating clip. See «ADJUSTMENT DEPTH FOR SECURING ROD»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjustment-depth-for-securing-rod) .
Cover for door lock To remove, unclip at top first, then pull bottom toward rear of door lock.
Installing pin Only installed for new parts; helps keep secure. Do not remove door lock until successfully installing operating rod.
Operating clip Engage in door lock. See «REMOVING AND INSTALLING SECURING ROD FOR LOCK CYLINDER»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-securing-rod-for) .

Front door lock operating rods, removing and installing

Note. The following list refers to see scheme 21.

Securing rod-lock cylinder Installing. See «REMOVING AND INSTALLING SECURING ROD FOR LOCK CYLINDER»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-securing-rod-for) .
Door lock
Door handle When removing door handle, securing rod -1- and operating rod -5- must be disengaged at door handle
Operating rod To remove, unclip at door lock
Operating clip Installing. See «REMOVING AND INSTALLING SECURING ROD FOR LOCK CYLINDER»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-securing-rod-for) .

Removing and installing securing rod for lock cylinder

Insert securing rod -2- for lock cylinder into socket at release lever -1- and snap into place.
Tilt operating clip -3-90° (not shown), insert into door lock release lever -4- and tilt back upward.
Clip securing rod -2- into operating clip -3-.
Do not bend locking lever -4- at door lock -5- (Maximum play at locking lever 1 mm. See «ADJUSTING LOCKING LEVER PLAY»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjusting-locking-lever-play) .)
Slide up casing on operating clip -3-.

Adjusting locking lever play

Insert securing rod -1- into operating clip -2- so that dimension -a- at the locking lever -4- is approx. 1mm.
During this, dimension -a- = 13mm (adjustment depth for securing rod) must be maintained. See «ADJUSTMENT DEPTH FOR SECURING ROD»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__adjustment-depth-for-securing-rod) .

Adjustment depth for securing rod

Dimension -a- of securing rod -1- must be 13mm "3mm when properly adjusted.
After adjusting correctly, slide casing -2- from operating clip -3- upward.

Door handle, assembly overview

Note. The following list refers to see scheme 25.

Door handle Remove door trim. See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) . Door component carrier removed Removing. See «DOOR HANDLE, REMOVING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-handle-removing) .
Locating pin When installing, be sure securing spring reaches completely around hinge arm.
Front doors
Seal for door handle Removing and installing. See «REMOVING AND INSTALLING SEAL FOR DOOR HANDLE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-seal-for-door) .
Mount for door handle Disengaging. See «DISENGAGING MOUNT FOR DOOR HANDLE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__disengaging-mount-for-door-handle) .
Harness connector Only vehicles with anti-theft warning system
Cover for door lock To remove, unclip at top first, then pull bottom toward rear of door lock
Operating rod Before removing door handle, disengage at clip -9-.
Operating clip Installing. See «REMOVING AND INSTALLING SECURING ROD FOR LOCK CYLINDER»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-securing-rod-for) .
Securing rod-lock cylinder Installing. See «REMOVING AND INSTALLING SECURING ROD FOR LOCK CYLINDER»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-securing-rod-for) .
Micro switch Only vehicles with anti-theft warning system. Removing and installing. See «REMOVING AND INSTALLING MICROSWITCH»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-microswitch) .
Hinge arm

Removing and installing microswitch

Mount for door handle -1- removed.
Carefully release locking tabs (arrows) and remove microswitch -3- upward.
Press back locking mechanism (arrow B) and slide harness connector up and out of mount.
Pull connecting cable out of seal -2
When installing, be sure to press cable completely into seal as shown.

Removing and installing seal for door handle

To remove seal, unclip and remove.
When installing, seal must be engaged completely in mount (arrows) (otherwise it won't seal!).

Door handle, removing

Note. The following list refers to see scheme 28.

Mount for door handle The lock cylinder is part of the mount and cannot be individually replaced
Locating pin When installing, be sure securing spring reaches completely around hinge arm
Hinge arm
Door handle Before removing, remove door trim and door component carrier To remove, remove locating pin -2- and flip up hinge arm -3-. Disengage slide at mount for door handle -1- using a screwdriver. See «DISENGAGING MOUNT FOR DOOR HANDLE»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__disengaging-mount-for-door-handle) . Remove mount for door handle and lock cylinder together with door handle.

Disengaging mount for door handle

Using a small screwdriver, disengage retainer for slide (arrow - A-) by lifting lightly.
Disengage slide -1- in direction of arrow -C- by pressing a screwdriver in direction of arrow -B-.

Removing trim

To remove, lift up door handle -2-, push locking mechanism -1- out in lengthwise direction using small screwdriver, and remove trim -3-.

Front door handle, preassembly

Note. Replacement door handles must be painted and preassembled before installing.

Note. The following list refers to see scheme 31.

Door handle When installing, insert springs -4- in mount For preassembly, insert door handle in mount -3- and slide on hinge arm -8- Slide in pivot pins -5- and -6- and peen with center punch as shown. See «PEENING PIVOT PIN»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__peening-pivot-pin) . Engage spring -4- as shown. See «CORRECT INSTALLATION POSITION OF SPRING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__correct-installation-position-of-spring) .
Buffer Insert after painting
Mount for door handle
Spring Installation position. See «CORRECT INSTALLATION POSITION OF SPRING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__correct-installation-position-of-spring) . Grease spring using G052 745 A3
Pivot pin Note varying lengths Installation position. See «PEENING PIVOT PIN»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__peening-pivot-pin) .
Pivot pin Note varying lengths Peening. See «PEENING PIVOT PIN»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__peening-pivot-pin) .
Clip
Hinge arm
Securing pin Assembly. See «INSTALLING LOCKING PINS»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__installing-locking-pins) .

Peening pivot pin

Note. Before peening the pivot pin, protect painted surfaces using a fabric-backed adhesive tape.

Support pre-assembled door handle on a solid surface (e.g. jaws of a vice).
Secure pivot pins against falling by creating a light center punch mark.
After peening pivot pins, check hinge arm for freedom of movement.

Correct installation position of spring

Install springs -1- as shown.
Grease with G 052 745 A3.
Pivot pin -2-.

Installing locking pins

Press in locking pin completely using auxiliary tool (self-made).
Spring clip on locking pin (arrow -B-) must fully lock home behind hinge arm.
Peened pivot pin (arrow -A-)

I - Door shell, adjusting

Front door trim removed See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim) .

Special tools and equipment

3371 adjustment gauge

Scheme 3

Note. Rear door shell must be adjusted first. See I - DOOR SHELL, ADJUSTING .

Dimension -a- = 3.5 - 0.5 mm
Dimension -b- = 4.5 - 0.5 mm
Dimension -c- = 3.5 - 0.5 mm

Loosen nuts at hinge -2- and shift door together with hinge (elongated holes in hinge)
Loosen bolts at hinge -2- insert base plate -3-. Tightening torque: 30 Nm (22 ft lb)

Loosen nuts at hinge -2- and shift door together with hinge (elongated holes in hinge)
Loosen bolts at hinge -2- insert base plate -3-. Tightening torque: 30 Nm (22 ft lb)

2. Adjusting to body contour

Note. Front portion of door is adjusted at hinge; rear portion of door is adjusted by moving striker.

Loosen nuts at hinge -2- and shift door (elongated holes in hinge). Tightening torque: 30 Nm (22 ft lb)

Loosen nuts at hinge -2- and shift door (elongated holes in hinge). Tightening torque: 30 Nm (22 ft lb)

Adjusting door at striker plate

Loosen Torx(R) bolts.
Shift striker until door shell is flush with body.
Tighten Torx(R) bolts to 16 Nm (12 ft lb).

II - Door component carrier, adjusting

Note. To adjust the tilt of the door around the B-pillar, shift the adjusting plate. If the rear portion of the door (e.g. at the bottom) sticks out too much, the adjusting plate must be shifted upward. This will tilt the bottom of the door toward the car interior, and the top of the door outward.

Door shell adjusted. See «I - DOOR SHELL, ADJUSTING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__i-door-shell-adjusting) .
Adjusting plate -4- installed

Loosen screws -3- (arrows). see scheme 42
Close door.
While second technician pushes door component carrier against roof and B-pillar (carrier must be pushed slightly beyond desired position due to return force of rubber seal), lightly tighten upper screws from inside.
Push adjustment plate -4- upward until it contacts surface of door shell -2- and door component carrier -1-. Tightening torque: 30 Nm (22 ft lb)

Reference size for door components carrier

Outer seal lip -3- must be flush with pillar and roof trim molding -2-.
Dimension a = 2.5 +/- 1 mm and is the gap between the roof trim molding and the door window glass -3-.

Note. After the car has been parked for a lengthy time and/or after replacing the central locking system pump, the central locking system must be operated several times before it will function properly. When the system is operating correctly, all locks will close within approx. 2 seconds. If the pump operates for longer than 5 seconds there is a leak in the system. When there is a leak in the system, the pump must not run for more than 30 seconds, after which the control module in the central locking system pump must switch off the pump. All the lock actuators, as well as front and rear distributors, are equipped with vacuum line connectors that lock when connected.

Central locking system, assembly overview

Note. The following list refers to see scheme 44.

Vacuum line
Left and right-front door actuator Removing and installing. See «REMOVING AND INSTALLING FRONT DOOR LOCK ACTUATOR»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-front-door-lock) . Disengaging Bowden cable for interior door mechanism. See «REMOVING AND INSTALLING BOWDEN CABLE FOR INSIDE DOOR MECHANISM»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-bowden-cable-for) .
Left and right-rear door actuator Removing and installing. See «REMOVING AND INSTALLING LOCK ACTUATOR FOR REAR DOOR»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-lock-actuator-for) . Disengaging Bowden cable for interior door mechanism. See «REMOVING AND INSTALLING BOWDEN CABLE FOR INSIDE DOOR MECHANISM»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-bowden-cable-for) .
Fuel filler flap lock actuator Removing and installing. See «REMOVING AND INSTALLING FUEL FILLER FLAP LOCK ACTUATOR»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-fuel-filler-flap) .
Rear lid lock actuator Removing and installing. See «REMOVING AND INSTALLING REAR LID LOCK ACTUATOR»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-rear-lid-lock) . Vacuum line routing. See «VACUUM LINE ROUTING IN REAR LID»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__vacuum-line-routing-in-rear-lid) .
Pump for central locking system Removing and installing. See «REMOVING AND INSTALLING PUMP FOR CENTRAL LOCKING SYSTEM»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-pump-for-central) .
Rear distribution box Securely attached to vacuum lines, with exception of rear lid line Allows for disconnection of vacuum line connector to rear lid. See «DISCONNECTING VACUUM LINES»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__disconnecting-vacuum-lines) .
Front distribution box Securely attached to vacuum lines, with exception of rear distribution box Allows for disconnection of vacuum line connector to rear lid. See «DISCONNECTING VACUUM LINES»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__disconnecting-vacuum-lines) .

Disconnecting vacuum lines

Note. Vacuum lines -1- are secured at actuators -2- and at distribution box via locking mechanisms.

To release locking mechanism, press on vacuum line connector at arrows.
Disconnect vacuum line connector.

Removing and installing front door lock actuator

Remove front door trim. See «FRONT DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim).
Remove door component carrier. See «DOOR SHELL AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__door-shell-and-door-component-carrier).
Disconnect locking rod -1-. see scheme 46
Unclip lock operating rod -5-.
Unclip locking rod of lock cylinder -4-.
Remove bolts from door lock -6-. see scheme 46 Tightening torque: 8 Nm (71 in. lb)
Disconnect vacuum line -2- from actuator -3-. See «DISCONNECTING VACUUM LINES»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__disconnecting-vacuum-lines).
Disconnect harness connector -7-. see scheme 46
Disconnect Bowden cable for interior door mechanism -8-. See «REMOVING AND INSTALLING BOWDEN CABLE FOR INSIDE DOOR MECHANISM»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-bowden-cable-for).

Removing and installing lock actuator for rear door

Remove rear door trim. See «REAR DOOR TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim).
Remove door component carrier. See «DOOR SHELL AND DOOR COMPONENT CARRIER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#rear-doors__door-shell-and-door-component-carrier).
Unclip lock operating rod -5- and disengage. See «INSTALLING LOCK CYLINDER LOCKING ROD»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__installing-lock-cylinder-locking-rod).
Unclip Bowden cable -2-. see scheme 47
Remove bolts from door lock -6-. Tightening torque: 8 Nm (71 in. lb)
Release vacuum line connector for pressurized line -4- and pull off of actuator -3-. see scheme 47 See «DISCONNECTING VACUUM LINES»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__disconnecting-vacuum-lines).
Disengaging Bowden cable for interior door mechanism -1-. See «REMOVING AND INSTALLING BOWDEN CABLE FOR INSIDE DOOR MECHANISM»(/audi/a8/d3-2002-2005/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system__removing-and-installing-bowden-cable-for).

Removing and installing fuel filler flap lock actuator

Remove trunk trim. See «LUGGAGE COMPARTMENT TRIM, REMOVING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim__luggage-compartment-trim-removing) .
Pull actuator -2- out of bracket toward rear by pressing on catch (arrow).

Removing and installing rear lid lock actuator

Remove rear lid trim. See «REAR LID TRIM, REMOVING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim__rear-lid-trim-removing).
Unclip operating rod from clip -4-. see scheme 49
Remove bolts -6- Tightening torque: 2 Nm (8 in. lb)
Disconnect hose from actuator.

Vacuum line routing in rear lid

Clip central locking system vacuum line -1- into bracket -2-.

Removing and installing pump for central locking system

Note. The pump for central locking is located in the trunk at left behind trunk trim.

Remove rear lid trim at left-rear. See «REAR LID TRIM, REMOVING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim__rear-lid-trim-removing).
Bend tabs (arrow) down and remove pump for central locking -3- toward rear out of bracket -7-. see scheme 51
Open noise insulation components -1- and -4- and remove pump.
Remove vacuum line -2- at pump.
To disconnect bracket -7-, remove bolts -5-.

Note. After installing the pump for central locking, tabs (arrow) must always be bent up again.

Front Doors, Central Locking System Audi A8 D3