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Body Front Audi A8 D3

Exterior Body Panels 1 illustration ~807 words

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.

CAUTIONUse 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!

Frames for radiator and headlights, removing and installing

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

  1. Frame for headlights Can be removed individually Removing: Remove headlights. See «HEADLIGHT, REMOVING AND INSTALLING»(ref-196898-S14818487482005101000000) for up to m.y. 1999 and «HEADLIGHTS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/steering-column-switches/#lights-switches-exterior) for m.y. 2000 on. Remove hood lock cable and set aside. To remove left frame, unscrew power steering oil cooler from radiator Remove locking lever -7- for lock pin. Pull off stop buffer -11- and unscrew bolt -2
  2. Bolts (4x) 6 Nm (63 in. lb)
  3. Square nuts (4x)
  4. Nuts (6x) 24 Nm (18 ft lb) For securing impact absorber -5- to longmember
  5. Impact absorber (2x) To remove, remove bumper. See «FRONT BUMPER (UP TO M.Y. 1999)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) or «FRONT BUMPER (M.Y. 1999 AND UP)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Checking. See «IMPACT ABSORBERS, TESTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__impact-absorbers-testing) .
  6. Frame for radiator Removing: Remove noise insulation. See «NOISE INSULATION PANEL, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#body-front__noise-insulation-panel-removing-and-installing) . Remove bumper. See «FRONT BUMPER (UP TO M.Y. 1999)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) or «FRONT BUMPER (M.Y. 1999 AND UP)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Remove frame for headlights -1-. Drain coolant. See «DRAINING»(ref-196862-S00475110942005100900000) . Disconnect hoses and harness connectors at radiator. Remove radiator coolant fan. If present, remove condenser. Do not separate or open refrigerant lines If present, remove ATF cooler. Remove radiator. Remove impact absorber -5-. Installation is in reverse order of removal
  7. Locking lever (2x) For lock pin Disconnect hood lock cable from locking lever and guide clips. See «HOOD»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids) . Removing: Pry locking lever at bottom over headlight frame and pull out toward front. Remove locking lever by turning it toward engine side.
  8. Stud bolt 30 Nm (22 ft lb)
  9. Sleeve
  10. Sealing washer
  11. Stop buffer (2x)
  12. Socket-head bolt (2x) 14 Nm (10 ft lb)
  13. Attachment rail For fender
  14. Lock washer Always replace
  15. Nut 100 Nm (74 ft lb)
  16. Mount For towing eye
  17. Sleeve

Left and right supporting components, removing and installing

  1. Bumper removed. See «FRONT BUMPER (UP TO M.Y. 1999)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) or «FRONT BUMPER (M.Y. 1999 AND UP)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .

Note. For vehicles from 02.97 on, the brace -1- for support can be replaced separately. Tightening torque for screw -2-: 15 Nm (11 ft lb).

Removing left support component

  1. Loosen mounting points of ABS hydraulic unit. See «ANTI-LOCK BRAKE SYSTEM (ABS) BOSCH 5.0»(/audi/a8/d3-2002-2005/remont/anti-locktraction-control/#antilock-brake-system) or «ANTI-LOCK BRAKE SYSTEM (ABS) BOSCH 5.3»(/audi/a8/d3-2002-2005/remont/anti-locktraction-control/#antilock-brake-system).
  2. Loosen mounts for air conditioning receiver/drier. See «ACCUMULATOR, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/automatic-hvac-system/#air-conditioning).
  3. Remove bolts -1- and -3-. see scheme 3 Tightening torque: 23 Nm (17 ft lb)
  4. Remove nut -2-. Tightening torque: 23 Nm (17 ft lb)
  5. Remove left support -4-.

Removing right support component

  1. Remove windshield washer reservoir. See «WINDSHIELD WASHER FLUID RESERVOIR»(ref-150488-S19415401112002111400000) for up to m.y. 1999 and «WIPER FLUID RESERVOIR, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/wiperwasher-systems/#windshield-wiper-and-washer-system__wiper-fluid-reservoir-removing-and-installing) for m.y. 2000 on.
  2. Remove combination bolts -6- and -7-. see scheme 3 Tightening torque: 23 Nm (17 ft lb)
  3. Remove nut -8-. Tightening torque: 23 Nm (17 ft lb)
  4. Remove left support -5-.

Special tools and equipment

3371 adjustment gauge

Scheme 1

Scheme 1: Special tools and equipment
Scheme 1: Special tools and equipment

Removing

  1. Remove bumper. See «FRONT BUMPER (UP TO M.Y. 1999)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) or «FRONT BUMPER (M.Y. 1999 AND UP)»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper).
  2. Remove wheelhousing liner. See «WHEELHOUSING LINER»(/audi/a8/d3-2002-2005/remont/mirrors/#exterior-equipment).
  3. Remove front turn signal. See «TURN SIGNAL LIGHTS, REMOVING AND INSTALLING»(ref-196898-S36669318312005101000000).
  4. Remove side turn signal. See «SIDE TURN SIGNAL LIGHTS»(/audi/a8/d3-2002-2005/remont/steering-column-switches/#lights-switches-exterior__side-turn-signal-lights).
  5. Remove bolts -1-, -4- and -5-. see scheme 5 Tightening torque: 9.5 Nm (84 in. lb)
  6. Remove combination bolt -3- at retaining plate -2-. Tightening torque: 9.5 Nm (84 in. lb)
  7. Remove fender -6-.

Installing

Installation is the reverse of removal, noting the following

  1. Adjust panel gap dimensions. Dimension -a- = 3.5 mm Dimension -b- = 3.5 mm
  2. Before installing wheelhousing liner, insert filler piece in fender.

Noise insulation panel, removing and installing

Note. The following list refers to see scheme 7.

  1. Noise insulation panel, front Removing: Remove quick-release screw -2-. Pull noise insulation panel slightly downward and remove toward back. When installing, push noise insulation over bumper -6- into bracket, as shown in bubble.
  2. Quick-release screws (6x)
  3. Washers (6x)
  4. Lock washers (6x)
  5. Speed nut
  6. Front bumper

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