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Hood Lids Audi A8 D3

Exterior Body Panels 6 illustrations ~1528 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!

Hood, lock pin and catch release

Note. The following list refers to (Scheme 2).

  1. Hood hinge
  2. Bolts (2x)
  3. Bolts (2x) 21 Nm (15 ft lb)
  4. Washers (2x)
  5. Hex nuts (2x) 21 Nm (15 ft lb)
  6. Gas-filled strut Proper disposal of gas-filled strut. See «PROPER DISPOSAL OF GAS-FILLED STRUT»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__proper-disposal-of-gas-filled-strut) . Removing: Open hood -9- and support. Pry off securing spring -8- using screw driver. Remove gas-filled strut.
  7. Nipple 10 Nm (7 ft lb) To remove, first remove gas-filled strut -6
  8. Securing springs (2x)
  9. Hood Different for left hand drive and right hand drive vehicles Removing: Prop up and secure hood in open position. Disconnect harness connectors. Remove gas-filled strut -6- at hood. Remove bolt -2- and take off hood. Adjusting: Height adjustment of rear portion is achieved via bolts -2- Height adjustment of front portion is achieved via lock pin -12- Horizontal and front/back adjustment is achieved via bolts -3- Adjusting. See «HOOD, ADJUSTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__hood-adjusting) .
  10. Catch
  11. Combination bolts (5x) 8 Nm (71 in. lb)
  12. Lock pin Adjusting Adjust castle nut -15- so that lock pin moves easily. Use screwdriver to adjust approximate depth of lock pin. Check hood cable adjustment. See «HOOD LOCK CABLE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__hood-lock-cable-removing-and-installing) . Close hood carefully. Hood height must match fender height. If not, adjust lock pin as needed Open hood, adjust lock pin and tighten castle nut -14
  13. Guide bushing
  14. Compression spring
  15. Castle nut 10 Nm (7 ft lb)
  16. Washer

Proper disposal of gas-filled strut

  1. Clamp gas-filled strut in vice in area -x-. Dimension -x- = 50 mm (2 in.) CAUTION: The gas-filled strut must be clamped only in designated area -x-, otherwise there is the danger of an accident!
  2. Using saw, cut into cylindrical part of strut at point within first third of cylinder's length (measured from cover edge at 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.

Hood, adjusting

Special tools and equipment

3371 adjustment gauge

Scheme 2

Scheme 2: Hood, adjusting
Scheme 2: Hood, adjusting
  1. Adjust gaps at left and right-front of hood to same dimensions.

Dimension -a- = 3.5 mm

Scheme 3

Scheme 3
Scheme 3

Radiator grill, removing and installing

  1. Turn twist locks -4- 180° (1/2 turn).
  2. Remove radiator grill -2-. NOTE: Guide plates -3- are installed into hood -1-.

Hood lock cable, removing and installing

Note. The following list refers to (Scheme 7).

  1. Hood lock cable Removing: Remove storage compartment on driver's side. See «STORAGE/COVERS»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-equipment) . Remove bolts -3-. Remove clamping nipple -6-. Unclip cable from clip -4-, pull through bulkhead, unclip from actuating mechanism -2- and remove. Adjusting: Install cable without putting tension on locking lever -7- and secure cable tightly with clamping nipple -6-.
  2. Operating mechanism
  3. Bolts (2x) 55 Nm (41 ft lb)
  4. Clips (2x)
  5. Guide sleeve
  6. Clamping nipple Route cable behind clamping nipple
  7. Locking lever For lock pin Removing. See item 7 in «FRAMES FOR RADIATOR AND HEADLIGHTS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#body-front__frames-for-radiator-and-headlights-removing) .

Rear lid, removing and installing

Note. The following list refers to see scheme 7.

  1. Stopper Adjusting. See «ADJUSTING STOPPER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__adjusting-stopper) .
  2. Bolt 21 Nm (15 ft lb)
  3. Hollow rivet
  4. Bolts (3x) 21 Nm (15 ft lb)
  5. Cable guide Different versions on left and right-sides
  6. Hex nuts (2x) 21 Nm (15 ft lb)
  7. Hood hinge
  8. Stop
  9. Gas-filled strut Pry off rear lid hinge Proper disposal. See «PROPER DISPOSAL OF GAS-FILLED STRUT»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids) .
  10. Lock Adjusting. See «ADJUSTING LOCK FOR REAR LID»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__adjusting-lock-for-rear-lid) .
  11. Hex nuts (2x) 6 Nm (53 in. lb)
  12. Hinged clip
  13. Operating rod
  14. Locking cylinder Removing and installing. See «REAR LID LOCK CYLINDER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__rear-lid-lock-cylinder-removing-and) . Disassembling. See «LOCK CYLINDER, DISASSEMBLING AND ASSEMBLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids) .
  15. Nut (2x) Always replace 4 Nm (35 in. lb) Self-locking
  16. Operating rod
  17. Bolt 6 Nm (53 in. lb)
  18. Stopper
  19. Rear lid Removing: Prop up and secure hood in open position. Remove rear lid trim. See «REAR LID TRIM, REMOVING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim__rear-lid-trim-removing) . Disconnect harness connector and pull cable harness out of rear lid. Pry both gas-filled struts -9- from respective rear lid hinges -7- Remove hex nuts -6- on both sides. Remove rear lid. Adjusting: Height adjustment of front portion is achieved via combination bolts -4-. Height adjustment of rear portion is achieved by shifting striker -21-. Loosen hex nut -6- for front/back adjustment. Adjusting. See «REAR LID, ADJUSTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__rear-lid-adjusting) .
  20. Screw 6 Nm (53 in. lb)
  21. Striker
  1. Clamp gas-filled strut in vice in area -x-. Dimension -x- = 50 mm (2 in.) CAUTION: The gas-filled strut must be clamped only in designated area -x-, otherwise there is the danger of an accident!
  2. Using saw, cut into cylindrical part of strut at point within first third of cylinder's length (measured from cover edge at 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.

Adjusting stopper

With rear lid closed, stopper -1- must rest against mating piece -2- with light pressure.

Note. The stop buffers cannot be used for adjusting the height of the rear lid -4-.

Scheme 4

Scheme 4: Adjusting stopper
Scheme 4: Adjusting stopper

Adjusting lock for rear lid

  1. Engage rear lid lock -1-.
  2. Secure lock in place with assembly drift -4- (e.g. 6 mm diameter drill bit).
  3. Attach operating rod -3- at lock cylinder and at rear lid lock so there is no tension.
  4. Install threaded coupling -2-.
  5. Remove drift -4- from lock.
  6. Release (open) lock -1-.

Free play (lengthwise) between lock and lock cylinder: max. 2 mm (5/64 in.)

Rear lid, adjusting

Special tools and equipment

3371 adjustment gauge

Scheme 5

Scheme 5: Rear lid, adjusting
Scheme 5: Rear lid, adjusting
  1. Adjust gaps at left and right of rear lid to same dimensions.

Dimension -a- = 3.5 mm

Scheme 6

Scheme 6
Scheme 6

Rear lid lock cylinder, removing and installing

Note. The following list refers to see scheme 13.

  1. Housing For lock cylinder
  2. Clip
  3. Coupling piece Assembling. See «ASSEMBLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__assembling) .
  4. Torsion spring Installing. See «ASSEMBLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__assembling) .
  5. Follower Installing. See «ASSEMBLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__assembling) .
  6. Circlip
  7. Clip
  8. Ball (2x) Both balls must be greased before installing When installing, make sure that balls do not drop out of holes
  9. Guide cap Guide cap cannot be removed without being destroyed
  10. Roller (2x) Assembling. See «ASSEMBLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__assembling) .
  11. Lock cylinder Removing: Remove cover of right-side light in rear lid. Press securing clip to side at operating rod for lock opening and for central locking actuator and remove operating rod. Loosen nuts at housing for lock cylinder. Pull housing for lock cylinder toward interior and out of light. Disassembling. See «DISASSEMBLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids) .
  12. Key

Scheme 7

Scheme 7: Disassembling
Scheme 7: Disassembling
  1. Insert key into lock cylinder.
  2. Press follower -1- toward lock and pry off circlip.
  3. Remove follower and then torsion spring.
  4. Pull coupling piece -3- from lock cylinder. See «REAR LID LOCK CYLINDER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids__rear-lid-lock-cylinder-removing-and) . NOTE: When coupling piece is removed rollers -10- should fall out. See «LOCK CYLINDER, DISASSEMBLING AND ASSEMBLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#hood-lids) .
  5. Pull lock cylinder out of housing.

Assembling

  1. Key inserted in lock cylinder
  1. Hold lock cylinder -1- so groove -2- faces technician.
  2. After greasing with G 000 400, slide compression spring -6- into lock cylinder.
  3. After greasing with G 000 400, place roller -3- into underside of lock cylinder.
  4. Install lock cylinder -1- vertically from below into housing -5-. NOTE: When installing the lock cylinder -1- in the housing -5-, make sure that both rollers -3- do not drop out of the guides during assembly. Align slot -2- and guide lug -4- during assembly.
  5. Press lock cylinder with key completely into lock cylinder housing against spring pressure.
  6. Place coupling piece -1- onto lock cylinder. NOTE: The coupling piece must be placed so that the two guide pins (arrows) for torsion spring are aligned.
  7. Turn key to left to stop and keep lock cylinder and key pushed into lock cylinder housing against spring pressure.
  8. Place upper roller in newly opened space.
  9. Using small screwdriver, push roller into lock cylinder while shifting coupling piece up until impact.
  10. Install torsion spring -1- so spring ends (arrows) lie on left and right of guide pins.
  11. Install follower -1- in position -A- or -B-: Position -A-: open Position -B-: closed Follower Lock cylinder housing
  12. Attach circlip.

Rear lid seal, removing and installing

  1. Butt joint -A- of rear lid seal -1- must be aligned with the ball stud of left hinge.
  2. Press seal on. NOTE: Seal is vulcanized in area of butt joint.

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