Body_Repairs_General_Information

Service
General InformationBody Repair,

Body Collision Repair
Edition 05.2007
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
Repair Group
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2008 Audi AG, Ingolstadt D3E8008F902

General InformationBody Repair, Body Collision Repair - Edition 05.2007
Contents
1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Removing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Battery, Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Electronic Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Paint, Glass, Upholstery, Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Fuel Tank or Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Airbag System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.8 Seat Belts, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.9 Working on Vehicles with Belt Tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.10 Separating Work, Straightening Work and/or Dent Removal on Vehicles with Airbags . . . . 4
1.11 Seats with Side Airbags, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Diagnosis of Vehicles in Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 General Information about Body Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Conditions in which Body and/or Parts are Passed for Painting . . . . . . . . . . . . . . . . . . . . 7
2.4 Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Separating Cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Replacement Body Sub-parts and Part Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Original Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Galvanized Body Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.9 Removing Remaining Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 New Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.11 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Expanded Foam Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Welding Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Work Procedures Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Body Repair Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Materials for Body Repair and Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1 Adhesive Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Sealing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Fastening Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.4 Surface Protection Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.5 Corrosion Protection Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.6 Filling Materials . . . . Copying
Protected by copyright. . . . . . for
. .private
. . . .or.commercial
. . . . . . purposes,
. . . . . .in.part
. . or. .in .whole,
. . . is. .not. . . . . . . . . . . . . . . . . . . 18
7 Body Bonded Joints
with respect . . . . . . of
to the correctness . .information
. . . . . .in.this
. . document.
. . . . . .Copyright
. . . . .by. .AUDI . . .AG.
..................... 19
7.1 Supporting Bonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Types of Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.3 Repair Methods for Replacing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Corrosion Protection Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.1 Corrosion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2 Long-term Body Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Warranty Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.4 Electrogalvinization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.5 Hot Galvanized Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
9 Disposal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.1 Environment Protection Practiced During Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9.2 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.3 Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.5 Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Contents i
10 Protection against Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

10.1 Connections between Aluminum/Magnesium and Steel . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11 Sheet Steel Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.1 Strengthened Steel Body Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.2 Yield Points of Steel Panels Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.3 Galvanized Body Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.4 Welding Work on Galvanized Body Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
12 Glass Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.1 Windshield Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12.2 Aluminum Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13 Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
13.1 The Audi Space Frame Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14 Contact Corrosion! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
14.1 Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
15 Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
16 Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
17 Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
18 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
19 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
20 Surface Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
21 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
21.1 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
22 Removing Dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
23 Reshaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24 Controlling Temperature when Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
25 Flanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
26 Welding Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
26.1 Assembly Section Cast Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
27 Assembly Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
28 Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
29 Resistance Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
30 Welding Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
31 Checking Weld Seams and Cast Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
32 Laser Weld Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
33 Rivets and Tools Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
34 Repairing Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
34.1 Punch Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
35 Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
36 Solid Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
37 Pop Rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
38 Solid Rivet, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
39 Punch Rivet, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
40 Pop Rivet, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
41 by copyright.
Protected Rivet Problems . .or. commercial
Copying for private . . . . . . .purposes,
. . . . .in. part
. . or
. .in. whole,
. . . .is.not
................................ 70
41.1 Open Countersinks . . . . . . . . . . . . . . . . . . .
. . . . . ................................ 70
41.2 Non-fitting Rivet Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
41.3 Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
41.4 Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
42 Set an Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
ii Contents
43 Same Material, Underlaying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

44 Separating Cuts, Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
45 Bonded Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
45.1 Pretreatment Valid for Replacement Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
46 Rivets Accessible from One Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
47 Explanation of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
47.1 Welding Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
48 Riveting Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
49 Set an Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
49.1 Perforate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
49.2 Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
50 Cavity Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
50.1 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Contents iii
iv Contents
1 Safety Instructions
Removing Components ⇒ page 1
Battery, Welding Procedures ⇒ page 1
Electronic Control Modules ⇒ page 1
Paint, Glass, Upholstery, Trim ⇒ page 2
Fuel Tank or Fuel Lines ⇒ page 2
Air Conditioning ⇒ page 2
Airbag
permitted System
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Seat Belts, Inspecting ⇒ page 3

Working on Vehicles With Belt Tensioners ⇒ page 4

Separating Work, Straightening Work and/or Dent Removal on
Vehicles with Airbags ⇒ page 4
Seats with Side Airbags, Removing ⇒ page 5
1.1 Removing Components

The vehicle must be secured on the hoist before its center of
gravity changes due to disassembly.
1.2 Battery, Welding Procedures
Note
Before disconnecting battery ensure that radio code is available.

Ensure radio is in an operational condition by inputting radio code
before releasing vehicle to customer.
Before welding, you must disconnect both battery terminals and

cover both battery poles.
You must remove the vehicle battery before performing work near
the battery that could produce sparks.
WARNING
Switch off ignition before connecting battery!⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery General Information
On vehicles with electronic ignition lock, ignition must be
switched off before removal
There should not be any people inside the vehicle when con‐
necting the battery!
1.3 Electronic Control Modules

Connect the ground (GND) connection of the electric welding ap‐
pliance directly to the part to be welded. When doing this, make
sure that no electrically insulated parts are between the ground
(GND) connection and the welding point..
Do not allow the ground (GND) connection or the welding elec‐
trode to touch the electronic control units and electrical wiring.
1. Safety Instructions 1
Procedure for Electronic Control Modules after accident repairs

⇒ page 2
1.3.1 Procedure for Electronic Control Mod‐

ules after accident repairs
It is only necessary to install new electronic control units after an
accident where at least one of the following conditions is present:
♦ The function check results in the message “Control module
faulty”.
If electronic components, e.g. ABS control modules, were re‐
moved for servicing and then reused, Protected
these are to be checked for
function according to the available documentation after installing.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
To do this, check all DTC memories withwitha respect
testertoand correctofany
the correctness information in this document. Copyright by AUDI AG.
possible malfunctions present.
1.4 Paint, Glass, Upholstery, Trim

No other vehicles may be parked unprotected in areas used for
body repairs. (Fire hazard due to flying sparks, battery, damage
to paintwork and glass).
1.5 Fuel Tank or Fuel Lines

Use extreme care when performing sanding and welding work
near the tank or other components carrying fuel. Where there are
doubts regarding safety, these parts must be removed.
1.6 Air Conditioning

No parts of the charged air conditioner system may be welded,
brazed or soldered. This also applies to any part of the vehicle if
there is a risk that the parts of the air conditioner system could
heat up. After paint repairs, the vehicle must not be heated up to
more than 176 ºF (80 ºC) in the drying booth or preliminary heating
zone, because heat causes a pressure increase which can burst
the system..
Note
The system must be evacuated when it is necessary to weld elec‐

trically near the refrigerant hoses. During the electrical welding
process invisible ultraviolet rays are given off which penetrate the
refrigerant hoses and decompose the refrigerant.
Solution ⇒ page 2
1.6.1 Solution:
Evacuate air conditioning system: ⇒ Refrigerant R134a - Serv‐
icing; Rep. Gr. 87 ; Refrigerant circuit, evacuating using A/C
service station Only extract system if it is required by the safety
precautions.
If it is necessary to evacuate the refrigerant when carrying out
repairs to a vehicle, avoid all contact with liquid refrigerant or re‐
frigerant vapor!
Wear rubber gloves to protect the hands and goggles to protect
the eyes! If the refrigerant comes into contact with unprotected
parts of the body it will cause frostbite..
2 1. Safety Instructions
WARNING
It is advisable to have a rinsing bottle for the eyes handy at all

times. If liquid refrigerant gets into the eyes, they should be
rinsed thoroughly with water for about 15 minutes.
Then use eye drops and obtain medical attention immediately
even if no pain is felt in the eyes. The doctor should be informed
that the cause of the frostbite was R12 or R134a refrigerant.
If the refrigerant comes into contact with other parts of the body
despite compliance with safety measures, the part of the body
concerned must be rinsed immediately with cold water for at
least 15 minutes.⇒ Refrigerant Protected
R134aby- copyright.
Servicing;CopyingRep. Gr.or commercial purposes, in part or in whole, is not
for private
87 ; Refrigerant, handling permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Although refrigerant does not present a fire hazard, smoking is

not permitted in rooms containing refrigerant vapors. The high
temperature of a burning cigarette causes a chemical breakdown
of the refrigerant vapor. The products of this breakdown are poi‐
sonous and cause violent coughing and sickness when inhaled.
1.7 Airbag System

Repair notes ⇒ Body Interior; Rep. Gr. 69 ; Safety precautions
for work on airbags
The battery Ground (GND) strap must be disconnected when
working on the airbag system or when performing straightening
work when repairing the body.
WARNING
Switch off ignition before connecting battery! ⇒ Electrical

Equipment; Rep. Gr. 27 ; Battery General Information
On vehicles with electronic ignition lock, ignition must be
switched off before removal
Airbag components must not even briefly be subjected to tem‐

peratures above 100C (212F).
Additional notes⇒ Body Interior; Rep. Gr. 69
Airbag components must not come into contact with grease,
cleaning agent, oil or similar.
Mechanically damaged airbag components must be replaced ⇒
Chapter: Disposal precautions, page ⇒ page 27 .
Wash hands after touching deployed airbag units.
1.8 Seat Belts, Inspecting
WARNING
After every accident, seat belt system must be checked sys‐

tematically. If damage is determined when checking the test
points, customer must be informed regarding necessity of
changing belts..
Additional notes ⇒ Body Interior; Rep. Gr. 69
1.9 Working on Vehicles with Belt Tension‐

ers
WARNING
Before beginning separation work, straightening work or dent

removal, remove mechanically activating belt tensioners with‐
out load detection (release lock). With electrically activating
belt tensioners, the battery Ground (GND) strap must be dis‐
connected.
Additional notes ⇒ Body Interior; Rep. Gr. 69 ; Seat belts,
inspecting
Note
If the belt webbing is completely unrolled, the load detection (re‐

lease lock) hinders the release of the mechanically activated belt
tensioner in an accident.
WARNING
With belt tensioners with load detection, the belt webbing must
not be pulled out when performing separation work, straight‐
ening work or dent removal. If strong shaking motions are
generated by separating work, straightening work or dent re‐
moval, the belt tensioners with load detection must be re‐
moved. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Additional notes ⇒ Body
with respect Interior;of Rep.
to the correctness Gr.in this
information 69document.
; SeatCopyright
belts,by AUDI AG.
inspecting
The following vehicles with no load detection on belt tensioners:

• Audi 100 sedan From MY 1982
• Audi 200/V8 From MY 1983
Safety belts with belt tensioners, removing and installing ⇒ Body
Interior; Rep. Gr. 69 ; Seat belts, inspecting
1.10 Separating Work, Straightening Work

and/or Dent Removal on Vehicles with
Airbags
The battery Ground (GND) strap must be disconnected when
working on the airbag system or when performing straightening
work when repairing the body.
WARNING
Switch off ignition before connecting battery!

Repair notes ⇒ Body Interior; Rep. Gr. 69 ; Safety precautions

for work on airbags
4 1. Safety Instructions
1.11 Seats with Side Airbags, Removing
WARNING
You must always follow safety precautions when removing

seats.
You can find the safety precautions in the repair manual belong‐
ing to each vehicle model ⇒ ⇒ Body Interior; Rep. Gr. 69 ; Safety
precautions for work on airbags .
2 General Notes
Diagnosis of Vehicles in Accidents ⇒ page 6
General Information about Body Repairs ⇒ page 6
Conditions in which Body and/or Parts are Passed for Painting
⇒ page 7
Straightening ⇒ page 7
Separating Cuts ⇒ page 7
Replacement Body Sub-parts and Part Sections ⇒ page 7
Original Joint ⇒ page 7
Galvanized Body Parts ⇒ page 7
Removing Remaining Material ⇒ page 8
New Parts ⇒ page 8
Replacement Parts ⇒ page 8
2.1 Diagnosis of Vehicles in Accidents

Damage to the running gear and assembly mountings, which
could have very serious effects later on is sometimes not discov‐
ered when accident vehicles are being repaired. Where the acci‐
dent damage indicates over-stressing of the vehicle, special
attention must be paid to the following components, completely
independent of the axle geometry check which must be done in
all cases:
♦ Check steering and steering linkages using steering wheel
angle for problem-free function, visual inspection for bends or
cracks.
♦ Check suspension, all suspension parts such as links, struts,
steering knuckle, stabilizer, subframe, axle body and their se‐
curing parts for bends or cracks.
♦ Check rims and tires for damage, true running and imbalance.
Check tires for cuts in the profile and the sides, check tire
pressure.
♦ Check mounts for engine, transmission, axles and exhaust
system for damage.
♦ Finally, a proper road test after repairs ensures that the vehicle
is safe to drive and can be handed over to the customer.
2.2 General Information about Body Re‐

pairs Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
When repairing, the original connection should always be re‐
stored.
Standard repairs are described in the repair manual. Further de‐

scriptions are not given because if there are more extensive
repairs, the damaged area should be removed at the original con‐
nection. Where this is possible, the joining techniques can be
implemented according to the preceding comparison.
All repairs with special separating cuts and joining techniques that
do not correspond to the original connection (production status)
checked and approved by the Technical Development by means
of calculation, strength testing and crash.
6 2. General Notes
2.3 Conditions in which Body and/or Parts

are Passed for Painting
Before a repaired vehicle or part is handed over to the paint shop
for painting, the repaired or beaten out, and where necessary,
filled surfaces must be prepared for painting by rubbing-down with
abrasive paper having a grade of P 80 - P 100.
This preparatory work is the job of the sheet metal worker and is
included in the time allowed for the repair.
2.4 Straightening
Body and floor sections are Protected
produced mainly from cold formed
deep drawn sheet metal. Forpermitted
this reason the reshaping
unless authorised by AUDI AG. ofAUDIacci‐
AG does not guarantee or accept any liability
dent damaged areas should be withcarried
respect toout in the same
the correctness manner.
of information in this document. Copyright by AUDI AG.
If the size of the damage does not allow it to be reshaped against

the direction of damage, the damaged part must be removed after
straightening the connecting surfaces.
2.5 Separating Cuts

In areas where cutting and the subsequent joining affect the ri‐
gidity of the body and also the operational safety and servicea‐
bility of the vehicle, the parting cuts must be made in accordance
with the Repair Manual instructions.
2.6 Replacement Body Sub-parts and Part

Sections
“Sub-parts” include sections of individual parts (e.g. front and rear
end points) that are delivered pre-cut from the parts depot.
– In contrast to this, “partial sections” are to be cut out from re‐
placement parts. In individual cases, work is to be performed
exactly according to the methods described and represented
in the body repair manual.
– Because the use of “sub-parts” or “partial sections” as well as
special resources influence repair times, the special resources
are included separately in the repair description.
2.7 Original Joint

“Original joint” refers to welding that is used by the vehicle man‐
ufacturer.
These welds should be reconstructed when performing body re‐
pairs.
When doing so, ensure that the production number of weld points
is not exceeded when making repairs.
Methods and procedures differing from the original connection
are described in the applicable body repair manual.
2.8 Galvanized Body Parts

Fully galvanized panels provide a high level of bodywork anti-
corrosion protection during manufacture. To be able to maintain
the warranty guarantee against perforation rusting when carrying
out repairs, the repair information from ⇒ page 31 must be fol‐
lowed exactly.
2. General Notes 7
WARNING
Because toxic galvanized oxide develops in welding emissions

when welding galvanized sheet steel panels, there must be
good workplace ventilation and flue-gas removal through ap‐
propriate means, e.g. welding emission exhaust system -V.A.G
1586 A- .
2.9 Removing Remaining Material

If the damaged body piece is removed roughly according to the
separating cuts in the applicable repair manual, e.g with pressure
hammer -V.A.G 1577- or body repair saw -V.A.G 1523 A- , drill
out most spot weld connections with spot weld remover -V.A.G
1731- .
In addition, we recommend the degree sander -V.A.G 1529- as
well as an angle sander to remove the weld connections that can‐
not be removed with the spot weld remover.
2.10 New Parts

New parts which are not accessible from the inside after a repair,
e.g. side members, should, to prevent corrosion, be pre-painted
in the color of the vehicle before being welded in. Here it is rec‐
ommended to mask the welding flanges.
2.11 Replacement Parts

In many cases, replacement parts are delivered only in the “basic
version” for parts reduction.
Examples:
• Audi 100 from MY 1991 roof without roof rail holes.
In these cases, we recommend that the workshop creates “pat‐
terns” from damaged parts.
Example: from MY Audi 100 1991 roof rail holes:
• Cut out side part from roof with the body repair saw -V.A.G
1523 A- , observing prominent contours, e.g. a part of the de‐
pression (rain gutter), when doing so. Deburr cut edges and
protect with fabric-reinforced adhesive tape.
Apply patterns before painting and allow for the material strength
of the pattern when marking the bore holes.
Check new replacement parts, such as doors, panels or fenders
for transport damage before sending to paint shop. This prevents
double painting, if transport or accident damage to the vehicle is
noticed during assembly.
8 2. General Notes
3 Expanded Foam Inserts
Caution
Expanded foam inserts expand only after reaching 180 °C.

Because of this, filler foam is used for repairs
Filler foam D 506 000 A2 is required for repairs.
Insert replacement expanded foam inserts.

Foam D 506 000 A2 must be applied before fitting replacement
part.
The foam hardens within 25 minutes
Do not do perform welding within 15 mm on either side of molded
foam element.
After painting vehicle, preserve cavities in repair area.
3. Expanded Foam Inserts 9

4 Symbols
Welding Legend ⇒ page 10
Work Procedures Legend ⇒ page 11
4.1 Welding Legend

Straight-line spot weld seam (single row) RP = Spot weld
Straight-line spot weld seam (double row)
Straight-line spot weld seam (double row, staggered)
Gas-shielded arc plug weld seam SG = gas-shielded welding
Gas-shielded arc stitch weld seam
Gas-shielded arc continuous weld seam
Gas-shielded arc continuous weld seam (intermittent)
Hard soldering
10 4. Symbols
4.2 Work Procedures Legend

Sanding ⇒ page 11
Set an edge ⇒ page 11
Perforate ⇒ page 11
Drill ⇒ page 11
Sanding ⇒ page 12
Cavity sealant ⇒ page 12
Adhesives ⇒ page 12
Fine seal ⇒ page 12
4.2.1 Sanding
– Wear away weld seam with a grinder around material appli‐
cation.
Note
The weld seams must be sanded so that the panel strength of the
exterior panels is not or only slightly weakened.
4.2.2 Set an edge

– To perform an overlapping weld.
4.2.3 Perforate
– To perform a gas-shielded arc plug weld later.
4.2.4 Drill
– To perform a gas-shielded arc plug weld later or drill out spot
welds (original connection).
4. Symbols 11
4.2.5 Sanding
♦ Removing paint on hard-to-reach areas (e.g. interior roof
frame) with brush -VAS 5182- .
4.2.6 Cavity sealant
4.2.7 Adhesives
4.2.8 Fine seal
12 4. Symbols
5 Body Repair Tools
Note
The following tools are organized according to V.A.G / VAS num‐

bers.
Special tools and workshop equipment required

♦ Hole pliers -V.A.G 1329-
♦ Basic equipment -V.A.G 1366/3-
♦ Undersealant spray gun -V.A.G 1379-
5. Body Repair Tools 13

♦ Heat gun -V.A.G 1416-
♦ Door tensioner -V.A.G 1438-
♦ Body tool trolley -V.A.G 1439-
♦ Body repair saw -V.A.G 1523 A-
14 5. Body Repair Tools

♦ Compressed-air chisel -V.A.G 1577-
♦ Flange finishing iron -V.A.G 1585-
♦ Welding emission exhaust system -V.A.G 1586-
♦ Spot weld remover -V.A.G 1731-

♦ Compressed air gun -V.A.G 1761/1-
♦ Compressed air gun for producing seals and undercoating

with factory-original optical characteristics.
♦ Also, all 310 ml cartridges can be used with this gun.
♦ Compressed air punch pliers and edge setter -VAS 1996-
♦ Compressed-air adhesive gun -V.A.G 2005-
♦ For body adhesive

♦ Door hinge replacement stud -3114-
16 5. Body Repair Tools

♦ Hose package -VAS 5023-
♦ Nozzle set 5023/1

♦
♦ Angle sander -VAS 5174-
♦ 710 Watt; 115 mm ∅

♦ Angle sander -VAS 5175-
♦ 1500 Watt; 180 mm ∅
♦ Brush -VAS 5182-
♦ For removing paint in hard-to-reach places (e.g. interior roof

frame)

6 Materials for Body Repair and As‐

sembly Procedures
Adhesive materials ⇒ page 18
Sealing materials ⇒ page 18
Fastening materials, see Body Repair Manual and ETKA
⇒ page 18
Surface protection materials, see Body Repair Manual and ETKA
⇒ page 18
Corrosion protection materials, see Body Repair Manual and ET‐
KA ⇒ page 18
Filling materials, see Body Repair Manual and ETKA
⇒ page 18
6.1 Adhesive Materials

For information on Adhesive material refer to: Body Repair Man‐
ual and ETKA.
6.2 Sealing Materials

For information on Sealing materials refer to: Body Repair Manual
and ETKA.
6.3 Fastening Materials

For information on Fastening materials refer to: Body Repair
Manual and ETKA.
6.4 Surface Protection Materials

For information on Surface protection materials refer to: Body
Repair Manual and ETKA.
6.5 Corrosion Protection Materials

For information on Corrosion protection materials refer to: Body
Repair Manual and ETKA.
6.6 Filling Materials

For information on Filling materials refer to: Body Repair Manual
and ETKA.
18 6. Materials for Body Repair and Assembly Procedures

7 Body Bonded Joints

Supporting bonds ⇒ page 19
Types of bonding ⇒ page 19
Repair methods for replacing parts ⇒ page 20
7.1 Supporting Bonds
(e.g. Audi 80)

The following procedure is used when repairing bonded points:
Separating procedure: ⇒ page 19
7.1.1 Separating procedure:

– Roughly cut out roof to gain access to the bonded point.
– Cut through bonded point with oscillating knife.
7.2 Types of Bonding

To increase body
Protected rigidity
by copyright. andforstrength,
Copying adhesive
private or commercial and inspot-weld
purposes, part or in whole, is not
bonded permitted
joints are being
unless increasingly
authorised used
by AUDI AG. AUDI AGin production.
does They
not guarantee or acceptare
any liability
differentiated as follows:
High-strength bonded joints ⇒ page 19

Spot-weld bonded joints ⇒ page 19
7.2.1 High-strength bonded joints

In bonded joints, the sheet metal parts are only bonded by adhe‐
sive.
The distance of the high-strength adhesive surfaces to each
should not be less than 2 mm or greater than 4 mm. If necessary,
the adhesive surfaces must be prepared.
Repair measures
– The bonded joints are restored with the materials specified in
the repair manual or replacement parts program.
7.2.2 Spot-weld bonded joints

In spot-welded bonded joints, an electrically conductive adhesive
is used between the panels, allowing good root penetration for
spot welding.
7. Body Bonded Joints 19

The distance of the spot-weld surfaces to each other should not

be greater than 1 mm. If necessary, the adhesive surfaces must
be prepared.
The welding current must not be increased for spot-weld bonding
operations. The pre-press period must be extended to approx. 30
- 50 cycles because of the displacement of the adhesive. The
fumes produced must be exhausted.
7.3 Repair Methods for Replacing Parts

Adhesive DA 001 730 A should be used in connection with com‐
pressed-air adhesive gun -V.A.G 2005- as replacement for spot-
weld adhesive.
Instructions for use ⇒ page 21 .
For simultaneous bonding and welding, the procedures are dif‐
ferentiated according to the type of weld (spot weld, gas-shielded
weld) as follows:
Straight-line spot weld and bonding ⇒ page 20
Gas-shielded welding and bonding (if spot welding is not possible)
⇒ page 20
Gas-shielded welding ⇒ page 20
Welding emission exhaust system ⇒ page 21
Preparation ⇒ page 21
Reconditioning ⇒ page 21
DA 001 730 A1 instructions for use ⇒ page 21
7.3.1 Straight-line spot weld and bonding

With spot welding and bonding, the entire area of spot welds and
bonding is replaced when making repairs, as in production.
With welding problems, e.g. there is a 3-layer panel connection
and only the outer panel is replaced, the repair spot weld should
be placed on the “old” spot weld.
7.3.2 Gas-shielded welding and bonding (if

spot welding is not possible)
If an adhesion area is not accessible with a straight-line spot
welding device, the area is welded with a gas-shielded arc plug
weld seam. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
In this case, adhesive is done without in order to maintain
withthe
respect to the correctness of information in this document. Copyright by AUDI AG.
welding bead. The gas-shielded arc plug weld distance is 15 mm.
7.3.3 Gas-shielded welding

SG 2 welding wire is suitable all steel types.
For variations, see respective repair manual, repair group 00.
20 7. Body Bonded Joints

On vehicles with highest-strength steel, spot welding devices with

inverter technology (see workshop equipment and special tools
catalog) are to be used.
7.3.4 Welding emission exhaust system

For spot welding in conjunction with spot weld adhesive, the same
standard exhaust system is used as with welding galvanized pan‐
els.
7.3.5 Preparation
The panels to be welded must be fitted before applying adhesive.
Due to adhesive displacement when spot welding, the bare spot
weld flange is coated with adhesive and thus protected from cor‐
rosion.
The adhesive surfaces in the welding area must be free of primer
and adhesive residue and well as dust and grease.
Our vacuum device -VAS 6216- is recommended for this.
7.3.6 Reconditioning
– Wipe escaping adhesive.
– Corrosion protection measure ⇒ Surface technology / chemi‐
cal materials binder
– Paint structure ⇒ Surface technology / chemical materials
binder
7.3.7 DA 001 730 A1 instructions for use

♦ If the adhesive escapes on both sides along the entire length,
too much was applied.
♦ On large parts, such as the roof, it is necessary to perform the
work with a helper. Otherwise the adhesive will dry before work
is complete.
♦ Before inserting mixing nozzle, ensure double cartridge open‐
ings are clean. Secure mixing nozzle and press out a bead
about 5 cm. long. Then apply adhesive to adhesive surface.
♦ After long breaks up to 30 minutes, press out a bead about 10
cm long so that new material is mixed. After breaks more than
30 min., replace mixing nozzle.
♦ 1 cartridge with 37 ml is enough for approx. 4 m of flange.
♦ The adhesive must cure before further surface work. Curing
time: 68º F (20° C ≈ 8 h 176º F (80° C) ≈ 20 min.
7. Body Bonded Joints 21

8 Corrosion Protection Measures

Corrosion protection ⇒ page 22
Long-term body protection ⇒ page 22
Warranty notes ⇒ page 22
Electrogalvinization ⇒ page 23
Hot galvanized coating ⇒ page 23
8.1 Corrosion Protection

The production standard corrosion protection should be renewed
after servicing with the materials specified by the manufacturer.
8.2 Long-term Body Protection

– Paint inside of new parts with finishing paint before welding.
– Prime bare panel surfaces immediately after repair (corrosion
protection primer ALN 002 003 10 or ALK 007 003 10).
– Holes must be deburred.
– Apply welding primer to both sides of welding flange (D 007
500 04).
– Primer weld area on inside and outside before sealing.
– Apply sealant only to primed panels.
– Completely seal panel overlap, panel edges, butt joints, weld
seams, etc. with sealant.
– Restore paint structure.
– Restoring undercoating — with long-term underbody protec‐
tive material.
– Preserve cavities in repair area after finish painting.
– Separation cuts (e.g. in side panel) must be completely pre‐
served. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Open water drains after cavity sealant material dries.

8.3 Warranty Notes

• 3 years - paint defects, since 03/25/83 for Audi passenger car
chassis
• 6 years - corrosion perforation, since 07.03.79 for Audi pas‐
senger car chassis.
• 12 years - corrosion perforation on all Audi vehicles starting at
model year 1998
22 8. Corrosion Protection Measures

8.4 Electrogalvinization
With electrogalvinization, the sheet steel band functions as a
cathode to zinc anode plates (positive electrodes).
The gap to the sheet steel is filled with electrolyte, an acidic, elec‐
troconductive liquid that contains zinc ions.
It is an electrochemical process by which zinc is dissolved with
the help of electric current and transferred to the sheet steel.
An even, fine, unstructured layer of zinc forms which can easily
be manipulated further, such as with cutting, pressing, welding,
priming and painting.
8.5 Hot Galvanized Coating

With hot-dip galvanized coating, the sheet steel panel runs
through an approx 842º F ( 450 ºC) liquid zinc bath. An extremely
thin layer of zinc-iron alloy forms directly on the panel surface as
an “adhesive material” for a layer of pure zinc which eventually
reaches a thickness of about 10 mm per side.
The galvanized blooms characteristic of hot-dip galvanized coat‐
ing are undesirable for body pieces and are therefore largely
prevented with various techniques, such as rerolling.
The body pieces of the floor assemblies, door pillars and wheel
housings that are not visible are hot-dip galvanized on both sides.
8. Corrosion Protection Measures 23

9 Disposal Information
Environment protection practiced during production ⇒ page 24
Recycling ⇒ page 25
Plastics ⇒ page 25
Disposal ⇒ page 27
Airbag ⇒ page 27
9.1 Environment Protection Practiced Dur‐

ing Production
The following are disposal requirements that apply to production
in Audi facilities:
• Omission or reduction of fluorohydrocarbons -HFCs- in soft
foam propellants (e.g. for seat upholstery), in release agents
in plastic finishing and cleaning solutions in production facili‐
ties.
• Use of solvent-free adhesive and production aids, thereby
considerably reducing emissions (pollution), disturbing odors
and fogging on glass surfaces.
• The use of recyclable materials for plastic parts such as:
• Bumper covers
• Instrument panel
• Engine encapsulation and the like
• Plastics made from recycled materials are being produced at
this time:
• Wheel housing liners
• Luggage compartment floor coverings
• Insulation mats and more
• The use of recycling-friendly materials as well as the reduction
of the number of types.
• Recycling-friendly designs
permitted lower-cost
unless authorised removal.
by AUDI AG. AUDI AG does not guarantee or accept any liability
Recycling means: ⇒ page 24
The basic environmental principles are: ⇒ page 24
9.1.1 Recycling means:

– Avoiding contamination
– Protection of landfill space
– Economical use of raw materials
9.1.2 Basic environmental principles

The basic environmental principles are:
♦ Prevention before reduction
♦ Prevention before reuse
♦ Reuse before disposal
24 9. Disposal Information
9.2 Recycling
As an important contribution to preserving the environment, plas‐
tic parts are produced partly from reusable “recyclable” or already
“recycled” raw materials.
Recycling concepts used must be as logistically simple as possi‐
ble for the service organization and the recycling company.
Self-imposed requirements: for basic recycling
– The removability of the parts was already simplified construc‐
tively.
– The variety of plastic part types was reduced.
– The plastic parts were already marked by the manufacturer
according to VDA-260.
With the help of this material identification “standardized coding”,
parts can be separated and collected according to type and tar‐
geted for recycling by the manufacturer or a recycling company.
The identification field contains:
♦ Manufacturer's identification
♦ Part number
♦ Production date and time
♦ Material code
For example, PP+ EPDM -T20- means:
it can be recycled
♦ Polypropylene -PP
♦ Elastomer-modified ethylene-propylene diene monomer
♦ Talcum reinforced - -T20-
9.3 Plastics
Table 1 ⇒ page 25
Table 2 ⇒ page 26
Table 3
9.3.1 Table 1
Examples of basic polymers often
permitted unless used in
authorised by the
AUDIautomotive
AG. AUDI AG does industry
not guarantee or accept any liability
(thermoplastics and duroplastics),
with respect to the abbreviation according
correctness of information to DINCopyright by AUDI AG.
in this document.
7728 or ISO 1043:
Abbreviation Description
ABS Acrylonitrile-butadiene-styrene-copolymer
EP Epoxy resin
PA 6 Polyamide with 6 c-atoms in monomer building block
9. Disposal Information 25
PA 66 Polyamide of 2 monomer building blocks with 6 c-atoms each
PBT Polybutylene-terephthalate (linear polyester)
PES Polyether sulfide
PET Polyethylene-terephthalate
PC Polycarbonate
PE Polyethylene
PF Phenolic formaldehyde resin
PMMA Polymethylmetacrylatewith respect to the correctness of information in this document. Copyright by AUDI AG.
POM Polyoxymethylene, Polyacetylene
PP Polypropylene
PPE Polyphenylene ether
PPS Polyphenylene sulfide
PTFE Polytetrafluoroethylene
PUR Polyurethane
PVC Poly vinyl chloride
SAN Styrene acrylonitrile copolymer
9.3.2 Table 2
Examples of abbreviations according to DIN 7728 or ISO 1043
for filler and strengthening materials frequently used in the auto‐
motive industry:
GF Glass fiber
GM Glass mats
GB Glass beads
T Talcum
M Mineral reinforcement
WD Sawdust
9.3.3 Table 3
- Examples of elastomer base polymers frequently used in the
automotive industry, abbreviations according to DIN-ISO 1629:
ACM Copolymers of ethyl acrylate or other acrylates with a small amount of a monomer which
facilitates vulcanization
AU Polyester urethane rubber
BR Butadiene rubber
CSM Chlorosulfonated polyethylene
CR Chloroprene rubber
EPDM Terpolymers composed of ethylene, propylene and a diene with an unsaturated part of the
diene in the side chain
ECO Copolymers composed of ethylene oxide (oxirane) and chloromethyloxirane (epichloro‐
hydrin)
FPM Fluorine rubber, fluoro-oxy groups on polymer chain
MVQ Silicone rubber with methyl and vinyl groups on polymer chain
NBR Acrylonitrile-butadiene rubber
NR Isoprene rubber (natural rubber)
SBR Styrene-butadiene rubber
9.4 Disposal
In order to be able to recycle vehicle parts after repair or servicing,
you must first collect all accumulated Audi recycling materials ac‐
cording to type.
This pre-sorting should be done according to the following mate‐
rial groups:
– Sheet metal or iron materials (“scrap steel”) → scrap dealer
and shredder operator
– Aluminum → engine reconditioning company; scrap dealer or
special engine scrap dealer
– Tires → scrap dealer
– Plastics → Polypropylene bumpers using Audi collecting logis‐
tics at the present time, further plastic recycling projected
– Batteries → existing recycling cycle using regional disposers
– Used oil → existing disposal method
– Brake fluid → Material cycle being prepared
– Coolant → Material cycle being prepared
– Refrigerant → existing disposal method
– Refrigerant permitted
oil for unless
R12 authorised
→ such byasAUDI engine
AG. AUDIoilAGrefrigerant oil for
does not guarantee or accept any liability
R134a → Material cycle
with respect being
to the prepared
correctness of information in this document. Copyright by AUDI AG.
– Oil-filled damping equipment, e.g. bumper dampers → remove

oil and use existing disposal method
– Gas-filled damping equipment, e.g. gas-filled struts → remove
gas, absorb escaping oil and use existing disposal method
– Separate recycling materials from foreign materials to make
segregated recycling possible. For example, remove tires from
rims and use both separate disposal methods.
9.5 Airbag
Disposal of pyrotechnic components ⇒ page 28
Undeployed pyrotechnic components ⇒ page 28
Pyrotechnic components ⇒ page 28
WARNING
Undeployed airbag units present a danger during disposal.
9. Disposal Information 27
9.5.1 Disposal of pyrotechnic components

(e.g. airbags, safety belts, pyrotechnic battery elements) are to
be disposed of properly in their original packaging, in accordance
with national legislation.
Refer to: (Airbag):⇒ Body Interior; Rep. Gr. 69 ; Disposing of
airbag modules or (Seatbelt pyrotechnic belt tensioners):⇒ Body
Interior; Rep. Gr. 69 ; Disposing of pyrotechnic belt tensioners
9.5.2 Undeployed pyrotechnic components

(e.g. airbags, safety belts, pyrotechnic battery elements) are to
be disposed of properly in their original packaging, in accordance
with national legislation.
Refer to: (Airbag):⇒ Body Interior; Rep. Gr. 69 ; Disposing of
airbag modules or (Seatbelt pyrotechnic belt tensioners):⇒ Body
Interior; Rep. Gr. 69 ; Disposing of pyrotechnic belt tensioners
If questions arise, contact Audi of America.
9.5.3 Pyrotechnic components

Pyrotechnic components deployed in an actual accident can be
disposed of as industrial waste.
WARNING with respect to the correctness of information in this document. Copyright by AUDI AG.
This does not apply to belt tensioners that function according

to the Wankelstraffer principle. These are to be treated like
undeployed pyrotechnic components (such as airbags, seat
belts, pyrotechnic battery components). Reason: Workshop
equipment cannot determine if Wankelstraffer belt tensioners
have deployed all pyrotechnic materials.
10 Protection against Contact Corrosion

Connections between aluminum/magnesium and steel
⇒ page 29
10.1 Connections between Aluminum/Mag‐

nesium and Steel
Note
♦ With connections between aluminum or magnesium and steel,

the corrosion protection measures described below must be
observed. At attachment points between aluminum and steel
or magnesium and steel:
♦ Fender
♦ Front hood
♦ Doors
♦ You must use protective foil on rear lid.
♦ When bolting aluminum or magnesium to steel, you may only
use Dacromet-coated screws which may only be used one
time. Dacromet is a green, chemical protective coating that
prevents contact corrosion.
♦ Non-metallic fastening or sealing elements (door seals, rear
lid seal) between two different metals should not be electrically
conductive.
♦ You can find special notes about the procedure in the corre‐
sponding repair groups in the repair manuals.
10. Protection against Contact Corrosion 29

11 Sheet Steel Repairs

Strengthened steel body panels ⇒ page 30
Yield points of steel panels used ⇒ page 31
Galvanized body parts ⇒ page 31
Welding work on galvanized body panels ⇒ page 31
11.1 Strengthened Steel Body Panels

Reinforced (high-strength) panels are being used increasingly in
our vehicles. You can see the areas where these panels are used
in a picture in the body repair manual ⇒ Body Repair; Rep. Gr.
00
What are high-strength panels?
Optically normal panels, but they posses a higher yield point than
normal body panels because of various alloys. That is, with the
same force applied to the panel, the dent in the high-strength
panel is not as deep as that in a normal body panel.
What must be observed when removing dents?
Dents are removed with standard tools. Due to the higher dent
resistance, there is greater rebound so that it may be necessary
to expend more force. When buckled areas are reshaped, breaks
in the material may occur.
What must be observed when straightening with a bench-type
straightening system or hydraulic press?
Due to the greater rebound characteristics of high-strength pan‐
els, it must be stretched more than a normal panel before it
remains in the desired position. Due to the higher application of
force, normal panels that are welded with high-strength panels
are strained more. In order to prevent normal panels from yielding
or tearing, an additional anchorage must be provided.
WARNING
♦ If a high-strength panel is stretched too much, it suddenly

springs back a lot unintentionally!
♦ For safety reasons, high-strength body panels must not be
heated when reforming as with normal body panels!
♦ Welding high-strength steel is not allowed due to strength
reasons.
What must be observed when painting?

If high-strength panels are warmed too quickly by a dryer, they
expand. If the panel is firmly secured by spot welds or bonding
with reinforcements located behind, dents will appear in these
places and remain visible after cooling off. For this reason, heat‐
ers should only be brought up to full capacity slowly. The drying
can be done safely in a drying booth.
What are high-strength hot-formed
Protected by steel
copyright. Copying panels?
for private or commercial purposes, in part or in whole, is not
They are steel panels

with that,
respectas their nameof suggests, are formed in by AUDI AG.
to the correctness information in this document. Copyright
a warm condition at temperatures between 900 °C and 950 °C.
The steel panels gain their high strength through a specific cool‐
ing process in the reshaping tool. they are form hardened.
The vehicle weight can be reduced without losing strength by us‐
ing high-strength hot-formed steel panels.
30 11. Sheet Steel Repairs

11.2 Yield Points of Steel Panels Used

1 MPa = 1 Newton/mm2
♦ Steel panel up to 140 MPa
♦ High-strength steel panels from 180 to 240 MPa
♦ High-strength hot-formed steel panels over 1000 MPa
11.3 Galvanized Body Parts

Preparation ⇒ page 31
Separating procedure ⇒ page 31
Joining techniques ⇒ page 31
11.3.1 Preparation
– Warm undercoating/sealing materials only with hot air device
(max. 420°C) or remove with rotating wire brush.
– Remove paint and priming material with paint remover (LLE
812 000 A2) or rotating plastic brush.
11.3.2 Separating procedure

– Do not use thermodynamic separating procedures (cutting
torch) if possible (only for rough cuts).
– In order to not cause any damage to the galvanized coating in
the area of separation, mechanical separation procedures are
preferred, e.g. spot weld drill, body repair saw.
11.3.3 Joining techniques

The resistance spot welding procedure only causes slight erosion
in the galvanized layer in the area of the weld. The protective
galvanized ring formed at the same time around the weld point
protects against corrosion.
Always use resistance spot welding whenever possible.
When using resistance spot welding, always observe galvanized
coatings of different thickness (perform a test weld).
Use gas-shielded welding as a substitute for resistance spot
welding only if necessary.
Welding primer (galvanized spray D 007 500 04) must be applied
between the fastening flanges.
Apply filler (ALN 787 200 10) to all connecting points.
11.4 Welding Work on Galvanized Body Pan‐

els
WARNING
Because toxic galvanized oxide develops in welding emissions

when welding galvanized sheet steel panels, there must be
good workplace ventilation and exhaust-gas removal through
appropriate exhaust system, e.g. -V.A.G 1586- .
11. Sheet Steel Repairs 31

Gas-shielded welding on galvanized panels ⇒ page 32

Joining techniques used (On Audi steel bodies) ⇒ page 32
Joining techniques used (On Audi aluminum bodies)
⇒ page 32
Straight-line welding on galvanized panels ⇒ page 33
“Unbuttoning test” ⇒ page 33
11.4.1 Gas-shielded welding on galvanized

panels
To produce good repair welds, observe the following notes:
♦ The amperage at welding transformer must be increased.
♦ At the same time, the wire feed must be readjusted because
increasing the voltage alone generates a large electric arc
(lower fusion penetration, porous seam construction).
♦ Use cylindrical gas nozzles instead of conical (splashes on a
gas nozzle that is too narrow causes formation of pores).
♦ Direct burner bout 12 cm over welding material in a neutral
angle position up to 10°.
♦ Use softest wire quality possible.
♦ CO2 as well as mixed gasses can be used as inert gas.
11.4.2 Joining techniques used (On Audi steel

bodies)
On Audi steel bodies
In production In repair
Spot welds Spot weld bonding / MAG plug
welding / MAG welding
MAG welding MAG welding
MIG soldering MAG welding
Laser welds MAG welding
Adhesives
Protected by copyright. Copying for private or Bondingpurposes,
commercial / MAGin welding
part or in whole, is not
Spotwith
weld bonding
respect to the correctness of informationBonding with Copyright
in this document. spot welding /
by AUDI AG.
additional spot welds / addi‐
tional
MAG welding
Pop rivets Pop rivets
Only use specified pop rivets
according to repair manual.
Commercially-available pop
rivets generally are not strong
enough.
Punch rivet Pop rivet N 909 236 01 ∅ 4.8
mm clamp length 6 - 8.5 mm
11.4.3 Joining techniques used (On Audi alu‐

minum bodies)
On Audi aluminum bodies
In production In repair
MIG welding MIG welding
Spot welds not used
MIG soldering not used
Laser welds Bonding and riveting
32 11. Sheet Steel Repairs

Adhesives Bonding and riveting

Punch rivets Punch rivets with VAS 5279
Pop rivets Pop rivets
Only use specified pop rivets
according to repair manual.
Commercially-available pop
rivets generally are not strong
enough.
11.4.4 Straight-line welding on galvanized pan‐

els
When performing resistance spot welding on galvanized panels,
observe following points:
• The flanges to be spot welded must lie against each other.
Clamp flanges with pliers, if necessary.
• This is especially important with high-strength panels because
the electrode strength is not great enough.
• Do not weld directly by the clamping pliers with the welding
tongs because a large amount of the welding current flows
through here due to shunting.
• With small spot weld spacing, weld points in sequential order
or weld every 3rd point to secure then finish welding. This
minimizes the shunting influence.
• Observe user's instructions and adjustment notes from man‐
ufacturer.
11.4.5 “Unbuttoning test”

For the necessary unbuttoning diameter, determine the panel
pairing based on the manufacturer's specifications and check with
test panels.
Check all spot weld connections 100% with bit sample.
Qualitatively acceptable spot welds do not tear into the contact
surface, but rather “unbutton”.
Calculate unbuttoning diameter with the following formula and
check on test panels before beginning repair.
Square root T1x 3.5 x 1.15
Note
T1 is the thinnest panel in a panel pairing
e.g. panel pairing 1.5 mm and 0.8 mm

Example calculation: Root of 0.8 x 3.5 x 1.15 = 3.6 mm un‐
buttoning diameter
With the test, the small welded test strip is rolled or pulled from
the second test strip with force perpendicular to the panel surface.
If the pressure of the welding tongs is not great enough, clamp

flanges with pliers as well to attain the proper force.

If the welding transformer amperage is not great enough for the
panel pairing, perform a gas-shielded plug weld.
11. Sheet Steel Repairs 33

12 Glass Repair
Windshield repair ⇒ page 34
Aluminum repairs ⇒ page 38
12.1 Windshield Repair

Aside from replacing windshields, under certain conditions there
is the less expensive possibility of repairing a windshield that has
been damaged by a stone.
Tinted windshields, windshields with colored liners or insulated
glass (Audi A8, A6) can be repaired because the tint is created
with colored intermediate foil.
Repairing the windshield is preferred to replacing it under the fol‐
lowing conditions.
Conditions ⇒ page 34
Special tools ⇒ page 35
Repair description ⇒ page 36
12.1.1 Conditions
• The damage location must not lie within the driver's direct field
of vision -1-. This field corresponds to a strip about 29 cm wide
(DIN A4 format across) central to the driver's line of sight in
direction of travel, bordered above and below by the wind‐
shield washer field.
• Cracks radiating out from the point of damage -2- must not be
longer than 50 mm and/or continue outward into the peripheral
area.
• The diameter of the point of damage
permitted -1- must
unless authorised not
by AUDI AG.be larger
AUDI AG does not guarantee or accept any liability
than 5 mm. with respect to the correctness of information in this document. Copyright by AUDI AG.
• The intermediate foil -2- or interior glass -3- must not be dam‐
aged.
• There must not be any dirt or moisture penetrating into the
lower area of the crack.
• Therefore, the date of damage should not date back very long.
The following damage may be repaired as long as it is not in the
field of vision or in the peripheral areas of the windshield:
34 12. Glass Repair

Bull's eye
Combination break
Star and crack
12.1.2 Special tools

Required special tools, workshop equipment, testing and meas‐
uring equipment, and aids
♦ Window repair permitted
kit -VAS 1993-
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Contains the following tools:
12. Glass Repair 35

1 - Transformer
2 - 1 set resin gauges
3 - Mirror
4 - Suction hook
❑ Use as vacuum pump
5 - Tool carrier
6 - Injector
❑ After first use in opaque
packaging
7 - Resins for at least 15 appli‐
cations
8 - 12V drill machine
9 - Drill and polish set
10 - Awl
11 - UV lamp
12 - Foil
13 - Battery connector cable
12.1.3 Repair description

• Repairs should not take place in direct sunlight.
• The repair location must be room temperature.
• The work area must be protected against moisture.
– Loosen impact area with hard metal awl but do not expand it
or remove any glass fragments.
– Remove any possible moisture with suction hooks while help‐
ing with hair dryer from inside. Stop repair if moisture cannot
be removed.
– Mount mirror -1- on inside and align so location of damage can
be seen clearly.
36 12. Glass Repair

– Mount tool carrier -2- with injector -3- so injector's rubber seal
lies directly over point of impact. Check by looking in mirror.
– Completely remove threaded spindle -2- from injector -1-.

– Fill injector -1- with 2 to 3 drops resin (this amount is resin is
sufficient for any damage).
– Return resin bottle to package immediately because resin is
UV sensitive.
– Wait until resin advances into rubber seal.
– Tighten injector -1- by turning threaded spindle -2-. The correct
pressure is achieved when the impact point turns clear from
the center out.
Note
The resin penetrates into the cracks very slowly and may not be
visible right away.
– Wait 10 minutes, then release injector to end of threads.

– Hold injector tightly when loosening so that it does not slip.
– Repeat procedure (at least 3 times) until all air is removed from
damage location. You can recognize this by the fact that all of
the cracks will no longer be visible. Tightening the injector cre‐
ates pressure up to 18 bar.
– Note in mirror when the damage location is filled. Then end
injection.
– Then swing carrier with injector to side and check whether
resin has flowed into all points of fracture.
– Remove any possible trapped air with the suction hook placed
on the repair location.
– Cut cover foil -1- keep ready. Remove injector with tool carrier
and lay cover foil immediately on damage location (do not
press down) to prevent air from entering. The foil contains an
activator to dry the resin.
– Immediately return injector to packaging because resin is UV
sensitive and can be reused for the next repair. Replace tool
carrier in released position in case and remove mirror with
mount.
12. Glass Repair 37

– Secure UV lamp -1- over damage location. Allow UV light to

act on resin for 10 minutes, then remove UV lamp.
– Smooth out damage location with removal blade and possibly
polish with 12 Volt drill machine and polishing set.
Note
♦ After the repair, the vehicle is ready to operate again without

any waiting time.
♦ Traces of fractures cannot be removed completely with many
types of breaks but they do not affect the results of the repair.
♦ After repair, the window is as strong as normal and further
cracks are prevented by the molded and hardened plastic res‐
in. The hardened resin is colorless and has the same refraction
index as glass.
12.2 Aluminum Repairs
Note
♦ This guide only applies to conventional steel vehicles on which

aluminum panels are installed.
♦ You can see the areas where these panels are used in a pic‐
ture in the respective body repair manual, ⇒ Body Repair; Rep.
Gr. 00
♦ For repairs with all-aluminum vehicles, e.g. Audi A8, the fol‐
lowing repair manual applies: ⇒ Body Repair; Rep. Gr. 00 ,
⇒ Body Repair; Rep. Gr. 50 , ⇒ Body Repair; Rep. Gr. 51 and
⇒ Body Repair; Rep. Gr. 53 .
Paint ⇒ page 38
Surface treatment ⇒ page 38
Removing dents ⇒ page 39
Controlling temperature when heating ⇒ page 39
WARNING
Use tools for either steel or aluminum.

Recommendation: Aluminum tool kit in tool storage unit -
V.A.G 2010/2-
12.2.1 Paint
Paint structure is identical to a steel body.

Only approved, aluminum-compatible materials may be used.
WARNING
Only remove glue dots on ground connections after painting.
12.2.2 Surface treatment

Only use wire brush on high-grade steel.
38 12. Glass Repair

Grinding disks should not be used because of their lubricating

effect.
Use P 80 to P 200 grit sanding discs.
Only use sanding discs, drill bit, drill and cutting discs with clean‐
ing block DA 009 802.
Clean surface with thinner.
Additional surface treatment same as with steel.
Note
Cover aluminum parts when sanding or welding steel parts. If

steel shavings get onto aluminum, remove this immediately be‐
cause they can cause contact corrosion.
WARNING

Recommendation: Aluminum tool kit in tool storage unit -
V.A.G 2010/2-
12.2.3Protected
Removing dents
There is a greater danger of stretching with aluminum than with
steel.
Sharp-edged and hard dent removal tools (e.g. steel hammer)
should be avoided and should be replaced with plastic, wood or
aluminum hammers.
Direct dent removal procedures, that is, aluminum panel lies di‐
rectly between counterhold and dent removal hammer, should be
reduced.
In contrast to steel, dent removal work on aluminum panels be‐
gins in the middle of the dent.
Aluminum panels should be pressed more than struck.
When finishing, handle counterhold loosely. Finishing that is too
forceful can cause the material to stretch. For this reason, you
should use a counterhold made of hardwood.
If the material still stretches, this can be corrected by supplying
heat and retracting.
WARNING
Retracting heat 302º F (150° C) max.
Replace part if a tear forms when removing dents.
12.2.4 Controlling temperature when heating

No tempering colors can be recognized when heating aluminum.
Therefore, temperature must be determined with thermo-pegs or
thermo-strips.
12. Glass Repair 39

Thermo-pegs and thermo-strips change color at specific temper‐

atures.
A - Warming area
B - Free zone
C - Thermo-pin or thermo-strip
40 12. Glass Repair

13 Aluminum
The Audi Space Frame concept ⇒ page 41
13.1 The Audi Space Frame Concept

For the first time ever -not just for Audi, but for the entire world- ,
vehicle bodies are being assembled as ASF - Audi Space Frame.
ASF means: A combination of aluminum sections and aluminum
die-cast joints.
All additional aluminum body pieces are attached to this new Audi
frame construction with gas-shielded welding, punch rivets, bond‐
ing and clinching (caulking two panels).
The special repair techniques are described in the following chap‐
ters.
13. Aluminum 41
14 Contact Corrosion!
Contact corrosion may occur if unsuitable connecting elements
(bolts, nuts, washers and so on) are used.
For this reason, only connecting elements with a special surface
coating are installed (Dacromet). These elements are distinguish‐
ed by their greenish hue.
Furthermore, all rubber, plastic and adhesive materials used are
non-conductive.
If there is any doubt about the reusability of parts, always install
new replacement parts.
Note: ⇒ page 42
14.1 Note:
Only use genuine Audi replacement parts! They are tested and
aluminum-compatible.
Additional equipment must be approved by Audi of America!
Damage via contact corrosion is not covered by warranty!
42 14. Contact Corrosion!

15 Threads
If damaged threads are repaired, inserts with galvanized coating
must be used.
Steel shavings from drilling must be removed completely.
Only replace threaded pins with genuine Audi parts.
Damaged threads can be repaired with thread inserts with galvan‐
ized coating.
Contact corrosion is prevented only by using this coating.
Some threads are already supplied with thread inserts at the fac‐
tory.
15. Threads 43
16 Bolts
Bolts cannot be welding with devices available in service.
In case of repairs, use steel hollow rivets with galvanized coating.
Contact corrosion is prevented only by using this coating.
Required drill bit diameter ∅ 5 mm.
Note
Rivet must sit flush against surface and rivet head must break
away predetermined breaking point in the rivet.
44 16. Bolts
17 Paint
Paint structure is identical to a steel body.
Only approved, aluminum-compatible materials may be used.
WARNING
Only remove glue dots on ground connections after painting.
17. Paint 45
18 Replacement Parts
Special aluminum alloys are used for the body.
The manufacturer heat-hardens the aluminum body after assem‐
bly. A temperature of 400º F (205° C) for 30 min. is needed for
this.
Because it is not possible to harden the body with workshop tools,
replacement parts are delivered pre-hardened.
Only use genuine Audi parts for repairs and follow specified in‐
structions.
46 18. Replacement Parts

19 Safety Precautions
Welding and sanding must be carried out with ventilation.
Never weld and sand in any area at the same time.
Clean workplace regularly in proportion to the amount of dust.
Accumulated dust must not be blown away with compressed air.
The exhaust system must be cleaned regularly.
Also, observe the corresponding regulations from the UVW and
the BG.
19. Safety Precautions 47

20 Surface Treatment
Due to the especially light way, aluminum dust or shavings do not
fall to the floor immediately, but rather stay in the air for some time.
Only perform surface or cutting work with ventilation.
Only use wire brush on high-grade steel.
Grinding disks should not be used because of their lubricating
effect.
Use P 80 to P 200 grit sanding discs.
Only use sanding discs, drill bit, drill and cutting discs with clean‐
ing block DA 009 802.
Commercially-available sanding materials can be used on alumi‐
num without the cleaning block.
Clean surface with thinner.
WARNING
48 20. Surface Treatment

21 Cutting
Cutting ⇒ page 49
21.1 Cutting
Perform cutting work only with the body repair saw or panel
shears.
The tooth pitch for aluminum saw blades is greater than for steel
panels.
Only use cutting discs with cleaning block DA 009 802.
Always use ventilation.
WARNING
Perform cutting work only according to the repair manual spec‐

ifications in the appropriate Body Collision Repair Manual
21. Cutting 49
22 Removing Dents
There is a greater danger of stretching with aluminum than with
steel.
Sharp-edged and hard dent removal tools (e.g. steel hammer)
should be avoided and should be replaced with plastic, wood or
aluminum hammers.
Direct dent removal procedures, that is, aluminum panel lies di‐
rectly between counterhold and dent removal hammer, should be
reduced.
In contrast to steel, dent removal work on aluminum panels be‐
gins in the middle of the dent.
Aluminum panels should be pressed more than struck.
Handle counterhold loosely when finishing. Forceful finishing can
cause the material to stretch. Use a hardwood counterhold to
avoid this.
Stretches in the material can be corrected by supplying heat and
retracting.
50 22. Removing Dents

23 Reshaping
Reshaping cannot be done as with a steel body.
Damaged cast joints or assembly sections must be replaced.
23. Reshaping 51
24 Controlling Temperature when Heat‐

ing
No tempering colors can be recognized when heating aluminum.
Therefore, the temperature must be determined using thermo-
strips.
If thermo-strips are used: V/150.4 temperature range 210º F (99°
C) - -260º F (-127° C) V/150.5 temperature range 269º F (132° C)
- -320º F (-160° C)
Supply source: Matra.
Thermo-strips change color at specific temperatures.
A - Warming area with respect to the correctness of information in this document. Copyright by AUDI AG.
B - Free zone
C - Thermo-strips
52 24. Controlling Temperature when Heating

25 Flanging
The outer side panel is delivered pre-hardened.
Therefore, flanging requires a special procedure and is carried
out in 2 steps.
– 1. Bend flange up with pliers. Maintain radius R = 2.5 mm.
– 2. Fasten upper area with hammer using counterhold. Radius
R = 2.5 mm must be maintained when doing so.
If the radius is not maintained the side panel could tear.
A level bond must be provided between inner and outer parts in
shaded area.
25. Flanging 53
26 Welding Repairs
Assembly section cast joints ⇒ page 54
26.1 Assembly Section Cast Joints

– Assembly section weld seam - saw of cast joints in center.
– Sand away rest of weld seam.
– Separate rest of assembly section from cast joints with chisel.
WARNING
Do not damage cast joints. If a cast joint is damaged or de‐

formed it must be replaced.
– Adjust new parts.

– Clean 40 mm on both sides of flange with wire brush and re‐
move oxide layer.
– Weld on assembly section, original weld seam.
54 26. Welding Repairs

27 Assembly Section
– Remove damaged area.
– Adjust new parts. To do this, shorten each welding groove by
1 material thickness -a-.
– Prepare sleeve -A- for insertion. Length approx. 40 mm.
– Insert sleeve in old and new piece.
– Clean 40 mm on both sides of flange and sleeve with wire
brush and remove oxide layer.
Note
The sleeve functions as a welding line retainer. The seam base

should fuse onto the sleeve.
– Weld connection, gas-shielded arc continuous weld seam all

around.
Maximum weld seam projection: 1.5 mm. Sand down if necessa‐
ry.
27. Assembly Section 55

28 Panel
– Separate weld seam at center with body repair saw and re‐
move damaged part.
– Remove rest of panel with chisel. Sand front of weld seam if

needed.
– Adjust new parts.
– Clean 40 mm on both sides of flange with wire brush and re‐
move oxide layer.

– Weld panel, original weld seam.
56 28. Panel
29 Resistance Spot Welding

– Loosen spot welds with spot weld drill or sand off.
WARNING
– Remove damaged part, separate with chisel if needed.

– Sand down projections.
– Adjust new part.
– Drill upper panel for plug welding -d- ∅ 8 mm for 1.3 mm, ∅10
mm for 2 mm panel thickness.
– Clean flanges and remove oxide layer with wire brush.
– Perform plug welding from center outward.
Note
Rivets are also permitted, to some extent. Observe Repair Man‐

ual “Body Repair”.
29. Resistance Spot Welding 57

30 Welding Aluminum
Metal Inert Gas (MIG) welding is used by the manufacturer and
in service.
Argon is used as inert gas.
AISi 12 ∅ 1 mm welding wire is used.
The welding device has a current control on the handle.
Clean undercoating and paint off of about 40 mm on both sides
of parts and then remove oxide layer with a wire brush before
welding.
To avoid formation of cracks, weld seams must be drawn around
section corners.
Only weld with ventilation -VAG 2011- .
Use panel 4D0 899 103 for welding practice and repairs.
Full particulars can be found in the aluminum welding training
guide.
Welding power source, inert gase and welding wire, ⇒ Special
Tools and Equipment Catalog.
58 30. Welding Aluminum

31 Checking Weld Seams and Cast

Joints
The color penetration process is used to test for surface cracks.
WARNING
Do not brush before the test or the cracks will be smeared.
All cracks must be sanded out and re-welded.
31. Checking Weld Seams and Cast Joints 59

32 Laser Weld Seam

Aluminum laser welding was adopted by Audi starting with the A2.
– Separate laser weld in upper area with straight sander.
– Remove part and loosen remainder with chisel, if necessary.
60 32. Laser Weld Seam

33 Rivets and Tools Overview

♦ Compressed air rivet pliers -V.A.G 2002B-
♦ Solid rivet N 103 239.01 4 x 8
♦ Solid rivet N 103,240.01 4 x 12
♦ Pop rivet pliers -VAS 5072-
♦ Punch rivet 4d0 803 217 N 3,35 x 5
♦ Punch rivet 4d0 803 217 C 3,35 x 4
♦ Pneumatic pop rivet pliers -V.A.G 2003-
♦ Pop rivet N 906 634.01 6 x 9
33. Rivets and Tools Overview 61

34 Repairing Rivets
Punch rivets ⇒ page 62
34.1 Punch Rivets

– First make separating cuts, if necessary.
– Press out punch rivet with rivet tool. Insert tip of die in imprint
in panel.
Note
Adjust rivet tool to material thickness for all procedures. If flange

is not accessible with rivet tool, remove damaged part with rough
cut.
WARNING
Punch rivets can either be drilled out or sanded down.
When pressing down, a hole forms on the inner panel while the
punch rivet remains on the outside.
Different inserts are used for the various rivet sizes.
– Separate bonded jointProtected
with chisel andCopying
by copyright. remove part.or commercial purposes, in part or in whole, is not
for private
62 34. Repairing Rivets

– Reshape flange on undamaged panel with rivet tool.

– Fit new parts and install solid or pop rivets, according to the
repair manual.
Note
The punch rivet is made of steel and is provided with a special

coating. Sparks when sanding are an indication of punch rivet
remnants. Remove punch rivet
Protected remnants
by copyright. and
Copying for change sanding
private or commercial purposes, in part or in whole, is not
disc. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
If punch rivet cannot be access with rivet tool, the aluminum can
be drilled out around the rivet with a nickel-plated spot weld drill
with spring-mounted bit (e.g. Hazet 1967).
If punch rivets fall into inside of vehicle, these must be removed.

A magnet can be used.
34. Repairing Rivets 63

35 Clinching
– Press back clinch point with rivet tool.
Note
Adjust rivet tool to material thickness for all procedures.

– Fit new parts and install solid or pop rivets, according to the
repair manual “Body Repair Manual”.
64 35. Clinching
36 Solid Rivet
– Sand off closing head and press out solid rivet with rivet tool.
– Fit new parts and install solid rivets.
36. Solid Rivet 65

37 Pop Rivet
– Drill out pop rivet, drill bit diameter 4.5 mm.
WARNING
Catch pop rivet remnants. If remnants fall in cavities, they

should removed with wax.

– Fit new parts and install pop rivets.
Note
Rivet is composed entirely of aluminum. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
66 37. Pop Rivet

38 Solid Rivet, Installing

– Fit new parts, apply adhesive and place new part on body and
secure.
– Stamp flange with rivet tool.
When stamping, the punch hole and the imprint are made in one
process.
Note
Adjust rivet tool to material thickness for all procedures. To pre‐

vent flange from gaping after stamping, insert staples in stamping
holes.
– Insert solid rivet and affix closing head with rivet tool.
There are corresponding rivet tool inserts for the various rivet di‐
ameters.
Note
In contrast to production, all rivet joints in service are also bonded.

See bonded joint. The solid rivet is made of aluminum.
2 solid rivets are available:

Solid rivet ∅ 4 x 8 for 2 panel connection
Solid rivet ∅ 4 x 12 for 3 panel connection
38. Solid Rivet, Installing 67

39 Punch Rivet, Installing

– Fit new parts, apply adhesive and place new part on body and
secure.
– No drilling or stamping of holes is needed with punch rivets.
– Attach Battery Punch Rivet Pliers -VAS 5279 A- and attach
rivets.
2 punch rivets are available:
4D0 803217 N
4D0 803217 Q
Note

See bonded joint. The punch rivet is made of aluminum.
68 39. Punch Rivet, Installing

40 Pop Rivet, Installing

– Fit new parts, place on body and secure.
– Drill old and new part or same material together, ∅ 2.5 mm.
– Remove new part.
– Imprint drilled holes in all parts with rivet tool.
Note
Adjust rivet tool to material thickness for all procedures. The di‐
ameter increases to 4.8 mm with imprinting. The imprint must face
inward on all parts.
Assembly sections cannot be imprinted. Lower new part with as‐

sembly section, remove part and drill out assembly profile to ∅
4.8 mm.
– Apply adhesive.
– Install pop rivet and pull pin with rivet pliers.
Note

See bonded joint. The rivet is made entirely of aluminum.
WARNING
Rivets with steel pins may not be used. with respect to the correctness of information in this document. Copyright by AUDI AG.
40. Pop Rivet, Installing 69

41 Rivet Problems
Open Countersinks ⇒ page 70
Non-fitting Rivet Heads ⇒ page 70
Air Gap ⇒ page 70
Rings ⇒ page 71
41.1 Open Countersinks

Countersinks open over the entire circumference are not permit‐
ted. Partially open countersinks up to a gap width of 0.04 mm are
permitted.
Sizing, e.g. with a cambered riveting die, is permitted as long as
teh tolerance for closing and setting head are maintained.
41.2 Non-fitting Rivet Heads

Loose rivets are not permissable.
Partial gap up to 0.05 mm allowed in some instances.
41.3 Air Gap

Bulge ⇒ page 71
Torque cracks ⇒ page 71
Indent ⇒ page 71
During the riveting process, the rivet material is pushed into the
gap and causes bending stress to the rivet.
Not permissable.
70 41. Rivet Problems

41.3.1 Bulge
Bulges must not exceed a gap width of 0.3 mm.
41.3.2 Torque cracks

Cracks must not overlap.
Permissable.
Not permissable.
41.3.3 Indent
Permissable indent depth 1/4 x height of head.
41.4 Rings
Offset closing head ⇒ page 72
Rings form when riveting die that is too small is used.
Not permissable.
41. Rivet Problems 71

41.4.1 Offset closing head

Impermissable as soon as the closing head touches the shaft and
the rivet hole is visible.
72 41. Rivet Problems

42 Set an Edge
– Set with setting pliers.
Note
Allow 22 mm for overlap when making separating cuts. Cannot

be set. Underlay same material. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
In order to be able to spackle the cutwith
location
respect to later, bevelofupper
the correctness information in this document. Copyright by AUDI AG.
panel 45° and chamfer edges.
A special metal filler is used. See Release.
Note
Spacking is applied to bare aluminum. filler cures at 120° C.
42. Set an Edge 73

43 Same Material, Underlaying

Same material -C- is created from remainder of new -B- or old
parts -A-. Same material should also be underlaid on beaded
panel edges. On small cross sections or large panel edges, the
same material is separated.
– Bevel both panels 45°. Round outer edge (radius = 3) and
chamfer inner edge.
Panel tips must be 3 to 4 mm apart.
74 43. Same Material, Underlaying

44 Separating Cuts, Filling

A special aluminum filler is used. Aluminum powder DA 004 200
A2 and hardener DA --4 201 A1. Hardener DA 004 211 A1 must
be used at temperatures over 68º F (20° C) and/or relative hu‐
midity above 80%.
– Follow instructions for use on container.
– Clean adhesive residue from gap with wire brush.
– Apply filler to bare aluminum and fill gap up to level of panel.
– Leave filler at room temperature about 20 min. until surface is
matte gray.
– Cure filler with hot air gun or infrared lamp at 248º F (120° C)
for approx. 20 min.
– Finish filler.
44. Separating Cuts, Filling 75

45 Bonded Joint
Caution
Pretreatment only valid for old flange.
– Remove adhesive residue, paint, wax, etc.

– Sand adhesive surface down to bare metal with clean 80 or
100 grit sanding disc.
– Work on flange with grindstone DA 009 800 and mount -
VAG 1931- .
There is no silica-based undercoating that guarantees long-term
durability of the bonded joint. The surface becomes matte.
– Remove sanding dust with clean brush.
Do not use any solvent.
– Lighly apply aluminum primer DA 009 801 with brush and allow
to dry.
Pretreatment Valid for Replacement Part ⇒ page 76
45.1 Pretreatment Valid for Replacement

Part
– Clean painted flange with D 009 401.04
Caution
Cover adhesive surfaces when painting inner side.
76 45. Bonded Joint

– Apply adhesive DA 001 730 A1 to body side, add parts and

secure. Adhesive bead diameter 3.5 mm.
Add and secure parts within 30 min. Otherwise, the adhesion will
be insufficient due to the formation of a surface skin.
– Install rivets and wipe away escaping adhesive.
Rivets must be installed at temperature up to 68º F (20° C) within
150 min and within 40 min. at temperatures over 68º F (20° C,
beginning at application of adhesive.
Note
♦ If the adhesive escapes on both sides along the entire length,

too much was applied.
♦ 1 cartridge with 37 ml is enough for approx. 4 m of flange.
The adhesive must cure before further surface work.

Curing time:
68º F (20° C: 8 h
176º F (80° C): 20 min.
Note
♦ On large parts, such as the roof, it is necessary to perform the

work with a helper. Otherwise the adhesive will dry before work
is complete.
♦ Before inserting mixing nozzle, ensure double cartridge open‐
ings are clean. Firmly install mixing nozzle and press out a
bead about 10 cm long and apply adhesive.
♦ After breaks up to 30 minutes, press out a bead about 10 cm
long so that new material is mixed. After breaks over 30 min.,
replace mixing nozzle and press out a 10 cm long bead. If more
cartridges are needed for a repair, these can be processed
with a mixing nozzle.
45. Bonded Joint 77

46 Rivets Accessible from One Side

– Remove paint and oxide layer on rivet head and glue dot for
ground pliers.
– Attach ground pliers as close to rivets as possible.
– Set welding current on Dent removing device for aluminum
vehicles -VAS 5196- to display 150.
– Weld 4 mm bolts with -VAS 5196/1- .
– Pull out bolts with -VAS 2003- and mouthpiece -VAS 2003/1- .
78 46. Rivets Accessible from One Side

47 Explanation of Symbols
Welding Legend ⇒ page 79
47.1 Welding Legend

Gas-shielded arc continuous weld seam
Gas-shielded arc continuous weld seam intermittent
Gas-shielded arc stitch weld seam
Gas-shielded arc plug weld seam SG = gas-shielded welding
47. Explanation of Symbols 79

48 Riveting Legend
Solid rivet with countersunk head
Pop rivet with countersunk head
80 48. Riveting Legend

49 Set an Edge
Perforate ⇒ page 81
Drill ⇒ page 81
– To perform overlapping riveting.
49.1 Perforate
– To perform a gas-shielded arc plug weld later.
49.2 Drill
– To perform gas-shielded arc plug welding or drill out clinching
points (original connection) or drill out retainer holes.
49. Set an Edge 81

50 Cavity Sealant
Adhesives ⇒ page 82
– Sealant spraying gun
50.1 Adhesives
82 50. Cavity Sealant

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Service

General InformationBody Repair,

Service Department. Technical Information

All rights reserved.

Copyright © 2008 Audi AG, Ingolstadt D3E8008F902

10 Protection against Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

43 Same Material, Underlaying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Seat Belts, Inspecting ⇒ page 3

Working on Vehicles With Belt Tensioners ⇒ page 4

1.1 Removing Components

1.2 Battery, Welding Procedures

Before disconnecting battery ensure that radio code is available.

Before welding, you must disconnect both battery terminals and

Switch off ignition before connecting battery!⇒ Electrical

1.3 Electronic Control Modules

Procedure for Electronic Control Modules after accident repairs

1.3.1 Procedure for Electronic Control Mod‐

1.4 Paint, Glass, Upholstery, Trim

1.5 Fuel Tank or Fuel Lines

1.6 Air Conditioning

The system must be evacuated when it is necessary to weld elec‐

It is advisable to have a rinsing bottle for the eyes handy at all

Although refrigerant does not present a fire hazard, smoking is

1.7 Airbag System

Switch off ignition before connecting battery! ⇒ Electrical

Airbag components must not even briefly be subjected to tem‐

1.8 Seat Belts, Inspecting

After every accident, seat belt system must be checked sys‐

1.9 Working on Vehicles with Belt Tension‐

Before beginning separation work, straightening work or dent

If the belt webbing is completely unrolled, the load detection (re‐

The following vehicles with no load detection on belt tensioners:

1.10 Separating Work, Straightening Work

Switch off ignition before connecting battery!

Repair notes ⇒ Body Interior; Rep. Gr. 69 ; Safety precautions

1.11 Seats with Side Airbags, Removing

You must always follow safety precautions when removing

2.1 Diagnosis of Vehicles in Accidents

2.2 General Information about Body Re‐

Standard repairs are described in the repair manual. Further de‐

2.3 Conditions in which Body and/or Parts

If the size of the damage does not allow it to be reshaped against

2.5 Separating Cuts

2.6 Replacement Body Sub-parts and Part

2.7 Original Joint

2.8 Galvanized Body Parts

Because toxic galvanized oxide develops in welding emissions

2.9 Removing Remaining Material

2.10 New Parts

2.11 Replacement Parts

3 Expanded Foam Inserts

Expanded foam inserts expand only after reaching 180 °C.

Insert replacement expanded foam inserts.

3. Expanded Foam Inserts 9

4.1 Welding Legend

4.2 Work Procedures Legend

4.2.2 Set an edge

4.2.6 Cavity sealant

5 Body Repair Tools

The following tools are organized according to V.A.G / VAS num‐