Service

Body Repairs
Audi A8 2003 ➤ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Edition 05.2011
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 overview for Body Repairs

Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear

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.

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 © 2011 Audi AG, Ingolstadt A004EKI0120

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Moulded foam inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Repair methods for bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.1 Floor group, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.2 Floor group, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Floor group, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Wing mounting flange - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Wing mounting flange - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Front wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4 Front longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5 Longitudinal member (front section) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1 Roof - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 Roof side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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2.1 Tools . . . . . . . . . . . . . . . . . . . . permitted
. . . . . unless
. . . .authorised
. . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG. .does
. . .not. .guarantee
. . . . . or. accept
. . . . any
. . liability
. . 54
2.2 Procedure . . . . . . . . . . . . . . . . . with . . .respect
. . . .to. the
. . correctness
. . . . . . of
. .information
. . . . . .in. this
. . document.
. . . . . .Copyright
. . . . . by. .AUDI
. . .AG.
. . 55
3 Roof side member - Renewal (long version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4 A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5 Outer B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Contents i
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7 Inner B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1 Rear cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 Rear cross member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Rear longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4.3 Rear wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5 Spare wheel well - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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.

ii Contents
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

00 – Technical data
1 Vehicle identification data

1.1 Vehicle identification number

The vehicle identification number appears in the windscreen on
the driver's side, on the vehicle data sticker and is stamped on
the suspension turret (right-side).

1.2 Type plate

The type plate is located on the passenger-side door pillar. Ve‐
hicles for certain export countries have no type plate.

1.3 Vehicle data sticker

The vehicle data sticker is located in the spare wheel well under
the luggage compartment floor (left-side in direction of travel).

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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.

1. Vehicle identification data 1

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

2 Moulded foam inserts

Various body cavities of the Audi A8 2003 are fitted with moulded
foam inserts.
The foam inserts reduce the noise transmitted to the interior when
driving.
These pre-moulded parts are fitted during body manufacture and
subsequently increase their volume in the paint shop drying oven
at approx. 180 °C after priming.

Caution

The replacement foam inserts expand only after reaching

about 180°C. For this reason, an additional filler foam is used
when performing repairs.
Filler foam required for repairs: D 506 KD1 A3.

As the required temperatures cannot be achieved under normal

workshop conditions, proceed as follows:
Remove residue of foam material on vehicle.
Restore paint coating; apply two coats (wet on wet) of glass/paint
primer D 009 200 02 if necessary, flash-off time approx.10 mi‐
nutes.
Requirement
Before continuing with this procedure, ensure that the replace‐
ment panel is ready for installation, i.e. cut to shape, matched up
to the vehicle, corrosion protection applied.
Renewing moulded foam insert
Fix moulded foam insert to vehicle.
Apply filler foam -D 506 KD1 A3- to replacement part.
Secure new part in position. Gently press in new part in vicinity of
moulded foam insert until it makes contact, and then weld into
place.
The foam hardens within 25 minutes.
Do not weld (SG) within 15 mm of the foam insert (on either side).
After painting the vehicle the repaired area must be cavity-sealed.

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with respect to the correctness of information in this document. Copyright by AUDI AG.

2 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

3 Repair methods for bonded joints

3.1 Body - rear

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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.

– Light mounting to outer side panel. 5x solid rivets.

3. Repair methods for bonded joints 3

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4 Body dimensions

4.1 Floor group, front

a - 836 ± 2 mm
Distance between front attach‐
ment points of front suspen‐
sion

b - 1067 ± 2 mm
Diagonal distance between at‐
tachment points of front sus‐
pension

c - 762 ± 2 mm
Distance between rear attach‐
ment points of front suspen‐
sion

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with respect to the correctness of information in this document. Copyright by AUDI AG.

4 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4.2 Floor group, centre

a - 1818 ± 2 mm
Distance between rear attach‐
ment points of front suspen‐
sion and rear axle mounting

b - 2245 ± 2 mm
Diagonal distance between
rear attachment points of front
axle and rear axle mounting

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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.

4. Body dimensions 5
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4.3 Floor group, rear

a - 1444 ± 2 mm
Distance between front attach‐
ment points of rear suspension

b - 1078 ± 2 mm
Distance between rear attach‐
ment points of rear suspension

c - 1599 ± 2 mm
Diagonal distance between at‐
tachment points of rear sus‐
pension

d - 1032 ± 2 mm
Distance between attachment
points of rear suspension

e - 1014 ± 2 mm
Distance between rear attach‐
ment points of rear suspension

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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.

6 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4.4 Body - front

a - 1026 ± 2 mm
Distance between front longi‐
tudinal members

b - 894 ± 2 mm

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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4. Body dimensions 7
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

c - 1428 ± 2 mm
Distance between wing panel
mountings

e - 848 ± 2 mm
Distance between attachment
points of suspension strut
mountings

f - 1510 ± 2 mm
Distance between front hinge
mountings

d - 1726 ± 2 mm
Diagonal distance between
hinge mountings and wing
panel mountings

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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.

8 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4.5 Body - centre

4.5.1 Front door opening

a - 929 ± 2 mm
Height of door opening

b - 1552 ± 2 mm
Distance between A-pillars

c - 1124 ± 2 mm
Distance between A-pillar and
B-pillar

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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.

4. Body dimensions 9
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4.5.2 Rear door opening

a - 964 ± 2 mm
Height of door opening

b - 917 ± 2 mm
Distance between B-pillar and
C-pillar

c - 1506 ± 2 mm
Distance between C-pillars

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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.

10 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4.6 Body - rear

a - 1096 ± 2 mm
b - 914 ± 2 mm
Distance between rear longitu‐
dinal members

c - 1259 ± 2 mm
Distance between side panels
(top)

d - 603 ± 2 mm
Distance between rear cross
panel flange and window cross
member flange

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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.

4. Body dimensions 11
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

5 Body panel gaps/shut lines

5.1 Body - front

N - 0.0 mm
A - 1.0 mm
D - 2.0 mm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
F - 3.0 mm 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.
J - 4.5 mm
K - 5.0 mm

Use special tool 3371 for adjusting or checking.

12 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

5.2 Body - centre

N - 0.0 mm
D - 2.0 mm
E - 2.5 mm
F - 3.0 mm
G - 3.5 mm
H - 4.0 mm
J - 4.5 mm
K - 5.0 mm
M - 6.0 mm

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5. Body panel gaps/shut lines 13

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

5.3 Body - rear

D - 2.0 mm
E - 2.5 mm
F - 3.0 mm
G - 3.5 mm
H - 4.0 mm
K - 5.0 mm

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.

14 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

6 Straightening jig

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.

Alignment bracket set -VAS 6181- (also suitable for quattro ver‐
sions)

Note

♦ The item numbers in the illustrations are identical with the end numbers on the alignment bracket mountings.
♦ The item numbers of the alignment bracket mountings marked with a circle are for checking the body with
mechanical units installed.
♦ The required basic set size is given for the alignment bracket mountings.
♦ The following illustrations show the right side of the vehicle.

6. Straightening jig 15
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

2 - MZ 260 and TV 400

4 - MZ 260
6 - MZ 602
12 - Mounting for bar
6 - MZ 602 and alignment
bracket mounting -8-
10 - Bolts for suspension strut
mounting
11 - Bolt for suspension strut
mounting
14 - Bar in place of steering
box 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
15 - Mounting
withfor steering
respect to the correctness of information in this document. Copyright by AUDI AG.

16 - MZ 140
20 - Bracket without MZ, and
front production mounting -21-
22 - MZ 200 (quattro only)
24 - MZ 080
26 - MZ 200
28 - MZ 602 and alignment
bracket mounting 29
30 - MZ 260
32 - MZ 142 and TV 400

16 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

2 - MZ 200 and TV 400

4 - MZ 260
6 - MZ 602
16 - MZ 140
22 - MZ 200
24 - MZ 080
26 - MZ 200
28 - MZ 602
30 - MZ 260
32 - MZ 142 and TV 400

Overview and locations of MZ elements

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.

6. Straightening jig 17
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4 - MZ 080
5 - Spacer
16 - MZ 080
18 - Left and right centring
piece identical
20 - Bracket without MZ, and
front production mounting -21-
24 - MZ 080
26 - MZ 140
30 - MZ 200

Overview of alignment brackets for vehicles with mechanical units

installed 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.

18 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4 - MZ 080
16 - MZ 080
20 - Bracket without MZ, and
front production mounting -21-
24 - MZ 080
26 - MZ 140
30 - MZ 200

Overview of MZ elements for vehicles with mechanical units in‐

stalled

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.

6. Straightening jig 19
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

2 - MZ 260 and TV 400

4 - MZ 260
6 - MZ 602
12 - Mounting for bar
6 - MZ 602 and alignment
bracket mounting -8-
10 - Bolts for suspension strut
mounting
11 - Bolt for suspension strut
mounting
14 - Bar in place of steering
box
15 - Mounting for steering
20 - Bracket without MZ, and
front production mounting -21-
22 - MZ 200 (quattro only)
24 - MZ 080
34 - MZ 140
36 - Base plate

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.

Overview of alignment brackets for long A8 vehicles (130 mm

longer) when repairing front-end damage

20 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

2 - MZ 200 and TV 400

4 - MZ 260
6 - MZ 602
16 - MZ 140
22 - MZ 200
24 - MZ 080
34 - MZ 140

Overview of MZ elements for long A8 vehicles (130 mm longer)

when repairing front-end damage
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.

6. Straightening jig 21
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4 - MZ 080
5 - Spacer
16 - MZ 080
18 - Left and right centring
piece identical
20 - Bracket without MZ, and
front production mounting -21-
24 - MZ 080
28 - MZ 602 and alignment
bracket mounting 29
30 - MZ 260
32 - MZ 142 and TV 400
34 - MZ 200

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.

Overview of alignment brackets for long A8 vehicles (130 mm

longer) when repairing rear-end damage

22 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4 - MZ 080 and base plate 36

16 - MZ 080 and base plate 36
20 - Bracket without MZ, and
front production mounting -21-
24 - MZ 080
28 - MZ 602 and alignment
bracket mounting 29
30 - MZ 260
32 - MZ 142 and TV 400
34 - MZ 200

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.

Overview of MZ elements for long A8 vehicles (130 mm longer)

when repairing rear-end damage

6. Straightening jig 23
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

2 - Front longitudinal member

When checking, bolt on MZ
last, as the longitudinal posi‐
tion of the impact damper
mounting can vary by
several mm due to production
tolerances - if necessary do not
bolt down.

3 - Spacer
38 - Front longitudinal mem‐
ber / top of wheel housing

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.

24 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Overview of front alignment brackets

6. Straightening jig 25
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

14 - Bar in place of steering

box
Lubricate bar with oil and take
care to avoid damage.

15 - Mounting for steering

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.

26 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

4 - Mounting for front longitudi‐

nal member
6 - Mounting for suspension
strut and alignment bracket
mounting -8-
12 - Mounting for bar
16 - Mounting for front longitu‐
dinal member
20 - Bracket
21 - Front production mounting
May have been forced up‐
wards by handling vehicle in
factory: when checking dimen‐
sions, pack with spacer up to 4
mm if necessary

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.

6. Straightening jig 27
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Overview of front alignment brackets

28 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

22 - Mounting for propshaft

(quattro only)

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.

6. Straightening jig 29
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Overview of centre alignment brackets

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.

30 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

26 - Mounting for rear axle

Do not insert pin until after fit‐
ting body on jig.

28 - Suspension strut mount‐

ing
Do not insert pin until after fit‐
ting body on jig.

30 - Mounting for rear axle 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.

6. Straightening jig 31
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

32 - Mounting for rear longitu‐

dinal member

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.

32 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Overview of rear alignment brackets

6.1 Portal gauge

Portal gauge -VAS 5007/15-

A - Extension
B - Telescopic column
C - Cross bar 1200 mm
42 - Mounting for A-pillar
42 - MZ 260
44 - Metal insert for inner A-pil‐
lar
44 - MZ 260
49 - Mounting for B-pillar

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.

6. Straightening jig 33
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

A - Extension
B - Telescopic column
C - Cross bar 1200 mm
44 - Metal insert for inner A-pil‐
lar
44 - MZ 260
49 - Mounting for B-pillar
46 - Mounting for A-pillar
46 - MZ 260

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.

34 Rep. gr.00 - Technical data

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

6.1.1 Portal gauge for long Audi A8

A - Extension
B - Telescopic column
C - Cross bar 1200 mm
44 - Metal insert for inner A-pil‐
lar
44 - MZ 260
49 - Mounting for B-pillar
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
46 - Mounting for A-pillar with respect to the correctness of information in this document. Copyright by AUDI AG.
46 - MZ 260

6. Straightening jig 35
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

50 – Body - front
RO: 50 72 55 00

1 Wing mounting flange - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

1.1 Tools
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Shielded arc welding equipment 250A

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.

♦ Rechargeable riveter -VAS 5279A-

1.2 Procedure
Cutting locations

WARNING

Take care not to damage node castings and extruded sections

when cutting.

– Separate weld seams using compact angle grinder -VAS

5167- .
– Separate original joint with rechargeable riveter -VAS 5279A- .

36 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Remove small punch rivets. Use rechargeable riveter -VAS

5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .
– Detach part.

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.

Replacement part
♦ Wing mounting strip
Preparing new parts
– Match up new parts.
– Prepare flanges on body and new parts for welding.
– Fix new part in position with alignment bracket.
Welding in

1. Wing mounting flange - Renewal 37

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Weld wing mounting flange to A-pillar using shielded arc weld‐

ing equipment 250A : SG continuous seam.

– Weld wing mounting flange to node casting on suspension

strut mounting using shielded arc welding equipment 250A :
SG continuous seam.

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.

38 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 50 72 55 02

2 Wing mounting flange - Partial re‐

newal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

2.1 Tools
Special tools and workshop equipment
Protected by copyright. required
Copying for private or commercial purposes, in part or in whole, is not

♦ Compact angle grinderwith

-VAS 5167-
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Pneumatic glue gun -V.A.G 2005 B-

♦ Shielded arc welding equipment 250A

2.2 Procedure
Cutting locations

WARNING

Take care not to damage node castings and extruded sections

when cutting.

– Remove small punch rivets. Use rechargeable riveter -VAS

5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .
– Make separating cut as shown using pneumatic sabre saw -
V.A.G 1523A- .

2. Wing mounting flange - Partial renewal 39

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Detach part.

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.

40 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement part
♦ Punch rivets (self-piercing rivets)
♦ 2-component epoxy adhesive -DA 001 730 A2-
♦ Silicone remover -LSE 020 100 A3-
♦ Silicate stone -DA 009 800 -
♦ Aluminium primer -DA 009 801 -
♦ Applicator -D 009 500 25 -
♦ Wing mounting flange (sub-part)
Preparing joints for adhesive application
– Clean bonding area with silicone remover - LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Apply 2-component body adhesive -DA 001 730 A2- to entire
riveting area using pneumatic glue gun -V.A.G 2005 B- .
Inserting new part
– Fix new part in position with alignment bracket.
– Prepare flanges on body and new parts for welding.
– Weld in new part using shielded arc welding equipment 250A :
SG continuous seam.
– Rivet in new part using rechargeable riveter -VAS 5279A- .

– Use rechargeable riveter -VAS 5279A- with attachments S2

and S3 from -VAS 5279/2 - or rechargeable riveter -VAS
5279B- with attachments S2 and S3 .

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.

2. Wing mounting flange - Partial renewal 41

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 50 74 55 00

3 Front wheel housing - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

3.1 Procedure
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Shielded arc welding equipment 250A

♦ Pneumatic sabre saw -V.A.G 1523A-

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.

WARNING

Take care not to damage node castings and extruded sections

when cutting.

– Make separating cut in plenum chamber as shown using pneu‐

matic sabre saw -V.A.G 1523A- .
– Make separating cut in support for suspension strut mounting
as shown using pneumatic sabre saw -V.A.G 1523A- .
– Make separating cut in longitudinal member in front of node
casting as shown using pneumatic sabre saw -V.A.G 1523A- .
– Detach wheel housing.
– Remove remaining material from node casting using compact
angle grinder -VAS 5167- .

42 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement part
♦ Wheel housing - front section
Welding in
– Prepare flanges on body and new parts for welding.
– Fix new part in position with alignment bracket.
– Weld suspension strut mounting/subframe mount from under‐
neath to plenum chamber using shielded arc welding equip‐
ment 250A : SG stepped seam.
– Weld suspension strut mounting to support using shielded arc
welding equipment 250A : SG continuous seam.

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.

3. Front wheel housing - Renewal 43

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Place backing plate of same material behind joint with plenum

chamber and weld in using shielded arc welding equipment
250A : SG continuous seam.

– Weld in front longitudinal member at node casting using shiel‐

ded arc welding equipment 250A : SG continuous seam.

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.

44 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 50 79 55 03

4 Front longitudinal member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

4.1 Tools
Special tools and workshop equipment required
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
♦ Compact angle grinder -VAS 5167-
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Shielded arc welding equipment 250A

♦ Pneumatic sabre saw -V.A.G 1523A-

4.2 Procedure

WARNING

Take care not to damage node castings and extruded sections

when cutting.

Cutting locations
– Make separating cut at longitudinal member in front of node
casting using pneumatic sabre saw -V.A.G 1523A- .
– Make separating cut at support plate and support using pneu‐
matic sabre saw -V.A.G 1523A- .
– Detach longitudinal member.

4. Front longitudinal member - Renewal 45

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Remove remaining material from node casting using compact

angle grinder -VAS 5167- .

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.

Replacement part
♦ Longitudinal member with moulded foam insert
Preparing new part
– Match up new part to body.
– Prepare flanges on body and new parts for welding.
– Fix longitudinal member in position on alignment bracket.
Welding in
– Weld in longitudinal member at node casting using shielded
arc welding equipment 250A : SG continuous seam.
– Weld support plate for suspension strut mounting to longitu‐
dinal member using shielded arc welding equipment 250A :
SG continuous seam.

46 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Weld support to longitudinal member using shielded arc weld‐

ing equipment 250A : SG continuous seam.

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.

4. Front longitudinal member - Renewal 47

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 50 80 55 00

5 Longitudinal member (front section) -

Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

5.1 Procedure

WARNING
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.
Take care not to damage aluminium node castings.

Cutting locations

Note

Detach bolted joint securing longitudinal member.

48 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

5. Longitudinal member (front section) - Renewal 49

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement parts
♦ Front longitudinal member
♦ Connecting collar with bolts
Preparing new parts

Note

Align longitudinal member with bolted-on parts.

Note

Threads must be free of paint and grease.

– Match length if necessary. Distance from node casting at least

1 mm.
– Insert threaded collar in longitudinal member.
– Insert longitudinal member with threaded collar in node cast‐
ing.
– Hand-tighten bolts.

– Tighten bolts 1 - 6. (Tightening torque 24 Nm).

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.

50 Rep. gr.50 - Body - front

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

51 – Body - centre
RO: 51 03 55 00

1 Roof - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

1.1 Tools
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Double cartridge gun -VAS 6453-
♦ Shielded arc welding equipment 250A

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.

♦ Rechargeable riveter -VAS 5279A-

1.2 Procedure
Cutting locations

Note

Refer to section on laser welding in General information on alu‐

minium.

– Separate original joint using compact angle grinder -VAS

5167- .

1. Roof - Renewal 51
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Remove small punch rivets. Use rechargeable riveter -VAS

5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .
– Remove remaining material using compact angle grinder -
VAS 5167- .

Replacement parts
♦ Roof
♦ Solid rivets
♦ 2-component epoxy adhesive -DA 180 A00 A2-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Silicone remover -LSE
permitted unless 020 by
authorised 100 A3-
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.
♦ Applicator -D 009 500 25 -
♦ Aluminium primer -DA 009 801 -
♦ Silicate stone -DA 009 800 -
Preparing joints for adhesive application
– Clean bonding area with silicone remover - LSE 020 100 A3- .

52 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Apply 2-component epoxy adhesive -DA 180 A00 A2- (two
cartridge sets) to entire riveting area using double cartridge
gun -VAS 6453- .
Welding in
Match up roof and fix in place.

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
– Weld in roof using shieldedwitharc welding
respect equipment
to the correctness 250Ain :this
of information SG document. Copyright by AUDI AG.
continuous seam (staggered - with gaps).
Riveting in

Note

♦ Use clamps.
♦ Rivet in roof using rechargeable riveter -VAS 5279 B- .

1. Roof - Renewal 53
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 51 35 55 00

2 Roof side member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .
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

1 - Separating cut in A-pillar

with respect to the correctness of information in this document. Copyright by AUDI AG.

2 - Roof side member

3 - Separating cut in B-pillar
4 - Separating cut in C-pillar
5 - D-pillar separating cut

2.1 Tools
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 5830-

54 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Shielded arc welding equipment 250A

♦ Rechargeable riveter -VAS 5279A-

♦ Alternatively, Protected
you can use the new rechargeable riveter -VAS
by copyright. Copying for private or commercial purposes, in part or in whole, is not

5279 B- . This iswitha respect

complete set.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
to the correctness of information in this document. Copyright by AUDI AG.

♦ Accessory set for rechargeable riveter -VAS 5279/1-

♦ Pneumatic sabre saw -V.A.G 1523A-

2.2 Procedure
Roof already removed

2. Roof side member - Renewal 55

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Cutting locations
– Separate original joint with rechargeable riveter -VAS 5279A- .
– Remove large punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S4 and D5 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S4 and
D5 .
– Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .
– Make separating cuts using pneumatic sabre saw -V.A.G
1523A- .

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.

– Separate original joint with rechargeable riveter -VAS 5279A- .

– Remove large punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S4 and D5 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S4 and
D5 .
– Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .

56 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Remove remaining material using compact angle grinder -

VAS 5167- .

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.

2. Roof side member - Renewal 57

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Replacement parts
♦ Side panel -4E0 809 601/4E0 809 602-
♦ Punch rivets (self-piercing rivets)
♦ 2-component epoxy adhesive -DA 001 730 A2-
♦ Aluminium primer -DA 009 801-
♦ Cleaning solution -D 009 401 04-
♦ Silicate stone -DA 009 800 -
Preparing new part
– Transfer separating cuts to new part and cut to size using
pneumatic sabre saw -V.A.G 1523A- .

58 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Place backing plate of same material behind separating cuts

-a-.

2. Roof side member - Renewal 59

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Preparing joints for adhesive application

– Take off roof side member and prepare flanges on body and
roof side member for bonding.
– Clean bonding area with silicone remover - LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Operate double cartridge gun -VAS 6453- with 2-component
epoxy adhesive -DA 180 A00 A2- and apply an approx.
100 mm long adhesive bead to a piece of cardboard before
starting application on the B-pillar.
Riveting in
– Rivet in roof side member using rechargeable riveter -VAS
5279A- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Use rechargeable riveter -VAS
permitted5279A- with attachments
unless authorised by AUDI AG. AUDIS2 andnot guarantee or accept any liability
AG does
S3 from -VAS 5279/2 - or rechargeable
with respect to theriveter -VAS
correctness 5279B-
of information with
in this document. Copyright by AUDI AG.
attachments S2 and S3 .

60 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Rivet in roof side member using rechargeable riveter -VAS

5279A- .
Use rechargeable riveter -VAS 5279A- with attachments S2 and
S3 from -VAS 5279/2 - or rechargeable riveter -VAS 5279B- with
attachments S2 and S3 .

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.

2. Roof side member - Renewal 61

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Welding in
– Weld inProtected
at separating
by copyright.cuts
Copyingusing shielded
for private arc purposes,
or commercial weldingin part
equip‐
or in whole, is not
ment : SG continuous seam.
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.

62 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

2. Roof side member - Renewal 63

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 51 35 55 00

3 Roof side member - Renewal (long

version)

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .
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
1 - Separating cut in A-pillar
with respect to the correctness of information in this document. Copyright by AUDI AG.

2 - Roof side member

3 - Separating cut in B-pillar
4 - Separating cut in C-pillar
5 - D-pillar separating cut

3.1 Tools
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 5830-

64 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Shielded arc welding equipment 250A

♦ Rechargeable riveter -VAS 5279A-

♦ Alternatively, you can use the new rechargeable riveter -VAS
5279 B- . This is a complete set.

♦ Accessory set for rechargeable riveter -VAS 5279/1-

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.

♦ Pneumatic sabre saw -V.A.G 1523A-

3.2 Procedure
Roof already removed

3. Roof side member - Renewal (long version) 65

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Cutting locations
– Separate original joint with rechargeable riveter -VAS 5279A- .
– Remove large punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S4 and D5 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S4 and
D5 .
– Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .
– Make separating cuts using pneumatic sabre saw -V.A.G
1523A- .

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.

– Separate original joint with rechargeable riveter -VAS 5279A- .

– Remove large punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S4 and D5 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S4 and
D5 .
– Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .

66 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Remove remaining material using compact angle grinder -

VAS 5167- .

3. Roof side member - Renewal (long version) 67

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Replacement parts
♦ Side panel -4E4 809 601 / 4E4 809 602-
♦ Punch rivets (self-piercing rivets)
♦ 2-component epoxy adhesive -DA 001 730 A2-
♦ Aluminium primer -DA 009 801-
♦ Cleaning solution -D 009 401 04-
♦ Silicate stone -DA 009 800 -
Preparing new part
– Transfer separating cuts to new part and cut to size using
pneumatic sabre saw -V.A.G 1523A- .

68 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Place backing plate of same material behind separating cuts

-a-.

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.

3. Roof side member - Renewal (long version) 69

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Preparing joints for adhesive application

– Take off roof side member and prepare flanges on body and
roof side member for bonding.
– Clean bonding area with silicone remover - LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Operate double cartridge gun -VAS 6453- with 2-component
epoxy adhesive -DA 180 A00 A2- and apply an approx.
100 mm long adhesive bead to a piece of cardboard before
starting application on the B-pillar.
Riveting in
– Rivet in roof side member using rechargeable riveter -VAS
5279A- .
Use rechargeable riveter -VAS 5279A- with attachments S2 and
S3 from -VAS 5279/2 - or rechargeable riveter -VAS 5279B- with
attachments S2 and S3 .

70 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Rivet in roof side member using rechargeable riveter -VAS

5279A- .
Use rechargeable riveter -VAS 5279A- with attachments S2 and
S3 from -VAS 5279/2 - or rechargeable riveter -VAS 5279B- with
attachments S2 and S3 .

3. Roof side member - Renewal (long version) 71

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Welding in
– Weld in at separating cuts using shielded arc welding equip‐
ment : SG continuous seam.

72 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

3. Roof side member - Renewal (long version) 73

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 51 37 55 00

4 A-pillar - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

4.1 Tools
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Pop rivet pliers -VAS 5072-
♦ Compact angle grinder -VAS 5167-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Drill -VAS 5830- 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.
♦ Pneumatic glue gun -V.A.G 2005 B-

♦ Shielded arc welding equipment 250A

74 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Rechargeable riveter -VAS 5279A-

♦ Pneumatic sabre saw -V.A.G 1523A-

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.

4.2 Procedure
Cutting locations
– Make separating cut as shown using pneumatic sabre saw -
V.A.G 1523A- . Do not damage internal reinforcements.
– Make separating cuts at side member as shown using pneu‐
matic sabre saw -V.A.G 1523A- ; take care not to damage
inner side member.
– Unfasten riveted joints at A-pillar.
– Remove large punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S2 and S3 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S4 and
D5 .
– Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and D2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
D2 .
– Remove remaining material using compact angle grinder -
VAS 5167- .

4. A-pillar - Renewal 75
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement parts
♦ Pop rivets
♦ A-pillar (sub-part) -4E4 809 849/4E4 809 850-
♦ 2-component epoxy adhesive -DA 001 730 A2-
♦ Aluminium primer -DA 009 801 -
♦ Solid rivets
♦ Silicate stone -DA 009 800 -
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.

76 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Preparing new part

– Transfer separating cuts to new part and cut to shape using
pneumatic sabre saw -V.A.G 1523A- .
– Fix outer A-pillar on portal gauge.

Note

Bolt on hinges and striker plate for better positioning.

Note

Refer to General information on bonding.

Preparing joints for adhesive application

– Clean bonding area with silicone remover - LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Apply 2-component body adhesive -DA 001 730 A2- to entire
riveting area using pneumatic glue gun -V.A.G 2005 B- .
Preparing new part
– Weld in weld pool backing to body side of joint.
Riveting inby copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Fitwith
outer A-pillar
respect and fixofin
to the correctness position.
information in this document. Copyright by AUDI AG.

Rivet in outer A-pillar using rechargeable riveter -VAS 5279A- .

Note

Rivet in new part with 4.8 x 9 mm aluminium pop rivets.

– Set pop rivets in overlap area using pop rivet pliers -VAS
5072- .
– Weld in outer side member using shielded arc welding equip‐
ment 250A : SG continuous seam.

4. A-pillar - Renewal 77
 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Weld in at separating cuts using shielded arc welding equip‐

ment 250A : SG continuous seam.

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.

78 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 51 41 55 00

5 Outer B-pillar - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

5.1 Tools
Special tools and workshop equipment required
♦ Drill -VAS 5830-
♦ Compact angle grinder -VAS 5167-
♦ Pop rivet pliers -VAS 5072-

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.

♦ Pneumatic glue gun -V.A.G 2005 B-

♦ Shielded arc welding equipment 250A

5. Outer B-pillar - Renewal 79

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Rechargeable riveter -VAS 5279A-

♦ Pneumatic sabre saw -V.A.G 1523A-

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.

5.2 Procedure
Cutting locations
– Make separating cut as shown using pneumatic sabre saw -
V.A.G 1523A- . Take care not to damage internal reinforce‐
ment.
– Take care not to damage inner side member when making
separating cuts in side member.
– Separate riveted joints on B-pillar using rechargeable riveter -
VAS 5279A- .
– Separate original joint with rechargeable riveter -VAS 5279A- .
Remove large punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S4 and D5 from -VAS 5279/2 - or re‐
chargeable riveter -VAS 5279B- with attachments S1 and D2 .
Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and D2 from -VAS 5279/2 - or re‐
chargeable riveter -VAS 5279B- with attachments S1 and D2 .
– Remove remaining material using compact angle grinder -
VAS 5167- .

80 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.
Replacement parts
♦ A-pillar (sub-part) -4E4 809 849/4E4 809 850-
♦ 2-component epoxy adhesive -DA 001 730 A2-
♦ Silicone remover - LSE 020 100 A3-
♦ Silicate stone -DA 009 800 -
♦ Aluminium primer -DA 009 801 -
♦ Solid rivets
♦ Pop rivets

5. Outer B-pillar - Renewal 81

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Preparing new parts

– Transfer separating cut to new part and cut to size using pneu‐
matic sabre saw -V.A.G 1523A- .
Preparing new part
– Fit outer B-pillar and fix in position.

Note

Bolt on hinges and striker plate for better positioning.

Preparing joints for adhesive application

– Clean bonding area with silicone remover - LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Apply 2-component body adhesive -DA 001 730 A2- to entire
riveting area using pneumatic glue gun -V.A.G 2005 B- .
– Countersink holes in all parts.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
– Prepare flanges on body and new
with parts for
respect to thewelding.
correctness of information in this document. Copyright by AUDI AG.

Riveting in

Note

Refer to General information on bonding.

– Fit outer B-pillar and fix in position.

Note

Use clamps.

Rivet in outer B-pillar using rechargeable riveter -VAS 5279A- .

– Set pop rivets in overlap area using pop rivet pliers -VAS
5072- .

82 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 51 45 55 00

6 Outer side member - Renewal

WARNING

Always observe safety precautions.

1 - Outer side member

2 - Separating cut in B-pillar
3 - Separating cut in A-pillar
4 - Separating cut in side mem‐
ber (front)
Partial renewal
Partial renewal is possible with
this separating cut.
5 - Separating cut in side mem‐
ber
Partial renewal
Partial renewal is possible with
this separating cut.
6 - Separating cut in side mem‐
ber
Partial renewal
Partial renewal is possible with
this separating cut.

6.1 Tools
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 5830-
Protected♦by Chisel
copyright. -VAS
Copying 5300/34-
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
♦ Socket
with respect for flow-drill
to the correctness screws
of information in this -VAS 6426
document. - by AUDI AG.
Copyright

♦ Compact angle grinder -VAS 5167-

♦ Double cartridge gun -VAS 6453-

6. Outer side member - Renewal 83

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Accessory set for rechargeable riveter -VAS 5279/1-

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.

♦ Rechargeable riveter -VAS 5279A-

♦ Alternatively, you can use the new rechargeable riveter -VAS
5279 B- . This is a complete set.

♦ Shielded arc welding equipment

♦ Pneumatic sabre saw -V.A.G 1523A-

6.2 Procedure
Cutting locations
– Mark off separating cuts according to degree of damage and
make cuts using pneumatic sabre saw -V.A.G 1523A- .
– Separate original joint with rechargeable riveter -VAS 5279A- .
– Separate bonded joints using chisel -VAS 5300/34- .
– Make separating cut 3 in front of node casting.

84 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Remove remaining material using compact angle grinder -

VAS 5167- .

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.

6. Outer side member - Renewal 85

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Replacement part
♦ Outer side member (sub-part) -4E4 809 838/4E4 809 837-
Preparing new part
– Transfer separating cuts to new part and cut to size using
pneumatic sabre saw -V.A.G 1523A- .

86 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Place backing plate of same material behind separating cuts

-a-.

6. Outer side member - Renewal 87

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Note

Refer to General information on bonding.

Preparing joints for adhesive application

– Prepare flanges on body and new parts for welding.
– Clean flanges on body and new parts with silicone remover -
LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
Riveting in
– Match up and fix new part in position.
– Check fit relative to bolt-on parts.
– Rivet in outer side member using rechargeable riveter -VAS
5279A- .

88 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Apply 2-component body adhesive -DA 180 A00 A2- to bond‐

ing area using double cartridge gun -VAS 6453- .

Welding in
– Weld in at outer separating cuts using shielded arc welding
equipment : SG continuous seam.
– Weld in lower side member using shielded arc welding equip‐
ment : SG continuous seam (staggered - with gaps).

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.

6. Outer side member - Renewal 89

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

90 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 51 42 55 50

7 Inner B-pillar - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

7.1 Tools
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.

Special tools and workshop equipment required

♦ Compact angle grinder -VAS 5167-
♦ Shielded arc welding equipment 250A

♦ Pneumatic sabre saw -V.A.G 1523A-

7.2 Procedure
• Outer B-pillar and outer side member already removed
• Roof side member (part section) already removed
Cutting locations
– Separate weld seam between inner B-pillar and inner side
member using compact angle grinder -VAS 5167- .
– Separate weld seam between B-pillar and roof side member
using compact angle grinder -VAS 5167- .

7. Inner B-pillar - Renewal 91

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Replacement part
♦ Inner B-pillar
Preparing new parts
– Prepare flanges on body and new parts for welding.
– Match up new parts.
– Fix inner B-pillar in position on alignment bracket.
Welding in
– Weld inner B-pillar to inner side member using shielded arc
welding equipment 250A : SG continuous seam.

92 Rep. gr.51 - Body - centre

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Weld inner B-pillar to roof side member using shielded arc

welding equipment 250A : SG continuous seam.

– Weld inner B-pillar to inner side member using shielded arc

welding equipment 250A : SG continuous seam.

– Weld inner B-pillar to roof side member using shielded arc

welding equipment 250A : SG continuous seam.

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.

7. Inner B-pillar - Renewal 93

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

53 – Body - rear
RO: 53 05 55 00

1 Rear cross panel - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

1.1 Tools
Special tools and workshop equipment required
♦ Pneumatic glue gun -V.A.G 2005 B-

♦ Pop rivetbypliers
Protected -VAS
copyright. 5072-
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.

♦ Shielded arc welding equipment 250A

♦ Rechargeable riveter -VAS 5279A-

94 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ When using the rechargeable riveter -VAS 5279A- , the at‐

tachment set -VAS 5279/2 - is also required.
♦ Alternatively, you can use the new rechargeable riveter -VAS
5279B- . This is a complete set.

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.

♦ Pneumatic sabre saw -V.A.G 1523A-

1.2 Procedure
Cutting locations
– Roughly cut out rear cross panel using pneumatic sabre saw
-V.A.G 1523A- .
– Separate original joint with rechargeable riveter -VAS 5279A- .
– Remove remaining material using compact angle grinder -
VAS 5167- .

1. Rear cross panel - Renewal 95

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

96 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement parts
♦ Rear cross panel
♦ Pop rivets
♦ Silicone remover -LSE 020 100 A3-
♦ 2-component epoxy adhesive -DA 001 730 A2-
– Match up new parts.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Check dimensional accuracy with respect to rear lid.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.

Preparing joints for adhesive application

– Clean bonding area with silicone remover - LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Apply 2-component epoxy adhesive -DA 001 730 A2- to entire
riveting area using pneumatic glue gun -V.A.G 2005 B- .
– Insert rear cross panel.
Riveting in

– Rivet in rear cross panel using pop rivet pliers -VAS 5072- .

1. Rear cross panel - Renewal 97

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 53 16 55 00

2 Rear cross member - Renewal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

2.1 Tools
Special tools and workshop equipment required
♦ Compact angle grinder -VAS 5167-
♦ Drill -VAS 5830-
♦ Pop rivet pliers -VAS 5072-

♦ Pneumatic glue gun -V.A.G 2005 B-

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
♦ Shielded arc welding equipment 250Awith respect to the correctness of information in this document. Copyright by AUDI AG.

98 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Pneumatic sabre saw -V.A.G 1523A-

2.2 Procedure
Cutting locations
– Roughly cut out rear cross member using pneumatic sabre
saw -V.A.G 1523A- .
– Detach part.
– Remove remaining material using compact angle grinder -
VAS 5167- .

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.

2. Rear cross member - Renewal 99

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement parts
♦ Rear cross member
♦ Pop rivets
♦ 2-component epoxy adhesive -DA 001 730 A2-

Note

Refer to General information on bonding.

Preparing new part

– New part for bonding only: Drill 4 x left + right
– Match up new part to body.
Preparing joints for adhesive application
– Clean bonding area with silicone remover - LSE 020 100 A3- .
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Apply 2-component epoxy
Protected adhesive
by copyright. Copying -DA 001or730
for private A2- to
commercial entirein part or in whole, is not
purposes,
riveting area using pneumatic
permitted gluebygun
unless authorised AUDI -V.A.G 2005
AG. AUDI AG does B- .
not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Riveting in

– Rivet in new part using pop rivet pliers -VAS 5072- .

Welding in
– Prepare flanges on body and new parts for welding.

– Weld in rear cross member using shielded arc welding equip‐

ment 250A : SG continuous seam.

100 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 53 48 55 62

3 Rear longitudinal member - Partial re‐

newal

WARNING

Always observe safety precautions.

Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .

3.1 Tools
Special tools and workshop equipment required
♦ Socket for flow-drill screws -VAS 6426 -
♦ Drill -VAS 5830-
♦ Pneumatic glue gun -V.A.G 2005 B-

♦ Shielded arc welding equipment

♦ Rechargeable riveter -VAS 5279A-
♦ Alternatively, you can use the new rechargeable riveter -VAS
5279 B- . This is a complete set.

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.

3. Rear longitudinal member - Partial renewal 101

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Pneumatic sabre saw -V.A.G 1523A-

3.2 Procedure
Cutting locations
• Spare wheel well already cut out

WARNING

Take care not to damage aluminium node castings.

– Separating cut behind node casting.

– Rear cross panel, welded seam.
– Detach part.

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.

102 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Replacement part
♦ Longitudinal member part section
♦ Impact damper mounting
♦ Sleeves
Preparing new part
– Transfer separating cut to new part and cut off hatched area.
Welding in
– Match up new parts.
– Prepare flanges on body and new parts for welding.
– Insert sleeves in body.
– Fix new parts in position on alignment bracket.

3. Rear longitudinal member - Partial renewal 103

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Weld in new part using shielded arc welding equipment 250A :

SG continuous seam.

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.

104 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 53 55 55 00

4 Side panel - Renewal

WARNING

Always observe safety precautions.

1 - Side panel
2 - Separating cut in C-pillar
3 - D-pillar separating cut
4 - Bonded area
5 - Separating cut in side mem‐
ber
6 - Moulded foam inserts
7 - Separating cut
Partial renewal
Partial renewal is possible with
this separating cut.
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.

4.1 Tools
Special tools and workshop equipment required
♦ Double cartridge gun -VAS 6453-
♦ Shielded arc welding equipment
♦ Rechargeable riveter -VAS 5279A-

4. Side panel - Renewal 105

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Alternatively, you can use the new rechargeable riveter -VAS

5279 B- . This is a complete set.

♦ Pneumatic sabre saw -V.A.G 1523A-

♦ Pop rivet pliers -VAS 5072-

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.

4.2 Procedure
Cutting locations

106 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Make separating cuts at C and D-pillar according to extent of

damage.
– Make separating cuts in side member according to extent of
damage. Take care not to damage internal reinforcement.
– Grind through outer edge at wheel arch using compact angle
grinder - VAS 5167- .
– Separate original joint with rechargeable riveter -VAS 5279A- .

4. Side panel - Renewal 107

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Separate original joint with rechargeable riveter -VAS 5279A- .

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.

108 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Remove remaining material using compact angle grinder -

VAS 5167- .

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.

4. Side panel - Renewal 109

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Remove remaining material using compact angle grinder -

VAS 5167- .

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.

110 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement parts
♦ Side frame (sub-part)
♦ Body adhesive -DA 001 730 A2-
Preparing new part
– Transfer separating cuts to new part and cut off hatched area
using pneumatic sabre saw - V.A.G 1523A- .

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.

4. Side panel - Renewal 111

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Weld in weld pool backing plates at separating cuts using surplus

material.

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.

112 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Fix new part on portal gauge.

Preparing joints for adhesive application
– Prepare flanges on body and new parts for bonding and weld‐
ing.
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Clean new part with silicone remover -LSE 020 100 A3- .
– Apply 2-component body adhesive -DA 180 A00 A2- to wheel
housing and entire riveting area using double cartridge gun -
VAS 6453- .
– Apply adhesive to beaded flange. Two beads of adhesive:
3.5 mm diameter.
– Place new part on portal gauge.
Welding in new part
– Weld in side panel using shielded arc welding equipment : SG
continuous seam.

4. Side panel - Renewal 113

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Bead over wheel arch flange. Wipe off emerging adhesive and
seal joint.

Riveting in
– Rivet in side panel using rechargeable riveter -VAS 5279A- .
– Weld in side panel using shielded arc welding equipment : SG
continuous seam (staggered - with gaps).

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.

114 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Rivet in side panel to closure plate using rechargeable riveter

-VAS 5279A- .
– Rivet in side panel to tail light mounting using rechargeable
riveter -VAS 5279A- .
– Rivet in side panel to rain channel using rechargeable riveter
-VAS 5279A- .

4. Side panel - Renewal 115

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
RO: 53 69 55 52
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4.3 Rear wheel housing - Renewal
with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

Always observe safety precautions.

116 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

1 - Outer wheel housing

2 - Moulded foam inserts
3 - Corner panel
4 - Lower C-pillar reinforce‐
ment

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.

4.4 Tools
Special tools and workshop equipment required
♦ Pneumatic glue gun -V.A.G 2005 B-

♦ Shielded arc welding equipment

♦ Rechargeable riveter -VAS 5279A-

4. Side panel - Renewal 117

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Alternatively, you can use the new rechargeable riveter -VAS

5279 B- . This is a complete set.

♦ Pneumatic sabre saw - V.A.G 1523A-

♦ Compact angle grinder -VAS 5167-

4.5 Procedure
• Side panel already removed
Removing
– Make separating cut parallel to inner wheel housing using
pneumatic sabre saw - V.A.G 1523A- .

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.

118 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

– Remove remaining material using compact angle grinder -

VAS 5167- .
– Press out remaining material using rechargeable riveter -VAS
5279A- .

4. Side panel - Renewal 119

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement part
♦ Rear outer wheel housing
Preparing joints for adhesive application
– Prepare flanges on body and new parts for bonding and weld‐
ing.
– Prepare bonding area with silicate stone -DA 009 800 - and
clean.
– Apply aluminium primer -DA 009 801 - to bonding surfaces
using applicator -D 009 500 25 - .
– Clean new part with silicone remover -LSE 020 100 A3- .
– Apply 2-component body adhesive -DA 0001 730 A2- to wheel
housing and entire riveting area using pneumatic glue gun -
V.A.G 2005 B- . 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.

120 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Installing
– Match up outer wheel housing and fix in position.
– Check fit relative to side panel.
– Rivet in new part using rechargeable riveter -VAS 5279A- .
– Alternatively, joint can also be welded using shielded arc weld‐
ing equipment : SG continuous seam (staggered - with gaps).

4. Side panel - Renewal 121

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

122 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

RO: 53 80 55 50

5 Spare wheel well - Renewal

Note

The spare wheel well is made of plastic.

WARNING

Always observe safety precautions. 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.

The cross panels are removed in the illustration to show the spare
wheel well more clearly. These parts do not necessarily have to
be removed for the repair.

1 - Spare wheel well

2 - Cross member
3 - Longitudinal member (right-
side)
4 - Longitudinal member (left-
side)

5.1 Tools
Special tools and workshop equipment required

5. Spare wheel well - Renewal 123

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

♦ Electric cutter -V.A.G 1561 A-

♦ Blade, offset -V.A.G 1561/10-

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.

♦ Scraper (15 + 25 mm) -V.A.G 1561/7+8-

♦ Double cartridge gun -VAS 5237-

5.2 Procedure
Removing
– Cut through adhesive bead all round using electric cutter -
V.A.G 1561 A- .

124 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

– Cut back adhesive bead using electric cutter -V.A.G 1561 A- ,

but do not remove all remaining material.

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.

5. Spare wheel well - Renewal 125

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Replacement parts
♦ Spare wheel well
♦ 2-component window adhesive set -DA 004 600 A2-
♦ Cleaning solution -D 009 401 04- . Observe safety precautions
when handling.
Preparing new part
– Clean bonding surface on spare wheel well with cleaning sol‐
ution -D 009 401 04- . 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
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.

Caution

♦ Bonding surface must be free of dirt and grease.

♦ Do not cut back bonding surface until immediately before
installation.
♦ Do not apply primer to bonding surface or treat with clean‐
ing solution.

126 Rep. gr.53 - Body - rear

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

Note

The cross-section of the adhesive bead is determined by the size

of the applicator nozzle opening and the rate of application.

Dimensions for adhesive application:

1- Adhesive bead
2- Old adhesive bead
3- Spare wheel well
• Dimension -a- = 8 mm
• Dimension -b- = 12 mm
• Dimension -c-: note variations in spacing from contact surface.

– Apply nozzle -2- so it is in full contact with bonding surface.

• Adhesive bead -1- is applied in direction indicated by
-arrow-.
– Apply adhesive/sealant -1- all round bonding surface -2-.

– Apply 2-component window adhesive set -DA 004 600 A2-

using double cartridge gun -VAS 5237- .

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.

5. Spare wheel well - Renewal 127

 Audi A8 2003 ➤
Body Repairs - Edition 05.2011

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.

Bonding area:
– If the bonding area has been damaged, the paint finish must
be repaired and corrosion protection applied as required.

Note

♦ After bonding has been completed, the vehicle must remain

stationary on a level surface for 3 hours at room temperature
(min. 15 °C) so that the adhesive components can harden
(curing time).
♦ Do not move the vehicle until the „curing time“ has elapsed.

128 Rep. gr.53 - Body - rear