Professional Documents
Culture Documents
001KAH00020-Body Repairs General Body Repairs
001KAH00020-Body Repairs General Body Repairs
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.
Repair Group
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.
Contents
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Fuel tank and fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Air conditioning system / refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Electronic control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Battery, power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 High-voltage components / electric vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Natural gas vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General notes on body repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Original joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Galvanised body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Removing remaining material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 New parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Moulded foam inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Symbols relating to procedures for separating components . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Symbols relating to welding, brazing and soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Symbols relating to rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Symbols relating to preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Symbols relating to corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Vehicle body construction features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Multi-material mix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
9
with respect4.2 Body of
to the correctness structures . .document.
information in this . . . . . .Copyright
. . . . .by. .AUDI
. . .AG.
........................................ 9
5 Assessing damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Checking weld seams and aluminium node castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Load paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Measuring procedures / damage diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.5 Overview of materials used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.6 Passive safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Thermal joining techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Resistance spot welding (RP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Shielded arc plug welding (SG plug welding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 SG continuous seams and stitch weld seams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4 MIG soldering/brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.5 Aluminium welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.6 Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.7 Laser soldering/brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.8 Replacement joining techniques in repair work (steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.9 Replacement joining techniques in repair work (aluminium) . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Cold joining techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Overview of riveting attachments (pairs of tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4 Overview of rivets and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.5 Flow-drill screws (FDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.6 Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8 Separating techniques in body welding; areas of application . . . . . . . . . . . . . . . . . . . . . . . . 47
8.1 Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2 Saw-cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.3 Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.4 Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.5 Separating bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Contents i
General InformationBody Repairs, General Body Repairs - Edition 05.2017
8.6 Pulling out rivets which are only accessible from one side . . . . . . . . . . . . . . . . . . . . . . . . 48
9 Surface repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.1 Dent removal techniques for sheet steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9.2 Dent removal procedures for aluminium panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.3 Bonded joints with aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.4 Processing metal and aluminium filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.5 Processing unleaded tin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9.6 Definition of “accurately aligned surface” / handover to paint shop . . . . . . . . . . . . . . . . . . 52
10 Performing straightening work on body structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.1 Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.2 Separating cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.3 Body sub-parts and part sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
11 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.1 Corrosion protection for attachments and welded parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
11.2 Cavity sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
12 Plastic repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
12.1 Repairing dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
12.2 Repairing scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
12.3 Repairing cracks and tears (up to a length of 100 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
12.4 Repairing holes (up to 30 mm diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
12.5 Plastic repairs (glass fibre materials) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
13 Glass repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
13.1 Repairing windscreens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
14 Thread repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
14.1 Thread repairs for safety-related components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
66
with respect to the correctness of information in this document. Copyright by AUDI AG.
ii Contents
General InformationBody Repairs, General Body Repairs - Edition 05.2017
1 Safety precautions
(AKAH000010; Edition 05.2017)
Note
The refrigerant must also be extracted from the circuit when arc-
welding in the vicinity of the refrigerant hoses. Arc-welding emits
invisible ultraviolet rays which can penetrate the refrigerant hoses
and decompose the refrigerant.
1.2.1 Remedy:
Extract refrigerant from refrigerant circuit ⇒ Air conditioning sys‐
tem; Rep. gr. 87 ; Heating, air conditioning
1.3 Electronic control units 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
Connect the earth connection of the electric welding appliance
with respect to the correctness of information in this document. Copyright by AUDI AG.
directly to the part which you are welding. When doing this, make
sure that there are no electrically insulating parts between the
earth connection and the welding point.
Earth connection and welding electrode must NOT make contact
with the electronic control units or the electrical wiring.
After an accident, the electronic control units only have to be re‐
newed if at least one of the following conditions applies:
♦ The housing is visibly deformed or damaged.
♦ The contact surface or the mounting bracket is deformed (al‐
though no external damage to the control unit is apparent).
♦ The connector is damaged or has been corroded by moisture.
♦ Functional check or self-diagnosis of the control unit indicates
the fault “Control unit defective”.
If electronic components (e.g. ABS control units) were removed
in order to carry out repair work and have now been re-installed,
they must be checked according to the documentation available;
for example, V.A.G. self-diagnosis must be performed.
1. Safety precautions 1
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Note
Before disconnecting the battery, make sure that you have the
radio code. Before returning the vehicle to the customer, enter the
correct code so that the radio is ready for use.
WARNING
Before connecting the battery, refer to the notes for the specific
vehicle in the Workshop Manual.
⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery
DANGER!
2 1. Safety precautions
General InformationBody Repairs, General Body Repairs - Edition 05.2017
WARNING
New parts which are no longer accessible from inside once the
repair has been completed (e.g. side members) should be provi‐
ded with suitable corrosion protection before being welded in. It
is advisable to mask off the welding flanges when doing so.
Please refer to the Paintwork manual for further information.
Check new replacement parts e.g. doors, bonnet and boot lid/
tailgate or wing panel for transportation damage before passing
them on to the paintshop. This avoids a second painting operation
which would become necessary if transportation or other damage
was not noticed until a later stage.
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 Explanation of symbols
3.1 Symbols relating to procedures for sep‐
arating components
1 - Grinding components off/down
2 - Drilling
3 - Spherical cutter
4 - BTR cutter
5 - Separating cut
6 - Opening up spot weld
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
7 - Saw-cutting
with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Stitch weld
2 - SG plug weld
3 - SG continuous seam
4 - SG continuous seam (stag‐
gered - with gaps)
5 - Brazing
6 - MIG brazing
7 - Resistance spot welding
(RP), general
8 - RP spot weld (single row)
9 - RP spot weld (double row)
10 - RP spot weld (double row,
offset)
3. Explanation of symbols 5
General InformationBody Repairs, General Body Repairs - Edition 05.2017
1 - Solid rivet
2 - Self-piercing rivet
3 - Use a riveting tool
4 - Pop rivet
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 3. Explanation of symbols
General InformationBody Repairs, General Body Repairs - Edition 05.2017
1 - Fixing in position
2 - Joddling
3 - Removing paint in locations
which are difficult to access
4 - Smooth off by hand
5 - Apply adhesive
6 - Joddling
7 - Flanging
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. Explanation of symbols 7
General InformationBody Repairs, General Body Repairs - Edition 05.2017
1 - Hohlraumkonservierung
2 - Sealing off
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.
8 3. Explanation of symbols
General InformationBody Repairs, General Body Repairs - Edition 05.2017
5 Assessing damage
node castings
The dye penetration test is suitable for identifying surface cracks.
The approved repair materials must be used.
Note
Do not brush off the relevant area prior to testing, as this would
fill in the cracks.
10 5. Assessing damage
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
The illustration shows how the crash energy
permitted isauthorised
unless distributed around
by AUDI AG. AUDI AG does not guarantee or accept any liability
the outside of the passenger compartment in the event of a side
with respect to the correctness of information in this document. Copyright by AUDI AG.
5. Assessing damage 11
General InformationBody Repairs, General Body Repairs - Edition 05.2017
12 5. Assessing damage
General InformationBody Repairs, General Body Repairs - Edition 05.2017
5. Assessing damage 13
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Note
14 5. Assessing damage
General InformationBody Repairs, General Body Repairs - Edition 05.2017
WARNING
Note
5. Assessing damage 15
General InformationBody Repairs, General Body Repairs - Edition 05.2017
WARNING
Note
Note
Safety measures
Adequate protective equipment must be used when working on
CFRP components.
16 5. Assessing damage
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Note
5. Assessing damage 17
General InformationBody Repairs, General Body Repairs - Edition 05.2017
18 5. Assessing damage
General InformationBody Repairs, General Body Repairs - Edition 05.2017
WARNING
Points to check:
– Check belt ⇒ General body repairs, interior; Rep. gr. 00 ;
Safety precautions; Checking belt .
– Check automatic belt retractor (locking action) ⇒ General
body repairs, interior; Rep. gr. 00 ; Safety precautions; Check‐
ing automatic belt retractor (locking action) .
– Perform visual inspection of belt buckle ⇒ General body re‐
pairs, interior; Rep. gr. 00 ; Safety precautions; Visual inspec‐
tion of belt buckle .
– Perform functional check of belt buckle ⇒ General body re‐
pairs, interior; Rep. gr. 00 ; Safety precautions; Functional
check of belt buckle .
– Check guide fittings and latch plate ⇒ General body repairs,
interior; Rep. gr. 00 ; Safety precautions; Checking guide fit‐
tings and latch plate Protected
.permitted by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Check securing components and anchorage points ⇒ General
with respect to the correctness of information in this document. Copyright by AUDI AG.
5. Assessing damage 19
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Note
WARNING
Note
20 5. Assessing damage
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Note
WARNING
WARNING
5. Assessing damage 21
General InformationBody Repairs, General Body Repairs - Edition 05.2017
WARNING
5.6.7 Notes on disposal 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
22 5. Assessing damage
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
Spot weld peel test
– To determine the required weld nugget diameter, establish the
setting parameters specified by the manufacturer and carry
out test using samples.
– Check all spot welds 100% by performing a chisel test.
High-quality spot welds peel off in the weld contact area; they do
not shear off.
– Calculate the weld nugget diameter according to the following
formula ("peel diameter") and carry out test on samples before
starting repair work.
Square root of T1 x 3.5 x 1.15
Note
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
WARNING
Note
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
WARNING
refer to the Workshop Manual for the relevant vehicle in such ca‐
ses.
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
WARNING
WARNING
Note
♦ Use - 4D0 898 103- sheet metal for practice welding and re‐
pairs.
♦ Refer to the training documentation on aluminium welding for
further details.
WARNING
Note
Note
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.
7.1 Bonding
Adhesive-bonded joints and spot-welded bonded joints are being
used increasingly at the factory, as they help to improve body
rigidity and strength.
They are distinguished as follows:
♦ In the case of adhesive-bonded joints, the joint between the
sheet metal parts is formed only by the adhesive.
♦ Adhesive-bonded joints with additional spot welds or rivets are
known as hybrid joints.
Note
The bonded joints may only be restored using the materials listed
in the Workshop Manual or parts catalogue.
Note
WARNING
Note
If adhesive comes out on both sides over the full length of the
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
Note
7.2 Rivets
Note
Note
– Insert solid rivet and use riveting tool to set closing head.
Appropriate inserts for the riveting tool are available for the vari‐
ous rivet diameters.
Note
WARNING
Note
– Apply adhesive.
– Fit pop rivet and use riveting tool to pull pin out.
Note
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.
Shear cracks
Cracks which do not overlap (top) are permissible.
Indentations
Permissible indentation depth is 1/4 x rivet head height.
Rings
Rings in the closing head occur if the tool insert used (from riveting
set) was too small.
Permissible ring depth is 1/4 x closing head height.
Formation of a ring around the entire circumference is not per‐
missible.
Stainless steel rivets must not be drilled out or ground down due
to the risk of corrosion.
Riveting procedure
A - Apply rivet
B - Pressing-in procedure
C - Setting and punching out
D - Finished Kerb-Konus riveted joint
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
Note
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.
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.
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
Note
Allow for offset resulting from hole finders; if necessary mark just
one surface at a time.
removed. Using the ring spanner (supplied with the repair kit), the
hole finders are now screwed into the existing holes in the alumi‐
nium panel not being renewed. The new aluminium panel is then
fitted on the vehicle and fixed in position with clamps. Using soft
blows with a rubber hammer, the holes from the existing panel
can now be transferred to the replacement part with the aid of the
hole finders. After being marked with the hole positions, the re‐
placement part is removed. Holes are predrilled at these points.
It is then possible to secure the new part to the body with flow drill
screws using the socket.
Equipment
Only equipment which is listed as approved in the workshop
equipment catalogue may be used.
7.6 Clinching
Clinching is a joining process which is used to join sheet metal
without additional materials. It can be classified either as a joining
process or as a forming process, as the joint is made by forming
the material.
Repair instructions
– Start by making separating cuts where necessary.
– Remove old flange by stripping it off.
– Align remaining flange.
Note
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.
8.1 Drilling
Drilling is used to loosen spot welds and rivets. When performing
drilling work, you must make sure that the components located
behind are not damaged. When loosening two-layer and multi-
layer welded joints, the panel remaining on the vehicle must not
be weakened any more than is necessary. Remove (vacuum up)
all metal particles carefully from cavities after performing drilling
work.
8.2 Saw-cutting
Two different types of saw are commonly used for saw-cutting
work:
♦ Short-stroke pneumatic saw
♦ Oscillating saw
Short-stroke pneumatic saws have the following advantages:
♦ Cutting is performed quickly.
♦ Radius sawing is possible.
♦ Can also be used for very angled profiles.
Oscillating saws have the following advantages:
♦ Clean, straight cuts.
♦ Low penetration depth makes them particularly suitable for
two-layered panels.
Note
Remove (vacuum
Protected by up) all
copyright. Copying for metal
private orparticles carefully
commercial purposes, from
in part or in cavities
whole, is not
after performing
permitted sawing
unless authorised work.
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.
8.3 Grinding
Grinding can be a very useful alternative to drilling, especially
when loosening high-strength welded joints. Grinding can be
used very effectively to loosen spot welds, laser-welded joints and
brazed joints. Again, it is important to ensure that the materials
located behind are not weakened or damaged any more than is
necessary.
Disadvantages of grinding:
♦ Due to flying sparks, extensive safety precautions on and
around the vehicle are necessary.
♦ Higher temperatures are generated than during drilling; this
results in more damage to the remaining material and the anti-
corrosion material.
8.4 Milling
In body repairs, milling work is performed using either a spherical
cutter -A- or a BTR cutter -B-.
Spherical cutters are used to loosen spot welds if, due to lack of
space, it is not possible to use a BTR cutter to do so.
When working with the BTR cutter, it is important to ensure that
the blades remain straight in the high-strength steel. The blades
can break easily as they become harder; you should therefore
always perform the work with a suitable tool (do not use a hand-
held drill).
8.5 Separating
Protected by copyright. bonded
Copying for private joints
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
Bonded joints
with respect oncorrectness
to the the body can be inseparated
of information this document.by applying
Copyright heat.
by AUDI AG.
The adhesives used during vehicle manufacture and repairs are
destroyed at temperatures between 180 and 200°C.
WARNING
Note
9 Surface repairs
Note
9. Surface repairs 49
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Note
WARNING
WARNING
Note
50 9. Surface repairs
General InformationBody Repairs, General Body Repairs - Edition 05.2017
WARNING
Note
9. Surface repairs 51
General InformationBody Repairs, General Body Repairs - Edition 05.2017
Note
WARNING
Note
Note
52 9. Surface repairs
General InformationBody Repairs, General Body Repairs - Edition 05.2017
10.1 Straightening
In series production, the vehicle body and floor sections are pri‐
marily manufactured from cold-formed deep-drawn sheet metal
panels. For this reason, the straightening of areas damaged in an
accident should be carried out in the same manner.
If the extent of the damage makes it impossible to straighten the
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
11 Corrosion protection
Corrosion protection as provided when vehicle leaves the factory
must be restored after repairs, using materials which have been
approved by the vehicle manufacturer.
The standard factory corrosion protection is described in the gen‐
eral and vehicle-specific ⇒ Paintwork manual .
WARNING
Note
Caution
Cleaning
♦ Anti-corrosion agents can be wiped off easily.
♦ Plastic cleaners are suitable for cleaning off dried-on materi‐
als. 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
♦ Cleaning with a steam cleaner is possible for larger with
surfaces.
respect to the correctness of information in this document. Copyright by AUDI AG.
Any spray on painted surfaces should be removed immedi‐
ately.
12 Plastic repairs
WARNING
Repairs that can be performed using plastic repair set include re‐
pairs to painted plastic body panels, such as the bumpers or
exterior mirror housings. Before starting a repair it is important to
check carefully whether the repair is feasible and economical (i.e.
repair or fit new parts?).
Plastic panels with a structured surface can also be repaired in
this way. However, it will not be possible to achieve quite the
original surface Protected
qualitybyofcopyright.
a newCopying
part. 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
12.1 Repairing dents
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Now apply heat to the affected area using a hot air blower until
the dent can be pressed out with a suitable tool.
– Lightly sand down the dented area with abrasive paper (120
grade).
– Then clean the repaired area with cleaning fluid. Allow to dry
for 5 minutes.
– Spray on a thin coat of primer and allow to dry for 10 minutes.
– Now you can fill any remaining surface irregularities with ad‐
hesive and smooth down with a spatula.
– The hardening process can be speeded up with the aid of an
infra-red lamp. Set to 15 minutes at 60°-70°C.
– Now rub down the repaired surface with sandpaper (120
grade).
– Remove sanding dust.
– Spray on a thin coat of primer and allow to dry for 10 minutes.
– Apply paint finish as specified in the Audi paintwork manual.
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.
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.
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.
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
1- Rupture/hole
♦ Glass fibre mat, polyester resin and hardener
2- Surface damage
♦ Glass fibre reinforced polyester resin, hardener
Note
Note
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.
13 Glass repairs
13.1.1 Requirements
Crater
Compound break
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Star and crack 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
14 Thread repairs
Inserts with a zinc-nickel coating must be used when repairing
damaged threads.
Make sure all steel chips have been removed.
Always use genuine parts when replacing studs.
Damaged threads can be repaired using thread inserts with zinc-
nickel coating.
WARNING
Note