Audi A4: Door, Removing and Installing

  Caution

This procedure contains mandatory replaceable parts. Refer to component overview and parts catalog prior to starting procedure.

Mandatory Replacement Parts

• Outer Door Seal - from Door

Removing

- Disconnect the door cut-off connector -1- from the A-pillar. Refer to → Electrical Equipment; Rep. Gr.97; Connectors.

- Tape off the A-pillar in the door arrester area using adhesive tape, so that the paint will not be damaged.

- Remove the door arrester bolt -2-.

- Remove the upper and lower cap -4-.

- Remove the set screw -3- from the upper and lower door hinge.

- Carefully remove the door upward out of the door hinges.

Installing

Install in reverse order of removal and note the following:

• Do not make any adjustments after installing the front door.

Tightening Specifications

• Refer to → Chapter "Overview - Door"

Door, Adjusting

Adjustment Dimensions

A -  Front Door to Body

• Gap dimension -a- = 4.0 to 6.0 mm.

B  -  Front Door to Fender

• Gap dimension -b- = 2.9 to 4.2 mm
• Flush dimension -c- = 0/-1.0 mm
• Parallel alignment = 0.5 mm

C  -  Front Door to Top of Rear Door

• Gap dimension -e- = 2.8 to 4.8 mm
• Flush dimension -d- = +- 0.7 mm
• Parallel alignment = 0.9 mm

D -  Front Door to Bottom of Rear Door

• Gap dimension -g- = 3.5 to 4.5 mm
• Flush dimension -f- = 0/-1.0 mm
• Parallel alignment = 0.5 mm

Door Adjustment, Checking

Special tools and workshop equipment required

• Gauge - Gap Adjustment -3371-
• Template -T40038/20-

• Adjustment dimensions. Refer to → Chapter "Adjustment Dimensions".

Door Adjustment, Checking using -T40038/20-:

- The door frame position is checked using the -T40038/20- at the following measuring point -arrow- at distance -c- from the B-pillar trim panel -1-.

• Dimension -c- = 100 mm.

Side Adjustment, Checking using -T40038/20-:

Minimum Side Adjustment Tolerance, Checking

- Position the template on the body measuring point.

• "min" lettering on the template faces toward the vehicle.

- The template contact points -B and C- must rest on the door window.

• Point -A- should contact the roof edge, but a small gap is permitted.

- If point -A- does have a gap at the roof edge, the maximum tolerance must be checked.

Maximum Side Adjustment Tolerance, Checking

- Position the template on the body measuring point.

• "max" lettering on the template faces toward the vehicle.

- The template contact points -A and C- must rest on the door window and on the roof edge.

- Contact point -B- may rest either on the door window, or there may be a gap.

• Adjustment is OK.

- If it is not OK, the door projects too far outward and must be adjusted.

Height Adjustment, Checking using -T40038/20-:

- Position the template on the body measuring point.

• "min" lettering on the template faces toward the vehicle.

- Contact point -A- must rest against the side and bottom of the roof edge.

- The contact points -B and C- must be pressed against the door window -4-.

- For a proper height adjustment, the lower edge of the window guide -3- must be near the template marking -1-. Then the adjustment is correct.

- If not, the door must be adjusted.

Preliminary Work for Length and Side Adjustment

Driver Side

- Remove the Relay and Fuse Panel 1 -SR1-, free it up and push it to the side. Refer to → Electrical Equipment; Rep. Gr.97; Relay Panel, Fuse Panel, E-Boxes; Component Location Overview - Relay Panel, Fuse Panel and E-Boxes.

- Remove the mount for the Vehicle Electrical System Control Module -J519-. Refer to → Electrical Equipment; Rep. Gr.97; Control Modules; Vehicle Electrical System Control ModuleJ519, Removing and Installing.

- Free up the wiring harness.

Front Passenger Side

- Remove the glove compartment. Refer to → Body Interior; Rep. Gr.68; Storage Compartments and Covers; Glove Compartment, Removing and Installing.

- If equipped, remove the Relay and Fuse Panel 4 -SR4-. Refer to → Electrical Equipment; Rep. Gr.97; Relay Panel, Fuse Panel, E-Boxes; Component Location Overview - Relay Panel, Fuse Panel and E-Boxes.

Length Adjustment

• Adjustment dimensions. Refer to → Chapter "Adjustment Dimensions".

Procedure

- Perform the preliminary work for length adjustment. Refer to → Chapter "Preliminary Work for Length and Side Adjustment".

- Loosen the bolts -1- and nuts -2- on the A-pillar.

- Adjust the door lengthwise.

- Tighten the bolts and nuts.

Tightening Specifications

• Refer to → Chapter "Overview - Door"

Side Adjustment

• Adjustment dimensions. Refer to → Chapter "Adjustment Dimensions".

Procedure

- Perform the preliminary work for the side adjustment. Refer to → Chapter "Preliminary Work for Length and Side Adjustment".

- Loosen the bolts -arrows- on the upper and lower hinge.

- Adjust the door to the center of the vehicle.

- Tighten the bolts.

Tightening Specifications

• Refer to → Chapter "Overview - Door"

Striker, Adjusting

• Adjustment dimensions. Refer to → Chapter "Adjustment Dimensions".

Procedure

- Loosen the bolts -arrows-.

- Slide the striker -1- until the door is flush with the body contour.

• When adjusting the striker, move it only toward the center of the vehicle.
• Do not adjust the door height using the striker because the door lock will be damaged.
• When adjusted correctly, the striker must engage in the center of the door lock.

- Tighten the bolts.

Tightening Specifications

• Refer to → Chapter "Overview - Door Handle and Door Lock"

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