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General InformationBody Repairs,
General Body Repairs
Edition 10.2007
Service
Service Department. Technical Information
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
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt 001KAH00020
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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.
Contents
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Diagnosis of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General notes on body repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Condition in which body and/or individual parts must be delivered to paintshop . . . . . . . . 1
1.4 Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Separating cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Body sub-parts and part sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Original joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.8 Galvanised body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.9 Removing remaining material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.10 New parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.11 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Removing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Battery, welding operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Electronic control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Procedure for electronic control units following accident repairs . . . . . . . . . . . . . . . . . . . . 4
2.5 Paintwork, glass, upholstery, trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Fuel tank and fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.8 Airbag system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.9 Checking seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.10 Working on vehicles with belt tensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.11 Cutting, straightening and/or dent removal work on vehicles with airbag . . . . . . . . . . . . . . 7
2.12 Removing seats with side airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Anti-corrosion measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Anti-corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Long-term body protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Notes on warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Electrolytic galvanisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Hot-dip galvanisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Notes on disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Active environmental protection at the factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Recycling means: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 The basic rules for environmental protection are: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.7 Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.8 Protection against contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Expanded foam inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Symbols for welding operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Symbols for work procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Cavity sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Body - Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8 Sheet steel repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Extra-high-strength body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Galvanised body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.3 Joining techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.4 Joining techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9 Plastic repair techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General InformationBody Repairs, General Body Repairs - Edition 10.2007
Contents i
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9.1 Plastic repair set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.2 Repairing dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.3 Repairing scratches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.4 Repairing cracks and tears (up to a length of 100 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.5 Repairing holes (up to 30 mm diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.6 Plastic repairs (glass fibre materials) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 Glass repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.1 Repairing windscreens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.4 Description of repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
11 Aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.1 Aluminium repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.2 Surface treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
11.3 Removing dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
12 The Audi Space Frame concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
14 Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
15 Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
16 Paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
17 Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
18 Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
19 Surface treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
20 Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 Removing dents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
22 Re-forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
23 Temperature monitoring during heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
24 Flanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
25 Welding repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
26 Extruded section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
27 Sheet metal panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
28 Plug welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
29 Welding aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
30 Checking weld seams and aluminium node castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
31 Laser weld seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
32 Overview of rivets and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
33 Riveting repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
34 Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
35 Solid rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
36 Pop rivet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
37 Fitting solid rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
38 Fitting punch rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
39 Fitting pop rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
40 Incorrect riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
41 Joddling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
42 Placing additional thickness of same material behind joint . . . . . . . . . . . . . . . . . . . . . . . . 73
43 Filling separating cuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
44 Bonded joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
45 Inaccessible rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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46 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
47 Explanation of symbols for riveting operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
48 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
49 Cavity sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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General InformationBody Repairs, General Body Repairs - Edition 10.2007
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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1 General notes
1.1 Diagnosis of accident vehicles
When repairing accident vehicles, damage to the running gear or
engine/gearbox mountings, etc. is not always identified. This
sometimes leads to serious subsequent damage. If the accident
damage indicates a high impact load on the vehicle, special at‐
tention must be paid to the following components, completely
independent of the wheel alignment check which must always be
performed:
♦ Check to ensure that the steering assemblies and steering
linkage operate correctly over the complete lock-to-lock range.
Carry out a visual check for bent or cracked parts.
♦ Check for distortion or cracking of running gear and all running
gear components such as links, suspension strut, wheel bear‐
ing housing, anti-roll bar, subframe and axle beam, as well as
associated fastening elements.
♦ Examine rims and tyres for damage, eccentricity and imbal‐
ance. Examine tyres for cuts/slits etc. in tread and sidewalls
and check inflation pressure.
♦ Examine the engine/gearbox/axle/exhaust system mountings
for damage.
♦ Finally, a thorough road test after completing repairs will give
the assurance that the vehicle is completely roadworthy and
ready for handing back to the customer.
1.2 General notes on body repairs
The aim of the repair is always to restore the original joint.
The Workshop Manuals describe the standard repairs. They do
not include any descriptions of more complex repair jobs, as these
involve detaching the damaged parts at the original joint. If pos‐
sible the joining techniques as listed in section 8 can be applied.
All repair jobs involving special separating cuts and joining tech‐
niques which do not restore the original joint (as produced by
factory) have been checked and approved by the Technical De‐
velopment division in calculations, strength and crash tests.
1.3 Condition in which body and/or individ‐
ual parts must be delivered to paintshop
Before a repaired vehicle or part is handed over to the paintshop,
the surfaces which have been repaired or beaten-out and possibly
filled must be prepared for painting by rubbing them down with
abrasive paper (grade P 80 to P 100).
This preparatory work is part of the job of the sheet metal worker
and is included in the time he is allowed for the repair.
1.4 Straightening
In series production, body and floor sections are primarily manu‐
factured 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 reform the part
as stated above, the damaged part should not be cut out until the
adjacent surfaces have been straightened.
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1. General notes 1
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1.5 Separating cuts
Separating cuts affecting the fatigue strength of the body and
therefore also vehicle reliability and roadworthiness must be
made as instructed in the relevant Body Repairs workshop man‐
ual.
1.6 Body sub-parts and part sections
A “sub-part” is a section of a complete part (e.g. end section front
and rear), which is already cut to size when it is supplied by the
Parts Department.
– “Part sections” on the other hand must be cut to size from re‐
placement parts by the workshop itself. The methods to apply
in each case are described and illustrated in the workshop
manual on Body Repairs.
– As the use of “sub-parts”/“part sections” and special tools and
equipment has an influence on the time required, special tools
and equipment are listed separately in the description of repair
operations.
1.7 Original joint
The term “Original joint” refers to the joint which was made at the
time the vehicle was manufactured.
These joints must be restored when carrying out body repairs.
When doing this, ensure that no fewer than the standard number
of spot welds are made when carrying out repairs.
Repair methods and procedures which deviate from the original
joint are described in the appropriate Body Repairs workshop
manual.
1.8 Galvanised body parts
The use of fully galvanised panels ensures a high level of corro‐
sion protection for the body shell. To be able to maintain the
warranty guarantee against perforation rusting when performing
repairs, it is essential to comply with the procedures from
⇒ page 22 onwards.
WARNING
As the welding of galvanised sheet steel gives off toxic zinc
oxide in the welding fumes, the workshop must have efficient
ventilation and fume extraction, e.g. in the form of a welding
fume extractor -V.A.G 1586 A- .
1.9 Removing remaining material
If the damaged body part has been roughly cut out by making the
separating cuts shown in the relevant workshop manual, e.g. us‐
ing pneumatic hammer -V.A.G 1577- or pneumatic sabre saw -
V.A.G 1523 A- , most spot welds can be drilled out using the spot
weld breaker -V.A.G 1731- .
We also recommend using a parallel grinder and an angle grinder
to remove the weld joints which cannot be removed with the spot
weld breaker.
1.10 New parts
To provide corrosion protection, new parts which are no longer
accessible from inside once the repair has been completed (e.g.
side members) should be pre-painted from inside in the vehicle's
General InformationBody Repairs, General Body Repairs - Edition 10.2007
2 1. General 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
with respect to the correctness of information in this document. Copyright by AUDI AG.
body colour before they are welded in. It is advisable to mask
welding flanges when doing so.
1.11 Replacement parts
In order to keep the number of different parts to a minimum, many
replacement parts are only supplied as a “basic version”.
Examples:
• Roof for Audi A6 2005 ▸ without holes for roof rail
We recommend that the workshop makes its own “templates”
from damaged parts for such cases.
Example: Roof for Audi A6 2005 ▸ holes for roof rail:
• Use pneumatic sabre saw -V.A.G 1523 A- to cut side section
out of "old" roof, paying attention to significant contours, e.g.
part of recess (rain channel). Deburr cut edges and protect
with fabric-backed adhesive tape.
Place template in position before painting and allow for material
thickness of template when marking drill holes.
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.
General InformationBody Repairs, General Body Repairs - Edition 10.2007
1. General notes 3
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 Safety notes
2.1 Removing components
Before the centre of gravity of the vehicle is changed substantially
by removing components, the vehicle must be properly secured
to the lifting platform.
2.2 Battery, welding operations
Before starting welding work, always detach both battery clamps
and cover battery terminals.
Always remove the vehicle battery before performing any work
which may generate sparks in the vicinity of the battery.
WARNING
Switch on ignition before connecting battery.
On vehicles with an electronic ignition lock the ignition must be
switched on before removing the battery ⇒ Workshop manual:
Electrical system, repair group 27 .
There must be nobody in the vehicle when connecting the bat‐
tery!
2.3 Electronic control units
Connect the earth connection of the electric welding appliance
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.
2.4 Procedure for electronic control units
following accident repairs
After an accident, the electronic control units only have to be re‐
newed in the following case:
♦ The functional test shows: “Control unit defective”.
If electronic components (e.g. ABS control unit) were removed in
order to carry out repair work and have now been re-installed,
they must be checked according to the documentation available.
Use the tester to interrogate the fault memory and eliminate any
faults found.
2.5 Paintwork, glass, upholstery, trim pan‐
els
No other vehicles may be parked unprotected in areas used for
body repairs. (Risk of fire due to flying sparks and risk of damage
to battery, paintwork or glass of other vehicles).
2.6 Fuel tank and fuel pipes
Take extreme care when performing sanding and welding work
near the tank or other components carrying fuel. If in doubt, al‐
ways remove these components.
General InformationBody Repairs, General Body Repairs - Edition 10.2007
4 2. Safety notes
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Audi A5 Service & Repair Manual
Covers: up to MY2016
This Audi A5 Workshop Manual is a comprehensive Service Repair Information System for Windows and Apple Mac. It includes detailed diagrams, illustrations, and manufacturers' specifications. The manual is designed for professional mechanics and DIY enthusiasts, offering a user-friendly menu-driven interface for servicing and repairs, including Strict Maintenance Operations.
Compatibility:
The Audi A5 Service & Repair Manual is compatible with Windows XP, Vista, 7, 8, and 10, Apple Macs OSX 10.6 and above, and Linux operating systems.
Key Features:
- Comprehensive Diagrams
- Zoom-In Illustrations
- Torque Specifications
- Special Tooling Requirements
- Menu Driven Pages
- 1000's of Photographs and Diagrams
- Search via Model/Year/Sales Model/Engine Code/Gearbox Code
This manual contains all the necessary instructions for vehicle repairs, from routine maintenance to extensive engine and transmission disassembly. It is widely used by mechanics worldwide for vehicle diagnosis and repair.
Comprehensive diagrams, detailed illustrations, manufacturers' specifications, and technical information are included. The manual also covers scheduled service information, Wiring Diagrams, Tightening Torques, and Operating Fluids.
PLEASE NOTE: This manual is approximately 9.2GB in size. A USB option is available for purchase for slow internet connections. The product is compatible with Windows, Macs, and Linux Operating Systems, and comprehensive instructions are included. All pages are printable for convenience.
Contents:
- General Information
- Engine Control, Fuel & Exhaust
- Engine Fuel & Emission Control
- Engine Lubrication
- Engine Mechanical
- Transmission
- Brake System
- Front & Rear Axle
- Steering System
- Clutch & Gearbox
- Propeller Shaft & Differential
- Cooling System
- Electrical System
- Heater & Air Conditioning
- Ventilation System
- Maintenance
- Lights and Switch
- Wiring Diagrams
- Technical Diagnostics
- Fault Finding Diagnostics
- Fuel System
- Suspension
- Wheels & Tyres
- Body & Chassis
- Interior Fittings
- Safety systems
- And much more...
