1994-2001 Audi A4 (B5) Service & Repair Manual

50-1 Body, front Lock carrier with attachments, removing and installing 1 - Hex bolt (6x) 45 Nm (33 ft lb) 2 - Hex bolt 45 Nm (33 ft lb) 3 - Hex bolt (4x) 10 Nm (7 ft lb) 4 - Hex bolts (2x) 10 Nm (7 ft lb) 5 - Access hole for special tool For service position, attach special tool 3369 here 6 - Cowl attachment hole Attachment for service position Page 1 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-2 Repair Manual, Heating & Air Conditioning, Repair Group 87 Notes: Repair Manual, Suspension, Wheels, Steering, Repair Group 48 7 - Lock carrier Removing: - Remove bumper page 63 - 1 . - Remove noise insulation panel page 50 - 18 . - Disconnect hood lock cable page 55 - 10 . - Drain engine coolant and disconnect coolant hoses Fig. 2 . - Disconnect condenser from lock carrier only (do not disconnect any lines) and secure with wire (e.g. at front wheel). Do not suspend condenser by its lines. Condenser lines must not be bent or kinked under any circumstances. - Remove hydraulic oil cooler only (do not disconnect lines) Fig. 1 . Page 2 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-3 Notes: Repair Manual, Automatic Transmission, Repair Group 37 Do not suspend hydraulic fluid cooler by its lines. Hydraulic fluid cooler must not be bent or kinked under any circumstances On vehicles with automatic transmission, remove ATF cooler On vehicles with charge air cooler, remove intake air duct - Loosen seal for hood -8- at left and right where fender meets lock carrier -7-. - Remove bolts -3- and -4-. A second mechanic is needed to support lock carrier -7- - Remove bolts -1- and -2-. Page 3 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-4 Installing: - Install in reverse order of removal. - Adjust headlights. Adjusting: - Center lock carrier -7- between fenders. - If fenders and hood are also being replaced, center them in relation to one another before adjusting lock carrier. 8 - Hood seal 9 - Hood lock cable Disconnecting page 55 - 10 10 - Hole in side panel Page 4 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-5 Fig. 1 Disconnecting hydraulic fluid cooler - Remove screws for cooling line (for power steering) at engine support and transmission. Repair Manual, General, Engine, Repair Group 19 Fig. 2 Disconnecting coolant hose - Drain coolant from radiator. - Pull out locking element for coolant line connecting flange at bottom of radiator and remove connecting flange. - Bleed coolant system. Page 5 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-6 Fig. 3 Disconnect hose for charge air cooler - On vehicles with charge air cooler, loosen bolt on hose clamp (arrow). - Remove hose. - Unscrew air duct to air cleaner at cowl and lift out. - Disconnect harness connectors for headlights, headlight height adjustment and blinkers. - Disconnect harness connector for coolant system temperature sensor for coolant fan at lower coolant hose area at radiator (left). Page 6 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-7 Lock carrier service position Notes: Do not remove noise insulation. Loosen only front quick-release screws page 50 - 18 . Bumper removed 1 - Combination bolt 45 Nm (33 ft lb) 2 - Combination bolt 45 Nm (33 ft lb) 3 - Combination bolt 10 Nm (7 ft lb) 4 - Combination bolt 10 Nm (7 ft lb) 5 - Access hole for special tool For service position, attach special tool 3369 here 6 - Cowl attachment hole Attachment for service position Page 7 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-8 Note: After assembly of the lock carrier, check headlight positioning and adjust if necessary. 7 - Lock carrier For service position - Screw special tool 3369 into threaded bore -5- on left side Fig. 1 - Remove left and right mounting screws - 1-. - Remove mounting bolts -3- and -4- and pull lock carrier -7- forward. - Secure lock carrier Fig. 2 . 8 - Hood seal 9 - Hood lock cable 10 - Hole in side panel Page 8 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-9 Fig. 1 Screw in special tool 3369 - Screw special tool 3369 in at left and right as shown. - Pull lock carrier forward until rear hole in lock carrier aligns with front threaded hole in fender flange. Fig. 2 Secure lock carrier - Secure lock carrier with screws at left and right as shown. Page 9 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

50-10 Front fender ( VIN 8D XA 200 000), assembly overview 1 - Combination bolt 4.5 Nm (40 in. lb) 2 - Threaded rivet Threaded rivet is inserted using VAG1618A 3 - Combination bolts (2x) 7.5 Nm (66 in. lb) 4 - Phillips head screw 4.5 Nm (40 in. lb) 5 - Metal nut (2x) 6 - Fender Remove bumper page 63 - 1 . Remove wheelhousing liner page 66 - 31 . Remove end plate Fig. 1 . Remove headlights Repair Manual, Electrical Equipment Disconnect electrical connectors for side blinkers - Remove bolts -1-, -3-, -4-, -7-, and -11-. Page 10 of 19 Body, front 11/20/2002 http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1

1994-2001 Audi A4 (B5) Service & Repair Manual

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