Service

Workshop Manual
Audi A6 1998 ➤
General body repairs, exterior
Edition 11.2004

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.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment

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 © 2015 Audi AG, Ingolstadt A0056006220

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Contents

50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Removing and installing lock carrier with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Lock carrier service position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Exploded view of front wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Exploded view of noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Removing, installing and adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Removing and installing gas-filled strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Removing and installing catch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Bonnet lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7 Removing and installing bottom part of bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.8 Removing and installing cable for bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Removing and installing rear lid and rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Removing and installing rear lid lock and handle mechanism . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Removing and installing remote release motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Removing and installing rear lid actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.6 Removing and installing rear lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Removing and installing gas-filled strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9 Adjusting buffer stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Avant rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Removing and installing rear lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5 Removing and installing rear lid lock and handle mechanism . . . . . . . . . . . . . . . . . . . . . . 23
3.6 Removing and installing rear lid actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Removing and installing front door and door subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3 Removing and installing window lifter and door window . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.4 Removing and installing window lifter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5 Adjusting front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.6 Adjusting front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.7 Removing and installing door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.8 Exploded
by AUDI AG.view of does
frontnotdoor handle andany door
liability lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised AUDI AG guarantee or accept
with respect1.9 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
to the correctness of information in this document. Copyright by AUDI AG. 33
1.10 Exploded view of door handle removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.11 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.12 Front door handle pre-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.13 Servicing central locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.14 Removing actuator for filler neck compartment lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.15 Removing and installing rear lid actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Contents i
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1 Removing and installing rear door and door subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2 Removing and installing door hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.3 Removing and installing window lifter and door window . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.4 Removing and installing window lifter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.5 Adjusting rear door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.6 Adjusting rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.7 Removing and installing door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.8 Exploded view of rear door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.9 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.10 Removing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.11 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.12 Rear door handle pre-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1 Servicing sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.1 Exploded view of sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.2 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.3 Exploded view of sunroof panel removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.4 Removing and installing trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.5 Removing and installing sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.6 Adjusting sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.7 Replacing panel seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.8 Adjusting zero position (motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.9 Checking and adjusting zero position (guide plate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2 Water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.1 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.1 Exploded view of front bumper removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.2 Removing and installing air inlet grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.3 Removing and installing RS6 air inlet grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.4 Attaching cover to wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.5 Attaching bumper to impact absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.6 Removing and installing guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.7 Removing cross member from cover/installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.8 Removing and installing impact absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 Saloon rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 Exploded view of rear bumper removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Exploded view of RS6 rear bumper removal and installation . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Removing and installing guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4 Removing and installing impact absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5 Attaching cover to side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Avant rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Exploded view of rear bumper removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2 Exploded view of RS6 rear bumper removal
Protected and Copying
by copyright. installation
for private .or.commercial
. . . . . . purposes,
. . . . . .in.part
. . or. .in.whole,
. . . .is not69
3.3 Removing and installing guide . . with . . .respect
. . . .to. the
. .correctness
. . . . . . of. .information
. . . . . .in.this
. .document.
. . . . . .Copyright
. . . . .by. .AUDI. . .AG.
. 70
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

3.4 Removing and installing impact absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.5 Attaching cover to side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1 Windows bonded flush with bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1.1 General information on removing and installing windows bonded flush with bodywork . . . . 72

ii Contents
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.2 Windscreen repair using repair resin, Talon VAS 1993/2 . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.4 Minimum setting times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.5 Cleaning off adhesive sealing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.6 Re-sealing windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.1 Exploded view of windscreen removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.2 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.3 Preparation for windscreen installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.4 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3 Side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Exploded view of side window removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2 Removing intact side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Removing shattered side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.4 Installing intact window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.5 Installing new window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4 Avant side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1 Removing and installing Avant side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2 Removing intact side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.3 Removing shattered side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.4 Installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5 Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.1 Exploded view of rear window removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.2 Removing intact rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.3 Removing shattered rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.4 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6 Avant rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.1 Exploded view of Avant rear window removal and installation . . . . . . . . . . . . . . . . . . . . . . 96
6.2 Removing intact rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.3 Removing shattered rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.4 Preparation for window installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.5 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1 Roof mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.1 Removing and installing roof joint moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.2 Removing and installing Avant roof joint moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.3 Removing and installing decorative roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4 Removing and installing Avant decorative roof trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2 Roof rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.1 Removing and installing roof rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3 Protective mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.1 Replacing protective side mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.2 Removing and installing trim cover for sill panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Removing and installing trim cover for sill panel (Allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4 Trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.1 Removing and installing B-pillar trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5 Rear lid decorative trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
113
5.1 Replacing
permitted unless rear
authorised by AUDI lidAG.decorative
AUDI AG does trim . . . .or. accept
not guarantee . . . .any
. .liability
................................. 113
with respect to the correctness of information in this document. Copyright by AUDI AG.
6 Rear view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1 Removing and installing rear view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.2 Replacing housing for exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.3 Replacing electric mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7 Protective sheeting for side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Contents iii
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

7.1 Bonding protective sheeting onto side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

8 Outer sill moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
8.1 Replacing outer sill moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
9 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
9.1 Removing and installing sill panel trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
9.2 Removing and installing sill panel trim (Allroad) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.3 Removing and installing sill panel trim (RS6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
9.4 Removing and installing sill moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10 Wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.1 Removing and installing front wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.2 Removing and installing rear wheel housing liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
11 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.1 Removing and installing cover for front wheel housing (Allroad and RS6) . . . . . . . . . . . . 126
11.2 Removing and installing cover for rear wheel housing (Allroad) . . . . . . . . . . . . . . . . . . . . 127
12 RS6 rear spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
12.1 Removing and installing Saloon rear spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
12.2 Removing rear spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
12.3 Removing and installing Avant rear spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

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.

iv Contents
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

50 – Body - front
1 Body - front

1.1 Removing and installing lock carrier with attachments

1 - Lock carrier
❑ Removing:
– Remove bumper
⇒ page 59 .
– Remove noise insula‐
tion ⇒ page 6 .

– Disengage Bowden ca‐

ble for bonnet lock
⇒ page 12 .
– Unscrew air duct be‐
tween lock carrier and
air cleaner at lock carri‐
er.

– Unplug connectors.

– Drain coolantProtected
and dis‐ by copyright. Copying for private or commercial purposes, in part or in whole, is not
connect coolant hoseunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
⇒ page 2 with respect to the correctness of information in this document. Copyright by AUDI AG.

– Only detach condenser

from lock carrier (do not
disconnect pipes) and
secure with wire (e.g. at
front wheel) ⇒ Air con‐
ditioning system; Rep.
Gr. 87 .

Note

Never leave condenser hanging by

its pipes. Condenser pipes are nev‐
er to be kinked.
❑ Only detach hydraulic
fluid cooler ⇒ page 2
(do not disconnect
pipes) ⇒ Running gear, front-wheel drive and four-wheel drive; Rep. Gr. 48 .

Note

Never leave hydraulic fluid cooler

hanging by its pipes. Hydraulic fluid
cooler pipes are never to be kinked.

– Vehicles with automatic gearbox: Disconnect pipes to ATF cooler ⇒ Rep. Gr. 37 .

– Vehicles with charge-air cooling: Disconnect air hose.

– Unfasten bonnet seal on left and right at transition to wing at lock carrier.

– Unscrew bolts ⇒ Item 2 (page 2) .

1. Body - front 1
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Note

Second mechanic is required to

hold lock carrier.

– Unscrew bolts ⇒ Item 3 (page 2) , ⇒ Item 4 (page 2) and ⇒ Item 5 (page 2) .

❑ Install in reverse order.
❑ Headlights must be readjusted.
❑ Adjusting:
– Align lock carrier between wings.

– If wings and bonnet are replaced as well, these must first be centrally aligned with one another.

2 - Torx bolt - 10 Nm
3 - Combi bolt - 50 Nm
4 - Combi bolt - 50 Nm
5 - Combi bolt - 50 Nm

Detaching hydraulic fluid cooler Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew hydraulic pipe for power steering at engine support
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

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

Disconnecting coolant hose

– Drain coolant at radiator -arrow-.
– Pull out locking element for connecting flange of coolant hose
at bottom of radiator and detach connecting flange.
– Bleed cooling system ⇒ Rep. Gr. 19 .

Detaching charge-air cooling hose

– Vehicles with charge-air cooling: Slacken off bolt at hose
clamp -arrow-.
– Detach hose.

2 Rep. Gr.50 - Body - front

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.2 Lock carrier service position

Special tools and workshop equipment required
♦ Front end service position special tool -3369-

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.
Do not remove noise insulation. Only slacken off front quick-release bolts ⇒ Item 1 (page 6) .

1 - Lock carrier
❑ Service position:
– Unscrew air duct be‐
tween lock carrier and
air cleaner at lock carri‐
er.

– On right side: Unscrew

bolt
⇒ Item 5 (page 4)
and screw in front end
service position special
tool -3369- .

– On left side: Screw front

end service position
special tool -3369- into
tapped hole
⇒ page 4

– Unscrew bolts
⇒ Item 2 (page 4) on
left and right.

– Unscrew bolts
⇒ Item 3 (page 4)
and
⇒ Item 4 (page 4)
and pull lock carrier
⇒ Item 1 (page 3) for‐
wards.

– Fix lock carrier in posi‐

tion ⇒ page 4

1. Body - front 3
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2 - Torx bolt - 10 Nm
3 - Combi bolt - 50 Nm
4 - Combi bolt - 50 Nm
5 - Combi bolt - 50 Nm
❑ For service position, unscrew combi bolt and screw in front end service position special tool -3369- in its
place.

Note

After fitting lock carrier, check head‐

light setting and adjust if necessary
⇒ Maintenance ; Booklet 402 .

Screwing in front end service position special tool -3369-

– Screw in front end service position special tool -3369- as
shown on left and right.

Fixing lock carrier in position

– Pull lock carrier forwards until rear hole at lock carrier coin‐
cides with front tapped hole of wing flange.
– Use bolts -2- to fix lock carrier -1- in position as shown on left
and right.

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 Rep. Gr.50 - Body - front

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.3 Exploded view of front wing

1 - Wing
❑ Remove bumper cover
⇒ page 59 .
❑ Remove wheel housing
liner ⇒ page 124 .
❑ Remove end plate
⇒ page 6 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Unfasten headlights ⇒
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.
Electrical system; Rep.
Gr. 94 .
❑ Unplug connectors for
side turn signal indica‐
tor.
❑ Unscrew bolts
⇒ Item 2 (page 5) ,
⇒ Item 3 (page 5) ,
⇒ Item 4 (page 5) ,
⇒ Item 5 (page 5)
and
⇒ Item 6 (page 5) .
2 - Combi bolt -10 Nm
3 - Combi bolt -10 Nm
❑ 2x
4 - Combi bolt -10 Nm
5 - Combi bolt -10 Nm
6 - Combi bolt -15 Nm

Note

♦ The combi bolt is gradually being

converted from the hexagon
head type to the Torx T30 socket
type.
♦ These bolts and washers are mi‐
cro-encapsulated and must be
replaced after being unfastened
or following wing removal.

7 - Holder
8 - Combi bolt -10 Nm

1. Body - front 5
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Removing and installing end plate

– Remove front wheel.
– Remove wheel housing liner.
– Unscrew bolts -1- from expanding clip -3- and take end plate
-2- out of wing -4-.

1.4 Exploded view of noise insulation

1 - Quick-release bolt - 2 Nm
❑ 3x
❑ Only unfasten these
quick-release bolts for
lock carrier service po‐
sition.
2 - Front noise insulation
3 - Quick-release bolt - 2 Nm
❑ 3x
❑ Use must be made of
longer
Protected quick-release
by copyright. Copying for private or commercial purposes, in part or in whole, is not
bolts if rear noise insu‐
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.
lation
⇒ Item 4 (page 6) is
fitted as well.
4 - Rear noise insulation
❑ Only fitted with special
engine/gearbox ver‐
sions
5 - Quick-release bolt - 2 Nm
❑ 2x
6 - Noise insulation mount
❑ Mark (recess) must face
left side of vehicle.
7 - Bolt
❑ 2x
8 - Speed nut
❑ 2x
9 - Speed nut
❑ 3x
10 - Clamping pin
❑ 4x

6 Rep. Gr.50 - Body - front

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

11 - Wheel housing liner

12 - Bumper
13 - Lock carrier with attachments

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.

1. Body - front 7
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

55 – Bonnet, rear lid

1 Bonnet

1.1 Contact corrosion

♦ Contact corrosion can occur if use is made of unsuitable con‐
necting elements (bolts, nuts, washers ...).
♦ For this reason, only connecting elements with a special sur‐
face coating (Dachromet) are fitted. These elements can be
recognised by their greenish colour.
♦ In addition, rubber components, plastic components and ad‐
hesives are made of non-conductive materials.
♦ Always fit new components in cases of doubt about re-use.

Caution

♦ Only use genuine replacement parts. These have been

checked and are compatible with aluminium.
♦ Accessories must have been released by Audi AG.
♦ Damage caused by contact corrosion is not covered by
warranty.

1.2 Removing, installing and adjusting bonnet

Note

The bonnet is made of aluminium – heed notes on corrosion protection ⇒ page 8 .

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 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Bonnet
❑ Removing:

Note

A second mechanic is required to

support and lift off the bonnet.

– Disconnect and unclip

tubing for windscreen
washer system.

– Detach gas-filled strut

⇒ Item 5 (page 9)
from bonnet
⇒ Item 1 (page 9)
⇒ page 11 .

– Unscrew nuts
⇒ Item 4 (page 9) .

– Detach bonnet.
❑ Install in reverse order.
❑ Adjusting:
– Align bonnet
⇒ Item 1 (page 9) be‐
tween wings.

– Bonnet height is adjus‐

ted by way of bonnet
lock ⇒ page 12 .

– Bonnet can be adjusted Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
with respect to wings by permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
means of buffer stops with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 10
❑ Joint dimensions
⇒ page 10
2 - Bonnet hinge
❑ Bonnet ⇒ Item 1 (page 9) must be removed or reliably supported.
❑ To remove, unscrew bolts ⇒ Item 3 (page 9) and nuts ⇒ Item 4 (page 9) .
3 - Torx bolt -15 Nm
4 - Hexagon nut - 15 Nm
5 - Gas-filled strut
❑ Removing ⇒ page 11
❑ To install, press gas-filled strut onto ball stud.
❑ Gas-filled strut cylinder must be fitted at body end.

1. Bonnet 9
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Adjusting bonnet
Special tools and work‐
shop equipment re‐
quired
♦ Adjustment gauge
-3371-

Joint dimensions
♦ Dimension -A- = 5.0
mm + 1 mm
♦ Dimension -B- = 5.0
mm + 1 mm
♦ Dimension -C- = 3.0
mm + 1 mm
♦ Dimension -D- = 5.0
mm + 1 mm
♦ Dimension -E- = 2.0
mm ± 0.2 mm
♦ Dimension -F- = 2.0
mm ± 0.2 mm
♦ Dimension -G- = 2.5
mm ± 0.2 mm

Height adjustment buffer stops

– With bonnet closed, buffer stops -1- and -2- must rest lightly
on lock carrier.

Note

Buffer stops can be used to adjust height of bonnet.

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.

10 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.3 Removing and installing gas-filled strut

– Support bonnet or secure to stop it closing.
– Use screwdriver to slightly lift retaining springs -arrow- at both
ends of gas-filled strut and unclip gas-filled strut -1-.
– To install, press gas-filled strut onto ball stud and engage.
– Gas-filled strut cylinder is installed at body end.

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.

Releasing gas from gas-filled strut

WARNING

Only clamp strut in this area to avoid risk of accident.

– Clamp gas-filled strut in vice in area -x- = 50 mm.

– Cover saw cut area with a cloth to catch fluid escaping.

WARNING

Wear safety goggles whilst sawing.

– Saw open cylinder of gas-filled strut in first third of overall cyl‐

inder length, based on reference edge at piston rod end.

1.4 Removing and installing radiator grille

Removing
– Release fasteners -arrows-.
– Swivel out radiator grille at top and then detach at bottom.
Installing

Note

Coat PU seal with lubricant to facilitate installation.

– Fit radiator grille in centre at bottom (heed centring element)

and swivel in (in direction of arrow).
• Dimension -a- = 2 mm ± 0.5 mm
– Make sure radiator grille is heard to fully engage.

1. Bonnet 11
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.5 Removing and installing catch

– Unscrew hexagon bolts -2- and detach catch -1-.
• Tightening torque for hexagon nuts 8 Nm

1.6 Bonnet lining

– Unfasten clips -2- (18x).
– Detach cover -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.

1.7 Removing and installing bottom part of

bonnet lock
– Disengage Bowden cable for bonnet ⇒ page 12 .
– Unscrew bolts -2- (4x).
– Take out bottom part of lock -1-.
3 - Lock carrier
– Bonnet is adjusted by moving bottom part of lock up or down.
• Tightening torque 10 Nm

1.8 Removing and installing cable for bonnet

12 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Cable for bonnet

❑ Removing:
– Remove driver's stor‐
age compartment ⇒
General body repairs,
interior; Rep. Gr. 68 .

– Unscrew bolts
⇒ Item 3 (page 13) .

– Disengage cable from

support bracket
-arrow B- and eyelet
-arrow A- of bottom part
of bonnet lock
⇒ Item 5 (page 13) .
– Detach clip
⇒ Item 4 (page 13) .

– Take cable
⇒ Item 1 (page 13) out of
guide slot of seal
⇒ Item 6 (page 13)
and pull through to‐
wards passenger com‐
partment.
❑ Install in reverse order.
2 - Bonnet lock cable
3 - Oval head self-tapping
screw - 1.5 Nm
4 - Clip
5 - Bottom part of bonnet lock
❑ Removing and installing
⇒ page 12
❑ Can be used to adjust
height of bonnet
6 - Seal

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.

1. Bonnet 13
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2 Rear lid

2.1 Removing and installing rear lid and rear lid lock

1 - Rear lid
❑ Removing:

Note

A second mechanic is required to

support and lift off the rear lid.

– Remove hazard warn‐

ing triangle with holder
⇒ Item 5 (page 15) .

– Remove rear lid lining.

– Disconnect and unclip

wires. 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
– Unscrew nuts for con‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
necting both hinges to
rear lid ⇒ page 18 .
❑ Install in reverse order.
❑ Adjusting:
– Adjust rear lid in vertical
and horizontal direc‐
tions by way of rear lid
hinge ⇒ page 18 .
– Adjust buffer stops
⇒ Item 2 (page 14) .

– Adjust striker pin

⇒ Item 6 (page 15) .

– Centrally align rear lid in

accordance with joint di‐
mensions ⇒ page 16 .
❑ Adjusting ⇒ page 16
2 - Buffer stop (2x)
❑ Adjusting:
❑ Rear lid is set with respect to side panel by way of striker plate.
– Use Phillips screwdriver to press home spring pin.

– Turn spring pin anti-clockwise to lock.

– Screw buffer stops into rear lid.

– Carefully close rear lid until it is flush with rear side panel.

– Gradually screw out buffer stops.

– Given correct adjustment, buffer stops must rest lightly on sill with rear lid closed.

– Turn spring pin clockwise with Phillips screwdriver to release.

14 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3 - Expanding nut
4 - Self-tapping screw - 1.5 Nm
5 - Holder
❑ To remove, take out hazard warning triangle, unscrew bolts ⇒ Item 4 (page 15) and detach holder.
6 - Striker plate
❑ Unscrew nuts ⇒ Item 7 (page 15) .
❑ Adjusting:
– Hand-tighten nuts ⇒ Item 7 (page 15) (it must still be possible to move striker pin).
– Carefully close rear lid until it is flush with rear side panel.

– Carefully open rear lid and tighten nuts ⇒ Item 7 (page 15) .
7 - Hexagon nut - 8 Nm

2.2 Removing and installing rear lid lock and handle mechanism

1 - Rear lid lock

❑ Swivel out hinged lever
⇒ Item 2 (page 15) of
operating rod
⇒ Item 4 (page 15)
and disengage from
rear lid lock.
❑ Unscrew hexagon nuts
⇒ Item 3 (page 15)
and detach rear lid lock.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Hinged lever permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Swivel over operating with respect to the correctness of information in this document. Copyright by AUDI AG.
rod after installing rear
lid lock.
3 - Hexagon nut - 8 Nm
4 - Operating rod
5 - Hexagon nut - 8 Nm
6 - Handle mechanism
❑ Removing:
– Remove rear lid trim.

– Unclip operating rod

⇒ Item 4 (page 15) from
handle mechanism.

– Unscrew nuts
⇒ Item 5 (page 15) and
take out handle mecha‐
nism.

7 - Actuator
❑ Removing ⇒ page 17
8 - Lock cylinder
❑ Removing:
– Remove handle mechanism.

– Remove operating lever ⇒ page 17 .

2. Rear lid 15
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Take lock cylinder out of handle mechanism.

9 - Remote release motor

❑ Removing and installing ⇒ page 17
10 - Bolt - 1.2 Nm
11 - Operating rod

2.3 Adjusting rear lid

Special tools and work‐
shop equipment re‐
quired
♦ Adjustment gauge
-3371-

Joint dimensions
• Dimension -A- = 3
mm + 1 mm
• Dimension -B- = 5
mm + 1 mm
• Dimension -C- = 1.5
mm ± 0.3 mm
• Dimension -D- =
Flush with rear lid
• Dimension -E- = 1.5
mm – 5 mm

Adjusting rear lid

– Remove trim for rear cross panel ⇒ General body repairs,
interior; Rep. Gr. 70 .

Note

Gas-filled struts must be fitted before adjusting new rear lid.

– Unfasten nuts -1-; it must be possible to move striker plate

-2-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Carefully close rear lid until
permitted unlessitauthorised
is flushbywith side
AUDI AG. panel.
AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Carefully open rear lid and tighten nuts -1- to 8 Nm.

16 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2.4 Removing and installing remote release

motor
– Unclip operating rod -3-.
– Unscrew (1.2 Nm) bolts -2- (2x).
– Unplug connector from remote release motor -1-.

Note

♦ Operating rod -4- need not be unclipped from hinged lever

-5-.
♦ Prior to installation in rear lid, connector must be plugged in at
motor.

2.5 Removing and installing rear lid actuator

1 - Release handle
❑ Unfasten catch and pull
out release handle.
2 - Seal
3 - Actuator
❑ Removing:
– Remove rear lid trim.

– Remove locking sys‐

tem.

– Use screwdriver to
press in fastener at left
operating lever
⇒ Item 1 (page 17) in
-direction of arrow A-
and thus release catch.

– Pull left operating lever

⇒ Item 1 (page 17)
downwards out of han‐
dle Copying
Protected by copyright. mechanism
for private or commercial purposes, in part or in whole, is not
⇒ Item by4 AUDI
permitted unless authorised (page AG. 17)
AUDI .AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew cross-head
bolts -arrows B- and de‐
tach actuator.

4 - Handle mechanism
❑ Removing
⇒ Item 6 (page 15)
5 - Lock cylinder
❑ Moulded seal

2. Rear lid 17
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2.6 Removing and installing rear lid hinge

Cover for rear lid hinge
– Insert wire or tube for central locking -2- as shown in cover
-1-.
– Engage trim -1- for rear lid hinge from underneath between
gas-filled strut -3- and hinge lever and clip upwards onto hinge
lever (can be heard to engage).
4 - Torx bolt - 8 Nm
5 - Stop
6 - Pop rivet nut
7 - Torx bolt - 8 Nm
9 - Pop rivet nut

Removing and installing rear lid hinge

– Unfasten (21 Nm) nut -2- at top left and right.
– Unscrew (21 Nm) nut -2- at bottom left and right.
– Lift rear lid -4- off hinge.
– Unscrew bolts -7- at front and rear (2x).
– Only slacken off centre bolt (21 Nm).
– Detach hinge -1-.

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
When adjusting the rear lid, the scales -8- at the hinge and rear
with respect to the correctness of information in this document. Copyright by AUDI AG.

lid facilitate adjustment of the rear lid hinge.

2.7 Removing and installing gas-filled strut

– Use screwdriver to slightly press back retaining springs at both
ends of gas-filled strut and unclip gas-filled strut.

Note

When removing or installing gas-filled strut, push back open rear

lid slightly, taking care not to damage components.

– Clip in gas-filled strut at bottom and then at top.

– Gas-filled strut cylinder -5- is installed at rear lid end.

18 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Releasing gas from gas-filled strut

WARNING

Only clamp strut in this area to avoid risk of accident.

– Clamp gas-filled strut in vice in area -x- = 50 mm.

– Cover saw cut area with a cloth to catch fluid escaping.

WARNING

Wear safety goggles whilst sawing.

– Saw open cylinder of gas-filled strut in first third of overall cyl‐

inder length, based on reference edge at piston rod end.

2.8 Installing rear lid seal

– Joint -A- of rear lid seal must be aligned with ball socket
-arrow- of left hinge.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– permitted
Press on seal.
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.

2.9 Adjusting buffer stops

– Open rear lid.
– Use Phillips screwdriver to insert spring pin in
-direction of arrow-.
– Turn spring pin anti-clockwise -arrow A- to lock.
– Screw home buffer stops.
– Gradually screw buffer stops back out again.
– Given correct adjustment, buffer stops must rest lightly on sill
with rear lid closed.
– Turn spring pin clockwise -arrow B- to release.

2. Rear lid 19
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3 Avant rear lid

3.1 Removing and installing rear lid

Removing
– Remove rear lid interior trim ⇒ General body repairs, interior;
Rep. Gr. 70 .
– Unplug connectors and disconnect hoses for central locking
and rear window washer system.
– Open and support rear lid.
– Use screwdriver to lift retaining spring -3- as shown and detach
gas-filled strut -1- from ball stud -2- at top.

– Unscrew hexagon socket head bolts -1- (2x) from rear lid -5-.
– Detach rear lid.
Installing

Note

♦ Following complete removal, pay attention to correct position

of gas-filled strut on installation.
♦ Damping element must be engaged at body end.
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
– On installation, gas-filled
with respect strut is ofonly
to the correctness pressed
information onto ball
in this document. studs.
Copyright by AUDI AG.

• Ball stud tightening torque 15 Nm

• Tightening torque for hexagon socket head bolts -1- 21 Nm

3.2 Adjusting rear lid

Special tools and workshop equipment required

20 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

♦ Adjustment gauge -3371-

Joint dimensions
♦ Dimension -A- = 4 mm + 1 mm
♦ Dimension -B- = 4 mm + 1 mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Dimension -C- = 4 mm +permitted
1 mmunless 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.
♦ Dimension -D- = 5 mm + 1 mm
♦ Dimension -E- = 2.5 mm ± 0.1 mm
♦ Dimension -F- = 3.3 mm ± 0.1 mm
♦ Dimension -G- = 3 mm ± 0.2 mm
♦ Dimension -H- = 2.5 mm ± 0.4 mm
♦ Dimension -I- = 0 to 1 mm

Adjusting rear lid

Note

Gas-filled struts must be fitted before adjusting new rear lid.

• Sill trim removed

– Unscrew combi nuts -1- and detach cover -2- for striker.
– Unfasten combi nuts -3-; it must be possible to move striker
plate -4-.

Note

Pay attention to correct installation position when fitting striker

plate (lug -arrow- must face rear).

3. Avant rear lid 21

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Note

The stop on the body end is of two-part design and is moved into
basic position on adjusting the rear lid.

– Slacken off bolt -5- and fully pull out top part -4- of stop -3-.
– Slightly tighten bolt -5-.
– Close rear lid and press it approx. 2 mm beneath body contour.
– Open rear lid and then pull top part of stop -4- outwards by
three notches.
– Tighten bolt -5- to 8 Nm.
– On installation, secure stop -3- with rivet -6-.
– On installing stop -2-, tighten bolt -1- to 8 Nm.

– Set rear lid with striker -4- to body contour position.

– Tighten hexagon nuts -3- to 21 Nm.
– Check gap dimensions in line with diagram of joints.
– Insert cover -2- for striker and tighten hexagon nuts -1- to 5
Nm.

3.3 Removing and installing rear lid hinge

– Remove rear roof frame trim ⇒ General body repairs, interior;
Rep. Gr. 70 .
– Unscrew bolts -1- and detach cover -2- for hinge -3-.
– On installation, cover must first be engaged by way of notches
-arrow- at top in roof flange.
– Tighten self-tapping screws -1- to 3 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.

22 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Unscrew hexagon nut -4-.

– Also unscrew bolts -1- and detach hinge -2-.
– Replace seal -3-.

3.4 Removing and installing rear lid seal

– Open rear lid and detach seal.
– On installation, first position seal in left and right bottom cor‐
ners.
– Press seal -1- onto body as shown.

3.5 Removing and installing rear lid lock and handle mechanism

Note

♦ The rear lid lock has 2 latching stages.

♦ Given correct adjustment, the rear lid lock latches in the 2nd stage (main latching position).

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. Avant rear lid 23

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Rear lid lock

❑ Swivel out hinged lever
⇒ Item 2 (page 24) of
operating rod
⇒ Item 4 (page 24)
and disengage from
rear lid lock.
❑ Unscrew hexagon nuts
⇒ Item 3 (page 24)
and detach rear lid lock.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Hinged lever permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Swivel over with
operating
respect to the correctness of information in this document. Copyright by AUDI AG.

rod after installing rear

lid lock.
3 - Hexagon nut - 8 Nm
4 - Operating rod
❑ Set operating rod such
that there is neither
strain nor play.
❑ Given correct adjust‐
ment, the rear lid lock
must engage in the 2nd
stage (main latching po‐
sition).
5 - Hexagon nut - 8 Nm
6 - Handle mechanism
❑ Removing:
– Remove rear lid trim.

– Unclip operating rod

⇒ Item 4 (page 24) from
handle mechanism.

– Unscrew nuts
⇒ Item 5 (page 24) and
take out handle mechanism.

7 - Actuator
❑ Removing ⇒ page 17
8 - Lock cylinder
❑ Removing:
– Remove handle mechanism.

– Remove operating lever ⇒ page 17 .

– Take lock cylinder out of handle mechanism.

9 - Remote release motor

❑ Removing and installing ⇒ page 17
10 - Bolt - 1.2 Nm
11 - Operating rod

24 Rep. Gr.55 - Bonnet, rear lid

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3.6 Removing and installing rear lid actuator

1 - Release handle
❑ Unfasten catch and pull
out release handle.
2 - Seal
3 - Actuator
❑ Removing:
– Remove rear lid trim.

– Remove locking sys‐

tem.
– Use screwdriver to
press in fastener at left
operating lever
⇒ Item 1 (page 25) in
-direction of arrow A-
and thus release catch.

– Pull left operating lever

⇒ Item 1 (page 25)
downwards out of han‐
dle mechanism
⇒ Item 4 (page 25) .

– Unscrew
Protected cross-head
by copyright. Copying for private or commercial purposes, in part or in whole, is not
bolts
permitted -arrows
unless authorisedB-by and de‐AUDI AG does not guarantee or accept any liability
AUDI AG.
withtach
respectactuator.
to the correctness of information in this document. Copyright by AUDI AG.

4 - Handle mechanism
❑ Removing
⇒ Item 6 (page 24)
5 - Lock cylinder
❑ Moulded seal

3. Avant rear lid 25

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

57 – Front doors, door components, central locking

1 Front door

1.1 Removing and installing front door and door subframe

1 - Door subframe

Note

Prior to removal, use a fine felt-tip

pen for example to mark position of
subframe at door.
❑ Removing:
– Remove door trim ⇒
General body repairs,
interior; Rep. Gr. 70 .

– Disconnect wiring from

door subframe and un‐
clip.

– Unscrew bolts
⇒ Item 3 (page 27) ,
⇒ Item 9 (page 27) ,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 6 (page 27) unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
and with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ Item 4 (page 27)
and lift out door sub‐
frame.
❑ Installing:
❑ Front door must have
been adjusted
⇒ page 30 .

Note

Insert subframe in door in line with

marks previously made and attach
loosely.

– First insert subframe in

front door and screw on
loosely with bolts ⇒ Item 3 (page 27) , ⇒ Item 4 (page 27) , ⇒ Item 6 (page 27) and
⇒ Item 9 (page 27) as well as adjustment wedges ⇒ Item 2 (page 27) and ⇒ Item 7 (page 27) .

– Close door, check setting and adjust door subframe.

– Repeat checking and adjustment procedure if necessary.

❑ Adjusting ⇒ page 30

Note

Tighten bolts ⇒ Item 3 (page 27) ,

⇒ Item 9 (page 27) ,
⇒ Item 6 (page 27) and
⇒ Item 4 (page 27) in stated se‐
quence.

26 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2 - Adjustment wedge
❑ Adjustment wedge must always be fitted.
❑ Moving the adjustment wedge ⇒ Item 7 (page 27) makes it possible to adjust the angle of the door
subframe in the area of the B-pillar ⇒ page 31 .
3 - Combi bolt - 30 Nm
4 - Combi bolt - 30 Nm
5 - Front door
❑ Removing:

Note

Removing the front door does not

involve removing the door sub‐
frame.

– Remove lower A-pillar trim ⇒ General body repairs, interior; Rep. Gr. 70 .

– Unplug connectors at A-pillar connector point.

– Unclip bellows between front door and A-pillar and pull wiring as well as central locking hoses out of A-
pillar.

– Unscrew T45 Torx bolts in door at upper ⇒ page 27 and lower hinge ⇒ page 28 and detach front door
complete with door subframe.
❑ Joint dimensions ⇒ page 30
6 - Combi bolt - 30 Nm
7 - Adjustment wedge
❑ Adjustment wedge must always be fitted.
❑ Moving the adjustment wedge ⇒ Item 7 (page 27) makes it possible to adjust the angle of the door
subframe in the area of the B-pillar ⇒ page 31 .
❑ A packing plate of appropriate size must be inserted if the adjustment range of one adjustment wedge
is not sufficient.

Note

Use is never to be made of two ad‐

justment wedges. 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 - Pad
❑ Self-adhesive
9 - Combi bolt - 30 Nm

1.2 Removing and installing door hinges

Upper door hinge
1- Hexagon bolt - 30 Nm
2- Upper door hinge
3- T45 Torx bolt - 30 Nm
4- Hexagon bolt (fitted from inside of vehicle) - 30 Nm
5- Stud bolt 23 Nm
6- Cap for stud bolt -5-

1. Front door 27
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Lower door hinge

1- Lower door hinge
2- Hexagon bolt - 30 Nm
3- Front door
4- Hexagon bolt - 30 Nm
5- Torx bolt - 30 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.

1.3 Removing and installing window lifter and door window

1 - Door subframe
❑ Removing and installing
⇒ page 26
2 - Window lifter
❑ Removing:
– Remove door subframe.

– Drill heads off pop rivets

⇒ Item 5 (page 28) ,
knock out shanks and
detach window lifter.

– Shake rivet shanks out

of door subframe.
❑ Installing:
– Set rivets
⇒ Item 5 (page 28) in
sequence -a-, -b-, -c-,
-d- and -e- using special
pop rivet tool -V.A.G
1753 A- .
– Heed different rivet di‐
ameters.

3 - Mount
4 - Torx bolt - 4.5 Nm
5 - Pop rivet
❑ Set using special pop
rivet tool -V.A.G 1753
A- .
❑ Rivet in sequence -a-,
-b-, -c-, -d- and -e-.
❑ Rivets -a-, -c- and -d- =
∅ 4.8 mm
❑ Rivet -e- = ∅ 6.0 mm
6 - Door window
❑ Removing:
– Lower window.

– Remove door subframe.

– Use felt-tip pen to mark position of window at both mounts ⇒ Item 3 (page 28) in longitudinal direction.

28 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Unscrew bolts ⇒ Item 4 (page 28) .

– Lift window out of mount ⇒ Item 3 (page 28) .

❑ Installing:
– Re-insert window in window lifter in line with marks made prior to removal.

– Tighten bolts ⇒ Item 4 (page 28) .

❑ Installation with new window:
– Insert window in guide and move to rear as far as it will go in direction of B-pillar.
– Fully raise window with window lifter without bolt ⇒ Item 4 (page 28) .

– Close mount ⇒ Item 3 (page 28) and tighten bolts ⇒ Item 4 (page 28) .

1.4 Removing and installing window lifter

motor
Removing
– Remove door trim ⇒ General body repairs, interior; Rep. Gr.
70 .
– Remove door subframe ⇒ page 26 .

Note

♦ Window lifter motor can be removed or installed with motor or

side window in any position.
♦ Unplug connectors before removing motor.

– Unscrew T30 Torx bolts -arrows- and detach motor.

Installing
• Tightening torque 6.5 Nm

Note

♦ After installing motor, switch ignition on and off again with wir‐
ing connected.
♦ Then raise door window as far as it will go and keep window
lifter switch pulled for approx. 2 seconds.
♦ This position represents the basic setting and the up/down
function is activated.

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.

1. Front door 29
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.5 Adjusting front door window

– Set upper stop of window lifter as follows:
• Top edge of side window -1- must press down inner sealing
lip of door window seal -2- by dimension -a-.
• Dimension -a- = min. 1 mm
• The setting applies to the entire area of the B-pillar and the
roof at the window frame -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.

1.6 Adjusting front door

Note

The rear door shell must be adjusted if this has not already been
done.

Joint dimensions

Note

Joint dimensions can be checked using adjustment gauge

-3371- .

• Dimension -A- = 3 mm + 1 mm
• Dimension -B- = 4.5 mm ± 0.5 mm
• Dimension -C- = 3.5 mm ± 0.5 mm

Longitudinal adjustment
– Slacken off hinge bolts -arrows A- at A-pillar at upper or/and
lower door hinge -1- and adjust position of door -2- (oversize
holes in hinge or in A-pillar -3-).
• Tightening torque 30 Nm

Note

Fig. shows lower door hinge.

30 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Adjustment with respect to body contour

– Slacken off hinge bolts -arrows B- at top or/and bottom of door
and adjust position of door (elongated holes in hinge).
• Tightening torque 30 Nm

Note

Adjustment for rear door area is to be made by way of striker plate

(towards centre of vehicle).

Adjustment by way of striker plate

– Slacken off bolts -2-.
– Move striker plate -1- until door shell is flush with body contour.
– Tighten bolts.
• Tightening torque 20 Nm

Note

Adjust only with respect to centreProtected

of vehicle; do not adjust height.
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.

Adjusting door subframe

• Front door must have been adjusted.
• Door trim removed
– By moving adjustment wedge at bottom of door, set position
of door subframe as shown ⇒ page 31 .
• The sealing lip -2- must follow the contour at the A-pillar and
roof frame -arrow-.
– Start by making height adjustment at door subframe.
– Once height adjustment is correct, slacken off lower bolts for
securing door subframe and press subframe towards centre
of vehicle.
– The process involves forcing the subframe -1- slightly towards
the centre of the vehicle (rubber seal exerts restoring force).
– Insert adjustment wedge accordingly at B-pillar.
– Tighten bolts at bottom to 30 Nm.
3 - Door window

Note

Use an improvised gauge to check correct setting ⇒ page 32 .

1. Front door 31
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Making improvised gauge

– Use plastic or plywood, for example, to make improvised
gauge to the specified dimensions.
• Dimension -a- = 3.7 mm
• Dimension -b- = 28.2 mm
• Given correct adjustment of the door subframe, the gauge
must make contact with both the door window and the roof trim
strip approx. 100 mm away from the 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.

1.7 Removing and installing door seal

Removing
– Remove lower and upper A-pillar trim, lower and upper B-pillar
trim and sill panel trim ⇒ General body repairs, interior; Rep.
Gr. 70 .
– Detach door seal from door flange.
Installing
– Position end of PVC lip in area of B-pillar at mark -X- in flange
(± 5 mm).
– Press on door seal -1- all round door flange.

1.8 Exploded view of front door handle and door lock

32 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Door handle mount

❑ Releasing ⇒ page 35
2 - Lock cylinder
❑ Take out door handle
prior to removal
⇒ page 34 .
3 - Hinged lever
4 - Door handle with trim
❑ Removing door handle
⇒ page 34
❑ Removing trim
⇒ page 33
5 - Door lock
❑ Prior to removal, disen‐
gage operating rod
⇒ Item 8 (page 33) at
hinged lever
⇒ Item 3 (page 33) .
❑ To remove, unscrew
multi-point bolts
⇒ Item 6 (page 33)
and take out door lock
downwards.
6 - Multi-point socket head bolt M8 - 20 Nm
7 - Locking pin
❑ With replacement parts only to maintain zero position.
❑ Remove locking pin after installing door lock and fitting operating rod ⇒ Item 8 (page 33) .
8 - Operating rod
❑ Disengage at hinged lever ⇒ Item 3 (page 33) to remove door lock.
9 - Operating rod

Removing trim
– Lift up door handle -2-, use a small screwdriver to press out
catch -1- in longitudinal direction and detach trim -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.

1.9 Removing and installing door lock

Removing
– Remove door trim ⇒ General body repairs, interior; Rep. Gr.
70 .
– Raise door window.
– Unplug central locking connector at door lock.

1. Front door 33
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– If old door lock is to be re-installed, disengage operating rod

-3- at clip of hinged lever -arrow-.
– If a new door lock is to be fitted, disengage operating rod -3-
at sleeve -5-.
– Unscrew multi-point socket head bolts -1- and take out door
lock -2- downwards between door subframe and front door.
Installing
Install in reverse order of removal.

1.10 Exploded view of door handle removal and installation

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.

1 - Door handle
2 - Clip
❑ When removing door
handle
⇒ Item 1 (page 34) , un‐
clip operating rod
⇒ Item 3 (page 34) at
this point.
3 - Operating rod
❑ Disengage at clip
⇒ Item 2 (page 34) be‐
fore removing door han‐
dle.
❑ After installing new door
lock, first insert operat‐
ing rod in sleeve and en‐
gage.
❑ Only then pull locking
pin
⇒ Item 5 (page 34) out
of door lock.
4 - Sleeve
❑ To lock operating rod
⇒ Item 3 (page 34) ,
slide sleeve
⇒ Item 4 (page 34) up‐
wards.
5 - Locking pin
❑ With replacement part
only
❑ Pull out after installing
operating rod
⇒ Item 3 (page 34) .
6 - Door lock
❑ Removing ⇒ page 32

34 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Making improvised tool

Note

To facilitate removal/installation, it is appropriate to make the im‐

provised tool shown in the illustration from a piece of welding wire.

• Dimension -a- = 300 mm

• Dimension -b- = 20 mm
• Dimension -c- = 10 mm
• Dimension -d- = 10 mm

Releasing door handle mount

– Using a small screwdriver, release the locking element for the
slide -arrow A- by raising it slightly. 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
– Use an offset open-ended wrench (17 mm) to release slide
with respect to the correctness of information in this document. Copyright by AUDI AG.
-3- of mount -2- in -direction of arrow B-.

1.11 Removing and installing door handle

Removing
– Remove door trim ⇒ General body repairs, interior; Rep. Gr.
70 .
– Raise door window.
– Move improvised tool -3- around hinged lever -1- as shown
and pull out locking pin -2- slightly in -direction of arrow A-.

1. Front door 35
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Use improvised tool -3- to pull locking pin -2- completely out
of hinged lever -1- in -direction of arrow A-.
– Fold hinged lever -1- upwards.
– Using a small screwdriver, release the locking element for the
slide -arrow B- by raising it slightly.
– Release slide -4- in -direction of arrow C-.
– Detach door handle with lock cylinder outwards.
– Detach door handle mount inwards.

Installing
Install in reverse order of removal.
– After inserting and locking door handle in mounting element,
use improvised tool to fit locking pin -2- in
-direction of arrow-.

– When doing so, clip -arrow B- at locking pin -2- must engage
fully around hinged lever -1-.
-Arrow A-: Caulked 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.
1.12 Front door handle pre-assembly

Note

Replacement door handles must be painted and pre-assembled prior to installation.

36 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Door handle
❑ When fitting, insert
spring
⇒ Item 4 (page 37) in
mount.
❑ For pre-assembly, in‐
sert door handle in
mount
⇒ Item 3 (page 37)
and fit hinged lever
⇒ Item 8 (page 37) .
❑ Insert pivot pins
⇒ Item 5 (page 37)
and
⇒ Item 6 (page 37)
and caulk with a centre
punch as shown in
⇒ page 37 .
❑ Engage spring
⇒ Item 4 (page 37) as
shown in Fig.
2 - Buffer
❑ Insert after painting.
3 - Door handle mount
4 - Spring
❑ Installation position
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
⇒ page 38 with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Lubricate spring with
grease -G 052 745 A3- .
5 - Pivot pin
❑ Heed different lengths.
❑ Caulking ⇒ page 37
6 - Pivot pin
❑ Heed different lengths.
❑ Caulking ⇒ page 37
7 - Clip
8 - Hinged lever
9 - Locking pin
❑ Fitting ⇒ page 38

Caulking pivot pin

– Position pre-assembled door handle on a firm base (e.g. vice
jaws).
– Tap pivot pins lightly with a centre punch to secure them in
position.
– Check freedom of movement of hinged lever after caulking.

1. Front door 37
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Installation position of spring

– Fit spring -1- as shown.
– Lubricate with grease -G 052 745 A3- .
2 - Pivot pin

Fitting locking pin

– Use improvised tool ⇒ page 35 to fully insert locking pin.
– When doing so, spring clip at locking pin -arrow B- must en‐
gage behind hinged lever.
-Arrow A-: Caulked pivot pin

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.

1.13 Servicing central locking system

♦ The A6 central locking system is now electrical, as opposed
to pneumatic.
♦ The door actuators are integrated into the door lock and have
two motors.
♦ The actuators cannot be replaced separately.
♦ The first motor locks the door, whereas the second motor locks
the interior door handle (SAFE function).
♦ The doors can then no longer be opened from the inside either.
♦ The actuators for the filler neck compartment lid and rear lid
have one motor each and can be replaced separately.
♦ Following an accident involving airbag triggering, the central
locking system control unit releases any locked doors.
♦ The central locking system control unit is located in front of the
driver's seat beneath the floor covering.

38 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.14 Removing actuator for filler neck com‐

partment lid
– Unplug connector.
– Slacken off bolts -2-, slide actuator -1- to rear and take out.

1.15 Removing and installing rear lid actuator

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.

1. Front door 39
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Release handle
❑ Unfasten catch and pull
out release handle.
2 - Seal
3 - Actuator
❑ Removing:
– Remove rear lid trim.

– Remove locking sys‐

tem.

– Use screwdriver to
press in fastener at left
operating lever
⇒ Item 1 (page 40) in
-direction of arrow A-
and thus release catch.

– Pull left operating lever

⇒ Item 1 (page 40)
downwards out of han‐
dle mechanism Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 4 (page 40) . 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.
– Unscrew cross-head
bolts -arrows B- and de‐
tach actuator.

4 - Handle mechanism
❑ Removing ⇒ page 15
5 - Lock cylinder
❑ Moulded seal

40 Rep. Gr.57 - Front doors, door components, central locking

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

58 – Rear doors, door components

1 Rear door

1.1 Removing and installing rear door and door subframe

1 - Door subframe

Note

Prior to removal, use a fine felt-tip

pen for example to mark position of
subframe at door.
❑ Removing:
– Remove door trim ⇒
General body repairs,
interior; Rep. Gr. 70 .

– Disengage door locking

Bowden cable
⇒ page 42

– Disengage bellows at B-
pillar and unplug con‐
nectors.

– Unscrew bolts
⇒ Item 3 (page 42) ,
⇒ Item 4 (page 42) ,
⇒ Item 6 (page 42)
and
⇒ Item 7 (page 42) .

– Lift door subframe out of

door shell.
❑ Installing:
❑ Rear door
⇒ Item 5 (page 42)
must have been adjus‐
ted ⇒ page 46 .

Note

Insert subframe in door in line with

marks previously made and attach
loosely.

– First insert subframe in door shell and screw on loosely with bolts ⇒ Item 3 (page 42) ,
⇒ Item 4 (page 42) , ⇒ Item 6Protected
(pageby42) and Copying
copyright. ⇒ Item for 7 (page
private 42) as purposes,
or commercial well asinadjustment wedge
part or in whole, is not
⇒ Item 2 (page 42) . 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.

– Close door, check setting and adjust door subframe.

– Repeat checking and adjustment procedure if necessary.
❑ Adjusting ⇒ page 46

1. Rear door 41
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Note

Tighten bolts ⇒ Item 3 (page 42) ,

⇒ Item 7 (page 42) ,
⇒ Item 6 (page 42) and
⇒ Item 4 (page 42) in stated se‐
quence.

2 - Adjustment wedge
❑ Adjustment wedge must always be fitted.
❑ Moving the adjustment wedge ⇒ Item 4 (page 42) makes it possible to adjust the angle of the door in
the area of the B-pillar.
3 - Combi bolt - 30 Nm
4 - Combi bolt - 30 Nm
5 - Rear door
❑ Removing:

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

Removing the rear door does not in‐

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

volve removing the door subframe.

– Remove lower B-pillar trim ⇒ General body repairs, interior; Rep. Gr. 70 .

– Unplug connectors at B-pillar connector point.

– Unclip bellows between rear door and B-pillar and pull wiring as well as central locking hoses out of B-
pillar.

– Unscrew T45 Torx bolts in door at upper ⇒ page 43 and lower hinge ⇒ page 43 and detach rear door
complete with door subframe.
❑ Joint dimensions ⇒ page 46
6 - Combi bolt - 30 Nm
7 - Combi bolt - 30 Nm

Disengaging Bowden cable

– Unfasten Bowden cable -5- from clip -4-.
– Unscrew bolt from actuating arm -3-.
– Unclip actuating arm and disengage Bowden cable.
1 - Bowden cable for interior door handle

42 Rep. Gr.58 - Rear doors, door components

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.2 Removing and installing door hinges

Upper door hinge
– Unscrew (30 Nm) bolt -3- to remove door shell.

Note

Door hinge -2- can also be detached (23 Nm) by way of stud bolt
-4-.

– To remove door hinge -2-, additionally unscrew (30 Nm) bolts

-1- (2x).
5 - Cap for stud bolt -4-

Lower door hinge

– Unscrew (30 Nm) bolts -3- to remove door shell.
– To remove door hinge -2-, additionally unscrew (30 Nm) bolts
-1- (2x).
– Coat lubrication points -arrows- with grease -G 000 150- .

1.3 Removing and installing window lifter and door window

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.

1. Rear door 43
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Door subframe
❑ Removing and installing
⇒ page 41
2 - Window lifter
❑ Removing:
– Remove door subframe.

– Drill heads off pop rivets

⇒ Item 3 (page 44) ,
knock out shanks and
detach window lifter.

– Shake rivet shanks out

of door subframe.
3 - Pop rivet
❑ Set using special pop
rivet tool -V.A.G 1753
A- .
❑ Rivet in sequence -a-,
-b- and -c-.
❑ Rivet -a- = ∅ 4.8 mm
❑ Rivets -b- and -c- = ∅ 6
mm
4 - Door window Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing: 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.
– Lower window.

– Remove door subframe.

– Use felt-tip pen to mark

vertical and longitudinal
position of window at
both mounts.

– Unscrew bolts
⇒ Item 7 (page 45) and lift window out of driver ⇒ Item 6 (page 44) .
❑ Installing:
– Re-insert window in window lifter in line with marks made prior to removal.

– Tighten bolts ⇒ Item 7 (page 45) .

❑ Installation with new window:
– Insert window in guide and move forwards in direction of B-pillar.

Note

On installation, make sure sealing

lips of window slot trim strip are not
pressed aside downwards.

– Fully raise window with window lifter without bolt ⇒ Item 7 (page 45) .

– Tighten bolts ⇒ Item 7 (page 45) .

– Adjust rear door window ⇒ page 46 .

5 - Locating element
6 - Driver
❑ Part of window lifter

44 Rep. Gr.58 - Rear doors, door components

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

7 - Bolt - 2.5 Nm
8 - Buffer
❑ After insertion, press in clamping pin ⇒ Item 9 (page 45) .
9 - Clamping pin

1.4 Removing and installing window lifter

motor
Removing
– Remove door trim ⇒ General body repairs, interior; Rep. Gr.
70 .
– Remove door subframe ⇒ page 41 .

Note

♦ Window lifter motor can be removed or installed with motor or

side window in any position.
♦ Unplug connectors before removing motor.

– Unscrew T30 Torx bolts -arrows- and detach motor.

Installing
• Tightening torque 6.5 Nm

Note

♦ After installing motor, switch ignition on and off again with wir‐
ing connected. 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
♦ Then raise door window as far as it will go and keep window
with respect to the correctness of information in this document. Copyright by AUDI AG.
lifter switch pulled for approx. 2 seconds.
♦ This position represents the basic setting and the up/down
function is activated.

1. Rear door 45
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.5 Adjusting rear door window

– As a check, use a pen with water-soluble ink to mark dimen‐
sion -a- = 9 mm on door window in parallel with B-pillar.
– Position door window at window lifter.
– Raise door window until it is nearly closed.
– Door window -1- and seal -4- for door subframe must be in
parallel in the area of the roof and C-pillar.
– Press door window -1- towards B-pillar -3-.

Note

Door window -1- must fit into seal -4- for door subframe -3- by
dimension -a- = 9 mm.

– Tighten bolts at mount at window lifter.

• Tightening torque 2.5 Nm
– Raise window -1- as far as it will go.
– Check dimension -a- and wipe off mark.

1.6 Adjusting rear door

Joint dimensions

Note

Joint dimensions can be checked using adjustment gauge

-3371- .

• Dimension -A- = 3 mm + 1 mm
• Dimension -B- = 4.5 mm ± 0.5 mm
• Dimension -C- = 3.5 mm ± 0.5 mm

Longitudinal adjustment
– Slacken off hinge bolts -arrows A- at B-pillar at upper or/and
lower door hinge -1- and adjust position of door -2- (oversize
holes in hinge or in B-pillar -3-).
• Tightening torque 30 Nm

Note

Fig. shows lower door hinge.

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.

46 Rep. Gr.58 - Rear doors, door components

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Adjustment with respect to body contour

– Slacken off hinge bolts -arrows B- at top or/and bottom of door
and adjust position of door (elongated holes in hinge).
• Tightening torque 30 Nm

Note

Adjustment for rear door area is to be made by way of striker plate

(towards centre of vehicle).

Adjustment by way of striker plate

– Slacken off bolts -2-.
– Move striker plate -1- until door shell is flush with body contour.
– Tighten bolts.
• Tightening torque 20 Nm

Note

Adjust only with respect to centre of vehicle; do not adjust height.

Adjusting door subframe

• Rear door must have been adjusted.
• Door trim removed
• The sealing lip -2- must follow the contour at the roof frame
-arrow-.
– Start by making height adjustment at door subframe.
– Once height adjustment is correct, slacken off lower bolts for
securing door subframe and press subframe towards centre
of vehicle.
– The process involves forcing the subframe -1- slightly towards
the centre of the vehicle (rubber seal exerts restoring force).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten permitted
bolts atunless
bottom to 30
authorised Nm.AG. AUDI AG does not guarantee or accept any liability
by AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.
3 - Door window

Note

Use an improvised gauge to check correct setting ⇒ page 48 .

1. Rear door 47
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Making improvised gauge

– Use plastic or plywood, for example, to make improvised
gauge to the specified dimensions.
• Dimension -a- = 3.7 mm
• Dimension -b- = 28.2 mm
– Given correct adjustment of the door subframe, the gauge
must make contact with both the door window and the roof trim
strip approx. 100 mm away from the 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.

1.7 Removing and installing door seal

Removing
– Remove lower and upper B-pillar trim, lower and upper C-pillar
trim and sill panel trim ⇒ General body repairs, interior; Rep.
Gr. 70 .
– Detach door seal from door flange.
Installing
– Position end of PVC lip in area of B-pillar at mark -X- in flange
(± 5 mm).
– Press on door seal -1- all round door flange.

1.8 Exploded view of rear door handle and door lock

48 Rep. Gr.58 - Rear doors, door components

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Door handle mount

❑ Releasing ⇒ page 35
2 - Hinged lever
3 - Door handle with trim
❑ Removing door handle
⇒ page 50
❑ Removing trim
⇒ page 49
4 - by
Protected Door lockCopying for private or commercial purposes, in part or in whole, is not
copyright.

❑ Prior to removal, disen‐

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.
gage operating rod
⇒ Item 7 (page 49) at
hinged lever
⇒ Item 2 (page 49) .
❑ To remove, unscrew
multi-point bolts
⇒ Item 5 (page 49)
and take out door lock
downwards.
5 - Multi-point socket head bolt
M8 - 20 Nm
6 - Locking pin
❑ With replacement parts
only to maintain zero po‐
sition at door lock.
❑ Remove locking pin af‐
ter installing door lock
and fitting operating rod
⇒ Item 7 (page 49) .
7 - Operating rod

Removing trim
– Lift up door handle -2-, use a small screwdriver to press out
catch -1- and detach trim -3-.

1. Rear door 49
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.9 Removing and installing door lock

Removing
– Remove door trim ⇒ General body repairs, interior; Rep. Gr.
70 .
– Raise door window.
– Unplug central locking connector at door lock.
– If old door lock is to be re-installed, disengage operating rod
-3- at clip of hinged lever -arrow-.
– If a new door lock is to be fitted, disengage operating rod -3-
at sleeve -5-.
– Unscrew multi-point socket head bolts -1- and take out door
lock -2- downwards between door subframe and rear door.
Installing
Install in reverse order of removal.

1.10 Removing door handle

1 - Door handle
2 - Clip
❑ When removing door
handle
⇒ Item 1 (page 50) , un‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
clip operating rod permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Item 3 (page 50) at with respect to the correctness of information in this document. Copyright by AUDI AG.

this point.
3 - Operating rod
❑ Disengage at clip
⇒ Item 2 (page 50) be‐
fore removing door han‐
dle.
❑ After installing new door
lock, first insert operat‐
ing rod in sleeve and en‐
gage.
❑ Only then pull locking
pin
⇒ Item 5 (page 50) out
of door lock.
4 - Sleeve
❑ To lock operating rod
⇒ Item 3 (page 50) ,
slide sleeve
⇒ Item 4 (page 50) up‐
wards.
5 - Locking pin
❑ With replacement part
only
❑ Pull out after installing
operating rod
⇒ Item 3 (page 50) .
6 - Door lock
❑ Removing ⇒ page 50

50 Rep. Gr.58 - Rear doors, door components

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Making improvised tool

Note

To facilitate removal/installation, it is appropriate to make the im‐

provised tool shown in the illustration from a piece of welding wire.

• Dimension -a- = 300 mm

• Dimension -b- = 20 mm
• Dimension -c- = 10 mm
• Dimension -d- = 10 mm

Releasing door handle mount

– Use an offset open-ended wrench (17 mm) to release slide
-3- of mount -2- in -direction of arrow B-.
– Using a small screwdriver, release the locking element for the
slide -arrow A- by raising it slightly.

1.11 Removing and installing door handle

Removing
– Remove door trim ⇒ General body repairs, interior; Rep. Gr.
70 .
– Raise door window.
– Move improvised tool -3- around hinged lever -1- as shown
and pull out locking pin -2- slightly in -direction of arrow 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.

1. Rear door 51
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Use improvised tool -3- to pull locking pin -2- completely out
of hinged lever -1- in -direction of arrow A-.
– Fold hinged lever -1- upwards.
– Using a small screwdriver, release the locking element for the
slide -arrow B- by raising it slightly.
– Release slide -4- in -direction of arrow C-.
– Detach door handle with lock cylinder outwards.
– Detach door handle mount inwards.

Installing
Install in reverse order of removal.
– After inserting and locking door handle in mounting element,
use improvised tool to fit locking pin -2- in
-direction of arrow-.

– When doing so, clip -arrow B- at locking pin -2- must engage
fully around hinged lever -1-.
-Arrow A-: Caulked 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.

1.12 Rear door handle pre-assembly

– The pre-assembly procedure for the rear door handle is the
same as for the front door handle ⇒ page 36 .

52 Rep. Gr.58 - Rear doors, door components

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

60 – Sunroof
1 Servicing sunroof

1.1 Exploded view of sunroof

1 - T25 combi bolts - 3 Nm

2 - Sunroof motor
❑ Prior to removal, take
out cover for sunroof
motor at moulded head‐
liner ⇒ General body re‐
pairs, interior; Rep. Gr.
70 .
3 - Frame
❑ Take out headliner prior
to removal.
❑ Removing and installing
⇒ General body repairs,
interior; Rep. Gr. 70
4 - Wind deflector
❑ Removing ⇒ page 53
5 - Tilting spring for wind de‐
flector

1.2 Removing and installing wind deflector

Removing 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
– Fully open sunroof. with respect to the correctness of information in this document. Copyright by AUDI AG.

– Press wind deflector -2- in -direction of arrow- out of holder

-3-.
– Take wind deflector to rear out of roof opening.

1. Servicing sunroof 53
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Installing
– Position spring -3- around retaining pin of wind deflector -2-.
– Also insert spring in wind deflector groove.

Note

The holder -1- has been removed in the illustration for greater
clarity.

– Slide stop -1- of wind deflector -2- to front beneath roof open‐
ing.
– Insert one retaining pin of wind deflector in holder -3-.
– On opposite side, press wind deflector slightly towards centre
of vehicle and engage second retaining pin in holder.

1.3 Exploded view of sunroof panel removal and installation

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.

54 Rep. Gr.60 - Sunroof

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Sliding headliner
❑ Take out sunroof panel
prior to removal.
2 - Spring for sliding headliner
❑ Removing:
– Remove trim frame for
moulded headliner ⇒
General body repairs,
interior; Rep. Gr. 70 .

– Unscrew countersunk
bolt
⇒ Item 7 (page 55) at
front and rear.
– Slide front spring
⇒ Item 2 (page 55) to
front or rear spring to
rear of sliding headliner
and take out.

– Pull sliding headliner

sideways out of oppo‐
site guide rail and lift out.

3 - Lower trim
❑ Removing ⇒ page 55
4 - Upper trim
❑ Removing ⇒ page 55
5 - Sunroof panel
❑ Removing:
– Tilt sunroof.

– Remove left and right

trim ⇒ page 55 .

– Unscrew T25 Torx bolts on left and right at sunroof panel and lift out panel ⇒ page 56 .
❑ Adjusting ⇒ page 56
6 - Panel seal
❑ Removing ⇒ page 57
7 - Countersunk head bolt - 1.5 Nm

1.4 Removing and installing trim

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

– Tilt sunroof.
– Carefully move sliding headliner to rear.
– Unclip lower trim -1- at rear in -direction of arrow A- from fas‐
tener and slide forwards -arrow B-.
– Detach lower trim from mounting rail towards centre of vehicle.
– Unclip trim -2- at front and in centre and detach in direction of
arrow.

1. Servicing sunroof 55
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Installing
– Press lower trim -1- onto upper edge -arrows- of mounting rail
-2-.

– Slide lower trim -1- backwards in -direction of arrow- until fas‐

tener engages in driver -2-.
– Press upper trim into guide plate.

1.5 Removing and installing sunroof panel

– Remove trim ⇒ page 55 .
– Unscrew T25 Torx bolts -arrows- on both sides and lift out
panel.
• Tightening torque 4.5 Nm + 0.5 Nm

1.6 Adjusting sunroof panel

– Make height adjustment at front and rear as shown to prevent
wind noise.
– Check height adjustment at end of each radius of roof opening
towards centre of vehicle.
– No point on panel should be higher at front or lower at rear
than roof.
– When performing height adjustment, always close sunroof
from open (not tilted) position.

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.

56 Rep. Gr.60 - Sunroof

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.7 Replacing panel seal

• Sunroof panel -3- removed
– Pull panel seal -2- out of sunroof panel -3-.
– Starting in centre, press new seal into sunroof panel -3- at rear
edge of panel.

Note

To facilitate seal installation, apply soap solution to edge of panel.

1.8 Adjusting zero position (motor)

• Motor removed, connectors plugged in
– Use rotary control to select “Roof closed”.
– Motor automatically assumes zero position and is switched off.
– Fit motor in this position with sunroof closed.

1.9 Checking andby copyright.

Protected adjusting zero
Copying for private position
or commercial purposes, in part or in whole, is not

(guide plate)
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.

Checking
The zero position can be checked with the sunroof panel in posi‐
tion using a pocket mirror and a torch.
• Trim removed ⇒ page 55
– Retract sunroof panel and close again.
– Carefully move sliding headliner to rear.
– Place pocket mirror on sunroof panel and check zero position
by viewing from the side.
– Given correct zero position, square hole in tilt mechanism of
guide plate -1- must be aligned with recess -arrow- on guide
rail -2-.

Adjusting
• Trim removed ⇒ page 55
• Sunroof panel removed ⇒ page 56
• Sunroof motor removed
– Slide guide plates -1- forwards on both sides.
– Align square hole at tilt mechanism of guide plate -1- with re‐
cess -arrow- at guide rail -2- for sliding headliner.
– This is the zero position.
– Install motor in zero position.

1. Servicing sunroof 57
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2 Water drain hoses

2.1 Cleaning water drain hoses

Note

For cleaning it is appropriate to make use of an improvised tool approx. 2300 mm long made from speedometer
drive cable core.

1 - Front water drain hose

❑ Front water drain hoses
⇒ Item 1 (page 58) are
routed in A-pillars and
end between door and
A-pillar. Cleaning is per‐
formed fromunless
sunroof
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
opening.with respect to the correctness of information in this document. Copyright by AUDI AG.

2 - Rear water drain hose

❑ Rear water drain hoses
⇒ Item 2 (page 58) are
routed in C-pillars and
end at side behind
bumper cover. Cleaning
is performed from lower
end of hose. This in‐
volves removing bump‐
er cover ⇒ page 65 .

58 Rep. Gr.60 - Sunroof

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

63 – Bumpers
1 Front bumper

1.1 Exploded view of front bumper removal and installation

1 - Cover
❑ Removing:
– Remove front wheels.
– Unfasten front half of Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
wheel housing liner permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

⇒ page 124 .
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Unscrew hexagon col‐

lared nuts
⇒ Item 10 (page 60)
on both sides.

– Screw oval head self-

tapping screws
⇒ Item 6 (page 60) out
of wheel housing liner
⇒ Item 5 (page 60) .

– Unscrew hexagon sock‐

et head bolt
⇒ Item 7 (page 60)
and pull out cover with
carrier to front.
❑ Installing:

Note

Before fitting bumper, press clips in‐

to wing ⇒ page 61 .

– Retainer tab of cover

must engage in clip
⇒ Item 4 (page 60) .

– Engage cover in guide

⇒ Item 2 (page 59) .

– Tighten hexagon col‐

lared nuts ⇒ Item 10 (page 60) .

– Screw in and tighten combi bolts ⇒ Item 7 (page 60) .

Note

Height of impact absorber with re‐

spect to cross member is adjusted
automatically ⇒ page 62 .

2 - Guide
❑ Removing ⇒ page 63

1. Front bumper 59
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3 - Wing
4 - Clip
❑ Retainer tab must engage in clip on installing cover ⇒ Item 1 (page 59) .
5 - Wheel housing liner
6 - Oval head self-tapping screw - 1 Nm
7 - Hexagon socket head bolt - 23 Nm
❑ Screw in as final step in bumper assembly procedure.
❑ Height with respect to cross member is adjusted automatically ⇒ page 62 .
8 - Air inlet grille
❑ Removing and installing ⇒ page 60
9 - Air inlet grille
❑ Removing and installing ⇒ page 60
10 - Hexagon collared nut - 6 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
1.2 Removing and installing air inlet grille
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach cover to front -arrow-.

1.3 Removing and installing RS6 air inlet

grille
– Detach air inlet grille to front -arrow-.

– Unscrew trim -1- over fog light, working from back of bumper
-arrows-.

60 Rep. Gr.63 - Bumpers

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.4 Attaching cover to wing

1 - Cover
❑ Slide onto carrier with
cross member.
❑ Clip into guide on left
and right of wing.
❑ Attach to wing with hex‐
agon collared nuts
⇒ Item 4 (page 61) .
2 - Expanding clip
❑ Expanding clips must be
pressed into wing be‐
fore fitting cover
⇒ Item 1 (page 61) .
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

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

4 - Hexagon collared nut - 6

Nm

1. Front bumper 61
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.5 Attaching bumper to impact absorber

Note

♦ The impact absorber is self-adjusting, i.e. it can provide compensation for height tolerances between bumper
and impact absorber when screwing in hexagon socket head bolt.
♦ In this way, the front bumper is automatically held and fixed in previously set position when screwing in
hexagon socket head bolts ⇒ Item 1 (page 62) .

1 - Hexagon socket head bolt

M8x132 - 23 Nm
2 - Lower drive bushing
❑ Plastic part pressed into
adjusting screw
❑ No replacement part
3 - Lower adjusting screw
❑ Screw in fully before fit‐
ting bumper.
❑ Left-hand thread
❑ No replacement part
4 - Lower threaded bushing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Secured with locking pin

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.
to stop it falling out
❑ No replacement part
5 - Locking pin
❑ No replacement part
6 - Impact absorber
❑ Removing and installing
⇒ page 64
7 - Upper threaded bushing
❑ Secured with locking pin
to stop it falling out
❑ No replacement part
8 - Upper adjusting screw
❑ Screw in fully before fit‐
ting bumper.
❑ Right-hand thread
❑ No replacement part
9 - Cover
❑ Removing and installing ⇒ page 59
10 - Nut
❑ Part of scope of delivery of cross member
11 - Upper drive bushing
❑ Plastic part pressed into adjusting screw
❑ No replacement part
12 - Cross member
❑ Removing from cover/installing ⇒ page 63

62 Rep. Gr.63 - Bumpers

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.6 Removing and installing guide

1 - Guide
❑ Bumper removed
❑ To remove, unscrew
oval head self-tapping
screws
⇒ Item 2 (page 63) .
2 - Oval head self-tapping
screw - 1 Nm
3 - Clip
4 - Cover
❑ Removing ⇒ page 59
❑ Cover must engage
properly in guide
⇒ Item 1 (page 63) on
installation.
5 - Hexagon nut - 6 Nm
❑ Only accessible after
unfastening front half of
wheel housing liner
⇒ page 124

1.7 Removing cross member from cover/in‐

stalling
• Bumper removed
– Unscrew (10x) Torx bolts -arrows- and take out cross member
-1-.

Note

Just remove one spray jet on vehicles with headlight washer sys‐
tem.

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.

1. Front bumper 63
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.8 Removing and installing impact absorb‐

er
• Bumper removed
– Unscrew hexagon bolts -2-.
– Unscrew nut -3- and pull impact absorber -1- out of longitudinal
member.
– On installation, tighten hexagon bolts -2- to 50 Nm and hexa‐
gon nut -3- to 4 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.

64 Rep. Gr.63 - Bumpers

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2 Saloon rear bumper

2.1 Exploded view of rear bumper removal and installation

1 - Combi bolt - 23 Nm
2 - Impact absorber
❑ Removing ⇒ page 67
3 - Cross member
❑ Remove cover.
❑ Unscrew combi bolt
⇒ Item 1 (page 65) and
pull cross member out of
longitudinal members.
4 - Rear cross panel trim
❑ To remove, unscrew
oval head self-tapping
screws Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ Item 5 (page 65) permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
(6x). with respect to the correctness of information in this document. Copyright by AUDI AG.

5 - Oval head self-tapping

screw - 1.5 Nm
6 - Cover
❑ Removing:
– Partially remove lug‐
gage compartment trim.

– Unscrew hexagon col‐

lared nuts
⇒ Item 10 (page 65)
and
⇒ Item 11 (page 65)
(accessible from lug‐
gage compartment).

– Disengage cover side‐

ways from guide and de‐
tach.

– Unplug connectors if ap‐

plicable.
❑ Attaching cover to side panel ⇒ page 67
7 - Guide
❑ Removing ⇒ page 67
8 - Oval head self-tapping screw - 1 Nm
9 - Wheel housing liner
❑ To unscrew hexagon collared nuts ⇒ Item 11 (page 65) , unfasten and press aside rear half of wheel
housing liner.
10 - Hexagon collared nut - 6 Nm
❑ 2x
11 - Hexagon collared nut - 6 Nm
❑ 2x
12 - Seal

2. Saloon rear bumper 65

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2.2 Exploded view of RS6 rear bumper removal and installation

1 - Oval head self-tapping

screw - 1 Nm
2 - Wheel housing liner
3 - Guide
❑ Removing ⇒ page 67
4 - Hexagon collared nut - 6
Nm
5 - Hexagon collared nut - 6
Nm
6 - Combi bolt - 23 Nm
7 - Impact absorber
❑ Removing ⇒ page 67
8 - Cross member
❑ Remove together with
impact absorbers
⇒ Item 7 (page 66) . To
do so, screw out combi
bolts
⇒ Item 6 (page 66) and
pull cross member to
rear.
9 - Clip
❑ For trim panel
10 - Cover
❑ Removing:
– Partially remove lug‐
gage compartment trim.

– Unscrew hexagon col‐

lared nuts
⇒ Item 4 (page 66) and
⇒ Item 5 (page 66) (ac‐
cessible from luggage compartment).

– Disengage cover sideways from guide and detach.

– Unplug connectors if applicable.

❑ Attaching cover to side panel ⇒ page 67
11 - Trim panel
❑ Pull off clips ⇒ Item 9 (page 66) and detach trim panel.

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.

66 Rep. Gr.63 - Bumpers

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2.3 Removing and installing guide

• Bumper removed
– Unscrew combi bolts -1- and detach guide -2-.
3 - Clip
• Tightening torque 1 Nm

2.4 Removing and installing impact absorb‐

er
• Bumper and cross member removed
– Unscrew hexagon bolt -2- and take impact absorber -1- out of
cross member -3-.
• Tightening torque 23 Nm

2.5 Attaching cover to side panel

– Press expanding clips -2- into side panel -3- before fitting cov‐
er -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.

2. Saloon rear bumper 67

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3 Avant rear bumper

3.1 Exploded view of rear bumper removal and installation

1 - Combi bolt - 23 Nm
2 - Impact absorber
❑ Removing and installing
⇒ page 70
3 - Cross member
❑ Remove cover.
❑ Unscrew combi bolt
⇒ Item 1 (page 68) and
pull cross member out of
longitudinal members.
4 - Centre support piece
5 - Right support piece
6 - Torx bolt - 1.5 Nm
❑ Used for attachment of
left, right and centre
support pieces
7 - Rear cross panel trim
❑ Unscrew oval head self-
tapping screws
⇒ Item 8 (page 68)
(6x).
8 - Oval head self-tapping
screw - 1.5 Nm
9 - Support piece
❑ Replace when installing
new bumper cover
❑ Do not release until
bumper cover has been
completely fitted
⇒ page 70
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 - Cover 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.
❑ Removing:
– Partially remove luggage compartment trim.

– Unscrew hexagon collared nuts ⇒ Item 14 (page 69) and ⇒ Item 15 (page 69) (accessible from
luggage compartment).

– Disengage cover sideways from guide and detach.

– Unplug connectors if applicable.

❑ Support piece ⇒ Item 9 (page 68) need not be replaced if the same cover is re-used.
❑ Attaching cover to side panel ⇒ page 71
11 - Guide
❑ Removing and installing ⇒ page 70

68 Rep. Gr.63 - Bumpers

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

12 - Oval head self-tapping screw - 1 Nm

13 - Wheel housing liner
14 - Hexagon collared nut - 6 Nm
❑ 2x
15 - Hexagon collared nut - 6 Nm
❑ 2x
16 - Left support piece
17 - Seal

3.2 Exploded view of RS6 rear bumper removal and installation

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1 - Oval headunless
permitted self-tapping
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
screw - with
1 Nmrespect to the correctness of information in this document. Copyright by AUDI AG.

2 - Wheel housing liner

3 - Guide
❑ Removing and installing
⇒ page 70
4 - Hexagon collared nut - 6
Nm
5 - Hexagon collared nut - 6
Nm
6 - Combi bolt
❑ 23 Nm
7 - Right support piece
8 - Torx bolt - 1.5 Nm
9 - Centre support piece
10 - Torx bolt - 1.5 Nm
11 - Impact absorber
❑ Removing and installing
⇒ page 70
12 - Cross member
❑ Remove together with
impact absorbers
⇒ Item 11 (page 69) . To
do so, screw out combi
bolts
⇒ Item 6 (page 69) and
pull cross member to
rear.
13 - Clip
❑ For trim panel
14 - Cover
❑ Removing:
– Partially remove luggage compartment trim.

– Unscrew hexagon collared nuts ⇒ Item 4 (page 69) and ⇒ Item 5 (page 69) (accessible from luggage
compartment).

– Disengage cover sideways from guide and detach.

– Unplug connectors if applicable.

3. Avant rear bumper 69

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

❑ Support piece ⇒ Item 16 (page 70) need not be replaced if the same cover is re-used.
❑ Attaching cover to side panel ⇒ page 71
15 - Trim panel
❑ Pull off clips ⇒ Item 13 (page 69) and detach trim panel.
16 - Support piece
❑ Replace when installing new bumper cover
❑ Do not release until bumper cover has been completely fitted ⇒ page 70

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

WARNING

Never release support piece following removal, as this could

cause injury.

Old support piece can be left in position if old bumper cover is re-
used.
– If bumper cover is replaced, new support piece -1- must be
clipped into bumper cover from underneath.
– Following complete installation of bumper cover, release sup‐
port piece by pulling release cord -arrow-.

Note

Pulling release cord slackens off support piece and bumper cover
is supported by cross member.

3.3 Removing and installing guide

• Bumper removed
– Unscrew combi bolts -1- and detach guide -2-.
– Clip -3-
• Tightening torque 1 Nm

3.4 Removing and installing impact absorb‐

er
• Bumper and cross member removed
– Unscrew hexagon bolt -2- and take impact absorber -1- out of
cross member -3-.
– On installing cross member -3-, tighten hexagon bolt -2- to 23
Nm.

70 Rep. Gr.63 - Bumpers

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3.5 Attaching cover to side panel

– Press expanding clips -2- into side panel -3- before fitting cov‐
er -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.

3. Avant rear bumper 71

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

64 – Glazing
1 Windows bonded flush with body‐
work

1.1 General information on removing and installing windows bonded flush with
bodywork

Special tools and workshop

equipment required
♦ Parting tool for bonded win‐
dows -V.A.G 1474 A-
♦ Suction holder -V.A.G
1344-
♦ Cutting tool -V.A.G 1351-
♦ Window removal set -V.A.G
1755-
♦ Cartridge gun -V.A.G 1628-
♦ Cartridge heater -V.A.G
1939 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.

72 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

♦ Electric cutter -V.A.G 1561

A-
♦ Blade (58 mm) -V.A.G
1561/2-
♦ Blade (U-shaped) -V.A.G
1561/3-
♦ Scraper (15+25 mm) -
V.A.G 1561/7+8-
♦ Offset blade -V.A.G
1561/10-
♦ Twin cartridge gun -VAS
5237-

♦ Reel -V.A.G 1654 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.

Note

♦ When cutting out windscreen, cover dash panel with sheeting

-V.A.G 1474/7- to provide protection.
♦ When using electric cutter for removal, mask window opening
with fabric-reinforced adhesive strip.
♦ Deburr tube at front so as not to damage paintwork.

1. Windows bonded flush with bodywork 73

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Caution

Observe manufacturer's safety instructions and directions for

use when handling materials.

1.2 Windscreen repair using repair resin,

Talon -VAS 1993/2-
Special tools and workshop equipment required
♦ Windscreen repair set -VAS 1993- or -VAS 6092-

Note

♦ Windscreens damaged by flying stones can be repaired using

repair resin, Talon -VAS 1993/2- .
♦ Such damage must not affect more than a certain area and
must not be in the field of long-distance vision.
♦ Further details can be found in the usage instructions provided
with each set.

1.3 Materials
♦ 2-pack window adhesive set -DA 004 600 A2- 1) 2)

♦ 1-pack window adhesive -DH 009 100 03- 3) 4)

♦ Glass and paint primer -D 009 200 02-

♦ Cleaning fluid -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
♦ Applicator -D 009 500 25-
with respect to the correctness of information in this document. Copyright by AUDI AG.

♦ Adhesive remover -D 002 000 10-

♦ Cutting cord -357 853 999-

♦ Cutting cord -357 845 955-

1) Heed minimum setting times ⇒ page 75 .

2) Use twin cartridge gun -VAS 5237- for working with this material.
3) Heat using cartridge heater -V.A.G 1939 A- in line with manufacturer's instructions.
4) 110 ml mini cartridge for sealing work and/or if 400 ml twin cartridge is not sufficient.

74 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.4 Minimum setting times

WARNING

♦ For safety reasons, make exclusive use when fitting wind‐

screens and rear windows of non-conductive 2-pack ad‐
hesive with the designations listed below.
♦ Vehicle is only safe to drive on completion of minimum
setting times.

Type of window Vehicle Adhesive sealing Setting time

material in hours
Windscreen With/ DA 004 600 A2 3
without
airbag
Rear window DA 004 600 A2 3
Side windows DH 009 100 03 3

1.5 Cleaning off adhesive sealing material

Adhesive remover -D 002 000 10- is recommended for cleaning.
Always heed safety instructions when working.

Caution

When cleaning from inside vehicle, take care not to press out
window just fitted.

Painted surfaces
– First clean painted surface with a dry cloth. Use adhesive re‐
mover -D 002 000 10- to clean off any remnants.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Plastic trim
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.

– Allow adhesive sealing material to set (approx. 1 hour) and

then pull off.

1.6 Re-sealing windows

– Allow leaking area to dry and then clean.
– Apply and spread adhesive sealing material in leaking area
between window and metal flange.
– Allow adhesive sealing material to flash off.
– Apply water to check for leaks.
– Carry out visual inspection from passenger compartment.

1. Windows bonded flush with bodywork 75

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2 Windscreen

2.1 Exploded view of windscreen removal and installation

1 - Windscreen
❑ Removing and installing
⇒ page 77
❑ Clearance from roof, di‐
mension -b- = 5.5 mm ±
0.5 mm
❑ Set side clearance, di‐
mension -h-.

Note

Stickers affixed to windscreen (e.g.

for airbag) must be attached in
same positions on new windscreen.

2 - Adhesive bead
❑ Heed setting times
⇒ page 75 .
❑ Note different distances
from edge of wind‐
screen:
❑ Dimension -a- = 15 mm
± 2 mm
❑ Dimension -g- = 8 mm ±
2 mm
❑ Dimension -f- = 33 mm
± 2 mm
3 - Adhesive bead
❑ Used to secure sur‐
round.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Spacer 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.
❑ Bond 4 spacers to wind‐
screen flange at equal
intervals.
❑ Dimension -c- = 1 mm
+1.5 mm
5 - Spacer
❑ Bond 5 spacers to surround -5- at equal intervals as shown.
❑ Dimension -d- = 3 mm
❑ Dimension -e- = 3 mm +3 mm
6 - Surround
❑ Part of scope of delivery of windscreen
❑ When performing repairs, detach surround and use glass scraper to remove adhesive
⇒ Item 3 (page 76) .
❑ Prime bonding area with glass and paint primer -D 009 200 02- .
❑ Press new surround centrally onto edge of windscreen and secure again with 1-pack window adhesive
-DH 009 100 03- (mini-cartridge).
7 - Plenum chamber cover
❑ On new replacement windscreens, protective beading in retaining strip must be pulled out before instal‐
ling plenum chamber cover.

76 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

❑ Do not press into retaining strip until windscreen adhesive has set.

2.2 Removing windscreen

Tools and materials required ⇒ page 72

WARNING

Always wear safety goggles and leather gloves when removing

windscreen.

– Remove wiper arms ⇒ Electrical system; Rep. Gr. 92 .

– Remove scuttle panel trim.
– Starting at bottom, pull water deflector on left and right out of
fastening strips.
– Remove left, centre and right sun visor ⇒ General body re‐
pairs, interior; Rep. Gr. 70 .
– Remove interior mirror ⇒ General Protected
body repairs, interior;
by copyright. Rep.
Copying for private or commercial purposes, in part or in whole, is not
Gr. 68 . 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 upper A-pillar trim ⇒ General body repairs, interior;
Rep. Gr. 70 .
– Pierce adhesive bead with awl from inside at bottom left corner
of windscreen.
– Thread cutting cord into awl and pull through to inside.

– Route cutting cord right round underneath windscreen.

– Screw end of cutting cord to securing bolt for wiper arms

-arrow-.

2. Windscreen 77
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Insert dash panel protective sheeting -V.A.G 1474/13- be‐

tween windscreen and dash panel.
– Secure start of cutting cord in reel and cut out initial section
roughly as far as centre of windscreen.

– Move reel to position shown and continue cutting.

– Move reel to position shown and attach guide roller.

• Route cord as shown.
– Cut out windscreen until cord is no longer guided by roller.

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 guide roller and continue cutting out windscreen.

78 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Move reel to position shown and attach guide roller at top cor‐
ner of windscreen.
• Route cord as shown.
– Insert front headliner protective sheeting -V.A.G 1474/11- be‐
tween windscreen and moulded headliner.
– Cut out windscreen until cord is no longer guided by roller.
– Remove guide roller and continue cutting out windscreen.
– Then repeat work described at top and bottom left corner of
windscreen.
– Completely cut out windscreen on this basis.
– Use double suction holders to remove windscreen from open‐
ing.

2.3 Preparation for windscreen installation

Note

♦ If the windscreen flange has been damaged, the paintwork

structure must be re-established ⇒ Vehicle paintwork and an‐
ti-corrosion measures taken if necessary ⇒ Surface treatment/
chemical materials .
♦ Start by cleaning the repaired area with cleaning fluid -D 009
401 04- and then apply glass and paint primer -D 009 200 02- .

Windscreen removed intact

– If an intact windscreen is to be re-used, trim residual adhesive
sealing material on windscreen and flange with electric cutter
-V.A.G 1561 A- and offset blade -V.A.G 1561/10- ; adhesive
sealing material is never to be completely removed.

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Do not trim bonding surface until shortly before
permitted unless installation.
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.
♦ Remaining material serves as bonding surface for new adhe‐
sive sealing material to be applied.
♦ Keep bonding surfaces clean and free from grease.
♦ Do not prime bonding surfaces and do not treat with cleaning
fluid.

New windscreen:
– Clean bonding area all round windscreen with cleaning fluid -
D 009 401 04- .
– Prime ( glass and paint primer -D 009 200 02- ) as described
below.

2. Windscreen 79
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Note

Ceramic layer on windscreen is not a primer. Priming must always

be performed before applying adhesive sealing material.

Application of primer
– Apply primer -2- evenly with applicator -1- in one operation.
– Start application with fully impregnated felt.
– Drying time approx. 10 minutes
– Primer width, dimension -a- approx. 20 mm
– Primer must be centred with respect to adhesive bead.

Dimensions for adhesive application

1- Adhesive bead
2- Primer
3- Windscreen
• Dimension -a- = 8 mm
• Dimension -b- = 12 mm
• Dimension -c- = Note different distances from edge of wind‐
screen ⇒ page 76 .

2.4 Installing windscreen

– Apply adhesive on completion of preparatory work.
– Apply full surface of nozzle to windscreen.
– Application direction -arrow-

Note

Cross-section of adhesive bead is determined by opening in tip

of nozzle and rate of application.

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.

80 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Apply adhesive sealing material -1- all round as shown.

– Note different distances from edge of windscreen ⇒ page 76 .
– Insert windscreen in opening using two double suction hold‐
ers.

Caution

Windscreen must be inserted within 15 minutes so as not to

impair adhesion of sealing material.

– Laterally align windscreen.

– Distance between edge of windscreen and roof frame must be
5.5 mm ± 0.5 mm.
– Do not press home weatherstrip -1- in fasteners -2- until ad‐
hesive has set.
– When pressing in, make sure sealing lip of weatherstrip rests
on windscreen and does not slip behind edge of windscreen.
3 - Pop rivet
a - Clearance at side and with respect to roof frame at top = 1 mm
– Fix windscreen in position in opening with adhesive tape.

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. Windscreen 81
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3 Side window

3.1 Exploded view of side window removal and installation

1 - Side window
❑ Removing
⇒ “3.2 Removing intact
side window”,
page 82 or
⇒ “3.3 Removing shat‐
tered side window”,
page 83
❑ Note different distances
between adhesive bead
and edge of window.
❑ Dimension -a- = 7 mm
❑ Dimension -b- = 6 mm
2 - Pad
❑ Self-adhesive
❑ Detach backing before
fitting and press on.
3 - C-pillar trim
❑ To remove side window,
drill off rivet heads,
knock out shanks and
detach trim.
4 - Pop rivet
5 - Door seal
❑ Detach from body
flange in area of pop riv‐
ets at C-pillar.

3.2 Removing intact side window 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
Tools and materials required ⇒ page 72 with respect to the correctness of information in this document. Copyright by AUDI AG.

WARNING

Always wear safety goggles and leather gloves when removing

window.

– Remove C and D-pillar trim ⇒ General body repairs, interior;

Rep. Gr. 70 .

82 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Affix adhesive strip -4- to side panel to avoid damaging paint‐

work.
– Unclip decorative trim -1- at bottom from fasteners -2- and pull
downwards out of decorative roof trim.
– Pop rivet -3-

– Starting at bottom -arrow C-, use

Protected plasticCopying
by copyright. wedge forto carefully
private pull purposes, in part or in whole, is not
or commercial

decorative roof trim -1- out of fasteners.

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

Take care not to bend decorative roof trim.

– Route cutting cord as shown around side window.

– Secure ends -x- and -y- in 2 handles from cutting tool -V.A.G
1351- .
– Employing a gentle sawing motion, pull cutting cord in
-direction of arrow A- and cut through adhesive bead at bottom
at side panel and at roof frame.
– Then pull cutting cord downwards through adhesive bead in
-direction of arrow B-.
– Remove window from opening.

3.3 Removing shattered side window

WARNING

Always wear safety goggles and leather gloves when removing

window.

– Protect body and passenger compartment against fragments

of glass.
– Remove glass fragments down to adhesive sealing material.
– Mask flange all round with fabric-reinforced adhesive strip.
– Cut through adhesive sealing material (with glass fragments)
in window opening using electric cutter -V.A.G 1561 A- and
offset blade -V.A.G 1561/10- (with roller stop).

3.4 Installing intact window

– If an intact window is to be re-used, trim residual adhesive
sealing material on window and flange with a carpet knife
shortly before installation; adhesive sealing material is never
to be completely removed.

3. Side window 83
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Note

♦ Remaining material serves as bonding surface for new adhe‐

sive sealing material to be applied.
♦ Keep bonding surfaces clean and free from grease.
♦ Do not prime bonding surfaces and do not treat with cleaning
fluid.

– Apply adhesive to remaining bead.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Bead height = 12 mm +3 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.
• Bead width = 8 mm ± 2 mm

Note

Use 1-pack window adhesive -DH 009 100 03- (mini-cartridge). If

more than one window has to be bonded, use can also be made
of the 2-pack window adhesive set -DA 004 600 A2- .

3.5 Installing new window

– Clean window in bonding area with cleaning fluid -D 009 401
04- and prime with glass and paint primer -D 009 200 02- .
– Observe 10 minute flash-off time for primer.
– Press decorative roof trim at D-pillar into fasteners.
– Note different distances between adhesive bead and edge of
window ⇒ page 82 .
– Apply adhesive.
• Bead height = 12 mm + 3 mm
• Bead width = 8 mm ± 2 mm
– Insert window and fix in position with adhesive strip.
– Moulded surround of side window must engage behind deco‐
rative roof trim ⇒ page 82 .
– Observe setting time.
– Allow setting time to elapse before installing lower decorative
trim and B-pillar trim.

84 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

4 Avant side window

4.1 Removing and installing Avant side window

Note

Use cutting wire -357 845 955- and window removal set -V.A.G 1755- to cut out side window.

1 - Pop rivet
2 - C-pillar trim
❑ Removing:
– Remove C-pillar trim Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
and detach door seal in 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.
area of trim.

– Drill off rivet heads,

knock out shanks and
detach trim to front.

3 - C-pillar trim
❑ Self-adhesive, remove
backing before fitting.
4 - Side window
❑ With moulded PU sur‐
round

Note

Replacement windows are supplied

with a hardened adhesive bead.
This is to be trimmed down to ap‐
prox. 2 mm before applying adhe‐
sive. The adhesive is applied in the
usual manner to this freshly trimmed
residual bead.

Caution
Never trim down adhe‐
sive bead as far as PU.
Windows which have
been trimmed down to
the PU can no longer be
bonded using workshop
equipment.

❑ Removing ⇒ “4.2 Removing intact side window”, page 86 or

⇒ “4.3 Removing shattered side window”, page 89
5 - Pop rivet
6 - Decorative trim
❑ Prior to removal, mask transition to side panel with adhesive strip to avoid damaging paintwork.
❑ Removing and installing ⇒ page 86

4. Avant side window 85

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Removing and installing decorative trim

Removing:

Caution

To prevent paintwork damage when removing and installing

decorative trim, always mask area at bottom of side window
and at side panel with adhesive strip.

– Starting from C-pillar, carefully prise decorative trim out of clips

-3-, then pull downwards out of decorative roof trim.
Installing:
– Slide decorative trim under decorative roof trim at D-pillar and
engage.
– After fitting window, apply horizontal swivel action to clip dec‐
orative trim onto fasteners.

4.2 Removing intact side window

Materials required ⇒ page 72

WARNING

Always wear safety goggles and leather gloves when removing

window.

– Remove C and D-pillar trim as well as side trim ⇒ General

body repairs, interior; Rep. Gr. 70 .

Note

Door seal must be removed in upper C-pillar area before rivet

heads can be drilled off to detach trim.

– On vehicles with window aerial or glass breakage sensor (anti-

theft alarm), unplug connector at window to be removed and
secure window wire with adhesive strip towards centre of win‐
dow.

Caution

If the wire is not disconnected, it will be severed on cutting and

the window destroyed. 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.

– Detach trim at C-pillar ⇒ page 85 .

– Remove anodised aluminium decorative trim at bottom
⇒ page 86

Note

Even slightly bent decorative trim is deemed to be damaged and

must be replaced.

86 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Pierce adhesive bead using trimming needle -2- with grip -1-.
– When doing so, take care to keep trimming needle as close as
possible to window.
– Unscrew grip and thread cutting cord into eye of needle.
– Pull end of cutting cord -A- to inside (use pliers and wear
gloves).

– Pull in cutting cord -1- with tube -2- beneath

Protected by copyright. moulded PU sur‐
Copying for private or commercial purposes, in part or in whole, is not
round of side window. 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.

– Route cutting cord -1- completely around window.

– Attach end of cutting cord -B- to striker.

4. Avant side window 87

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Attach outer end of cord -1- to striker -2- (place fabric-rein‐

forced adhesive strip -3- beneath cord).

– Attach reel as shown and secure cutting cord in it.

– Cut out first area at C-pillar and bottom of window.

– Move reel and continue cutting.

– Whilst cutting, press cutting cord towards D-pillar.

– Move reel as shown and continue cutting.

– Press cutting cord upwards whilst cutting.
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.

88 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Move reel downwards and completely cut out side window.

– Whilst cutting, press cutting cord towards C-pillar.
– Use double suction holders to take out side window.

4.3 Removing shattered side window

WARNING

Always wear safety goggles and leather gloves when removing

window.

– Protect body and passenger compartment against fragments

of glass.
– Remove glass fragments down to adhesive sealing material.
– Unplug electrical connections for window aerial.
– Mask flange all round with fabric-reinforced adhesive strip.
– Cut through adhesive sealing material (with glass fragments)
in window opening using electric cutter -V.A.G 1561 A- and
offset blade -V.A.G 1561/10- (with roller stop).

4.4 Installing side window

Note

♦ Keep bonding surfaces clean and free from grease.

♦ Do not prime bonding surfaces and do not treat with cleaning
fluid.

– Press decorative roof trim and decorative trim at bottom com‐

pletely into fasteners.
– Trim down adhesive bead of side window to approx. 2 mm.
– Trim down adhesive bead at window flange.
– Centrally apply adhesive sealing material all round window on
remaining material.
• Dimension -a- = 8 mm + 2 mm
• Dimension -b- = 12 mm + 3 mm

Caution
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Window must bepermitted
insertedunlesswithin 15byminutes
authorised so as
AUDI AG. AUDI AG not
does to
not impair
guarantee or accept any liability
adhesion of sealing material.
with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Avant side window 89

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Align window with window opening and press into window

opening.
– Window must be pressed in such that sealing lip makes con‐
tact with corner of decorative roof trim at top and with D-pillar
-arrow-.
– Secure window with pop rivets -1- and additionally fix in posi‐
tion with adhesive strip.
– Install C-pillar trim.
– Heed setting times ⇒ page 75 .

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.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

5 Rear window

5.1 Exploded view of rear window removal and installation

1 - Rear window
❑ Removing
⇒ “5.2 Removing intact
rear window”,
page 92 or
⇒ “5.3 Removing shat‐
tered rear window”,
page 94
❑ Set dimension -f- on in‐
stallation.
2 - Adhesive stopper strip
❑ Bond on next to busbar
⇒ page 92
3 - Upper spacer
❑ Bond 4 spacers to win‐
dow flange at equal in‐
tervals (dimension -c- =
1 mm + 1.5 mm).
4 - Adhesive bead
❑ Note different distances
from edge of window:
❑ Dimension -b- = 12 mm
± 2 mm
❑ Dimension -d- = 13 mm
± 2 mm
❑ Dimension -e- = 10 mm
± 2 mm
❑ Bead width = 8 mm ± 2
mm
❑ Bead height = 12 mm +
3 mm
5 - Spacer
❑ Note different heights:
❑ Standard glass: Dimen‐
sion -x- = 6.3 mm
❑ Heat-absorbing glass: Dimension -x- = 4.9 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.

5. Rear window 91
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Bonding on adhesive stopper strip

– Bond on adhesive stopper strip -2- at a distance of -a- = 10
mm from moulded surround of rear window -1-.
– Bond on spacers in line with marks on rear window.

5.2 Removing intact rear window

Tools and materials required ⇒ page 72

WARNING

Always wear safety goggles and leather gloves when removing

window.

– Remove rear shelf ⇒ General body repairs, interior; Rep. Gr.

70 .
– Unplug/unscrew electrical connections for heated rear win‐
dow.
– Press connections onto window towards centre of vehicle.
– Pierce adhesive sealing material in bottom corner of window
with awl until eye of awl becomes visible on outside.

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.

92 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Thread in start of cutting cord and pull into inside of vehicle.

– Thread cutting cord into reel and secure.
– Position cutting cord around rear window as shown.
– Cutting cord must be pressed beneath trim strip at upper edge
of window.

– Place end of cutting cord around buffer stop -arrow- and se‐
cure with bolts for rear lid hinge.

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.

– Cut out first section.

– Move reel to position shown and attach guide roller in bottom

corner of window.
• Route cord as shown.
– Cut out window until cord is no longer guided by roller.

5. Rear window 93
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Remove guide roller and continue cutting out window.

– Move reel to position shown and attach guide roller in top cor‐
ner of window.
• Route cord as shown.
– Cut out window until cord is no longer guided by roller.
– Insert rear headliner protective sheeting -V.A.G 1474/12- be‐
tween moulded headliner and rear window.
– Remove guide roller and continue cutting out window.
– Then repeat work described in top and bottom right corner of
window.
– Completely cut out window on this basis. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Use double suction holders to take out window.

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.

5.3 Removing shattered rear window

WARNING

Always wear safety goggles and leather gloves when removing

window.

– Protect body and passenger compartment against fragments

of glass.
– Remove glass fragments down to adhesive sealing material.
– Unplug/unscrew electrical connections for heated rear win‐
dow.
– Mask flange all round with fabric-reinforced adhesive strip.
– Cut through adhesive sealing material (with glass fragments)
in window opening using electric cutter -V.A.G 1561 A- and
offset blade -V.A.G 1561/10- (with roller stop).

94 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

5.4 Installing rear window

– New window: Clean and prime as already described for wind‐
screen installation.
– Window removed intact: Apply adhesive directly to freshly
trimmed old bead.
– Bond spacers to window flange at top and to rear window at
bottom.
– Note different spacers for heat-absorbing and standard glass.
– For this, heed fitting marks on window and trim strip.
– Bond on adhesive stopper strip -2- at a distance of -a- = 10
mm from moulded surround of rear window -1-.
– Bond on spacers in line with marks on rear window.
– Note different heights for heat-absorbing and standard glass.

Note

Any adhesive sealing material emerging at lower edge of window

on insertion is to be removed immediately.

– Heed setting times ⇒ page 75 .

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. Rear window 95
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

6 Avant rear window

6.1 Exploded view of Avant rear window removal and installation

Note

Use cutting wire -357 845 955- and window removal set -V.A.G 1755- to cut out rear window.

1 - Rear window
❑ Removing
⇒ “6.2 Removing intact
rear window”,
page 97 or
⇒ “6.3 Removing shat‐
tered rear window”,
page 99
❑ Set dimension -a- on in‐
stallation.
❑ Dimension -b- must be
at least 1 mm.
2 - Adhesive bead
❑ Note different distances
from edge of window.
❑ Distances from edge of
window are specified by Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

marks ⇒ page 100 .

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.
❑ Dimensions for adhe‐
sive application and ad‐
hesive bead cross-sec‐
tion ⇒ page 100
3 - Upper rear lid trim
❑ Removed prior to taking
out rear window

Note

Take care not to damage visible

moulded surrounds when pulling in
cutting cord and performing subse‐
quent cutting operation.

4 - Upper Velcro strip (4x)

❑ The Velcro strips at the
top and bottom are self-
adhesive and must always be fitted, as these specify the distance from the window flange.
❑ Bond Velcro strip at top to window domes.
5 - Lower Velcro strip (4x)
❑ Bond Velcro strip to body domes.
6 - Lower rear lid trim
❑ Remove prior to taking out rear window.
7 - Rear wiper
❑ Remove prior to taking out rear window.

96 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

8 - Seal for rear wiper

Caution
To avoid leakage, shaft
of wiper motor must be
centred with respect to
grommet on installing
window.

6.2 Removing intact rear window

– Remove rear lid interior trim ⇒ General body repairs, interior;
Rep. Gr. 70 .
– Remove rear wiper ⇒ Electrical system; Rep. Gr. 92 .
– Open rear lid and use grip -1- to guide trimming needle be‐
neath sealing lip and pierce adhesive bead.
– Unscrew grip and thread cutting cord into eye of needle.
– Pull one end of cutting cord to inside (use pliers and wear
gloves).
– Use plastic wedge to detach sealing lip from window flange
and spray with cleaning fluid -D 009 401 04- (lubricant substi‐
tute).

– Use insertion tube -1- to route second end of cutting cord

around window.

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.

– Use trimming needle and grip to pull second end of cutting cord
-B- inwards as shown.
– Thread end of cutting cord -A- into reel -V.A.G 1654 A- and
secure.

6. Avant rear window 97

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Attach second end of cutting cord to rear lid hinge.

– Attach reel -V.A.G 1654 A- to rear window as shown.

– Press cutting cord in -direction of arrow- whilst cutting in side
area.
– Cut out window at bottom.

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.

– Move reel and cut out window.

– Press cutting cord in -direction of arrow- whilst cutting in lower
window area.
– Cut out side area of window.

– Move reel and cut out window.

– Press cutting cord in -direction of arrow- whilst cutting in side
area.
– Cut out window at top.

– Move reel and cut out window.

– Press cutting cord in -direction of arrow- whilst cutting in upper
area.
– Completely cut out window and lift it out of rear lid using suction
holder -V.A.G 1344- .

98 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

6.3 Removing shattered rear window

WARNING

Always wear safety goggles and leather gloves.

– Protect body and passenger compartment against fragments

of glass.
– Remove glass fragments down to adhesive sealing material.
– Unplug electrical connections for heated rear window and win‐
dow aerial.
– Mask flange all round with fabric-reinforced adhesive strip.
– Cut through adhesive sealing material (with glass fragments)
in window opening using electric cutter and offset blade -V.A.G
1561/10- (with roller stop).

6.4 Preparation for window installation

Note

♦ If the window flange has been damaged, the paintwork struc‐

ture must be re-established ⇒ Vehicle paintwork and anti-
corrosion measures taken if necessary ⇒ Surface treatment/
chemical materials .
♦ Start by cleaning the repaired area with cleaning fluid -D 009
401 04- and then apply glass and paint primer -D 009 200 02- .

Window removed intact

– If an intact window is to be re-used, trim residual adhesive
sealing material on window and flange with electric cutter -
V.A.G 1561 A- and scraper (15+25 mm) -V.A.G 1561/7+8- ;
adhesive sealing material is never to be completely removed.

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
♦ Remaining material serves as bonding surface for new adhe‐
with respect to the correctness of information in this document. Copyright by AUDI AG.

sive sealing material to be applied.

♦ Keep bonding surfaces clean and free from grease.
♦ Do not prime bonding surfaces and do not treat with cleaning
fluid.

6. Avant rear window 99

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

New window

Note

♦ Distance of primer/adhesive area from edge of window is

marked all round by way of two dotted lines -2-.
♦ Primer and adhesive must be applied centrally with respect to
these lines.

– Clean bonding area all round window with cleaning fluid -D

009 401 04- .

Note

Ceramic layer on window is not a primer. Priming must always be

performed before applying adhesive sealing material.

– Bond Velcro strips -3- to window domes on left and right.

Caution

When applying primer, always take care to avoid contact be‐

tween primer/adhesive bead and busbar of heated rear win‐
dow. New replacement windows are provided with an adhesive
stopper strip next to the busbar for this purpose.

– Evenly apply glass and paint primer -D 009 200 02- -2- with
primer applicator -D 009 500 25- -1- (felt ball with wire) all
round and centrally aligned with the marks to the window.
– This sets distance, dimension -b-, from edge of window.
– Width of primer, dimension -a-, is set by marks on window.
– Drying time approx. 10 minutes

Note

Allow primer to dry thoroughly before touching-up primer strip.

– Apply adhesive material all round and centrally aligned with

primer.
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
Adhesive beadwith cross-section
respect to the correctness of information in this document. Copyright by AUDI AG.

1- Adhesive bead
2- Primer
3- Window
• Dimension -a- = 8 mm
• Dimension -b- = 12 mm
• Dimension -c- is set by marks on window

100 Rep. Gr.64 - Glazing

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

6.5 Installation instructions

– Apply adhesive material all round cleaned window such that it
is centrally aligned with primer.

Caution

Window must be inserted within 15 minutes so as not to impair

adhesion of sealing material.

– Use double suction holders to insert window in opening, align

and press in as far as spacer of trim strip.
– Fix window in position in opening with adhesive strip.
– Heed setting times ⇒ page 75 .

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. Avant rear window 101

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

66 – Exterior equipment
1 Roof mouldings

1.1 Removing and installing roof joint moulding

1 - Roof joint moulding

❑ Removing:
– Starting at rear, prise
carefully out of roof joint.
❑ Installing:
– Attach sealing strip
⇒ Item 2 (page 102) to
roof joint moulding.

– Apply lubricant (e.g.

soap solution) to sealing
strip.

– Starting at windscreen
⇒ Item 3 (page 102) ,
slide roof joint moulding
under surround and
press section by section
halfway into roof joint.

– Likewise slide roof joint

moulding under sur‐
round at rear window
and press completely in‐
to roof joint.

2 - Sealing strip
❑ Apply lubricant before
fitting.
3 - Windscreen

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.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.2 Removing and installing Avant roof joint moulding

1 - Roof joint moulding

❑ Removing:
– Starting at rear, prise
carefully out of roof joint.
❑ Installing:
– Attach sealing strip
⇒ Item 2 (page 103) to
roof joint moulding.

– Apply lubricant (e.g.

soap solution) to sealing
strip.

– Starting at windscreen
⇒ Item 3 (page 103) ,
slide roof joint moulding
under surround and
press, working from
front to rear, section by
section fully into roof
joint.

2 - Sealing strip
❑ Apply lubricant before
fitting.
3 - Windscreen

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.

1. Roof mouldings 103

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.3 Removing and installing decorative roof trim

Note

Removal of decorative roof trim does not involve taking out side window.

1 - Decorative roof trim

❑ Removing:
– Remove B-pillar trim ⇒ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
General body repairs, permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
interior; Rep. Gr. 70 . with respect to the correctness of information in this document. Copyright by AUDI AG.

– Detach door seals in

area of decorative roof
trim.

– Prise trim strip

⇒ Item 2 (page 104) out
of decorative roof trim.

– Carefully prise decora‐

tive roof trim out of clips
-4- (4x).

Note

Decorative roof trim is not to be twis‐

ted or bent as this would cause visi‐
ble damage.

– Drill heads off pop rivets

⇒ Item 3 (page 104) ,
knock out shanks and
detach decorative roof
trim.

2 - Trim strip
❑ Coat edges with lubri‐
cant to facilitate installa‐
tion.
❑ Press into decorative
roof trim, working from
front to rear.
3 - Pop rivet
4 - Clip
❑ 4x

104 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1.4 Removing and installing Avant decorative roof trim

Note

Removal of decorative roof trim does not involve taking out side window.

1 - Decorative roof trim

❑ Removing:
– Remove B-pillar trim ⇒
General body repairs,
interior; Rep. Gr. 70 .

– Detach door seals in

area of decorative roof
trim.

– Prise trim strip

⇒ Item 2 (page 105) out
of decorative roof trim.

– Carefully prise decora‐

tive roof trim out of clips
⇒ Item 5 (page 105)
(7x).

Note

Decorative roof trim is not to be twis‐

ted or bent as this would cause visi‐
ble damage.

– Drill heads off pop rivets

⇒ Item 3 (page 105) ,
knock out shanks and
detach decorative roof
trim.
2 - Trim strip
❑ Coat edges with lubri‐
cant to facilitate installa‐
tion.
❑ Press into decorative
roof trim, working from
front to rear.
3 - Pop rivet
4 - Side window
5 - Clip
❑ 7x
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.

1. Roof mouldings 105

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

2 Roof rail

2.1 Removing and installing roof rail

1 - Roof rail
❑ Prior to removal, take
out moulded headliner
⇒ General body repairs,
interior; Rep. Gr. 70 .
❑ Place roof rail in position
and screw on until seal
makes even contact.
Centrally align roof rail.
❑ On installation, heed
tightening sequence for
bolts
⇒ Item 2 (page 106) :
Centre - front - rear.
2 - Bolts - 23 Nm
❑ Unscrew 3 bolts and de‐
tach roof rail
⇒ Item 1 (page 106) .
3 - Gaskets with bonded-in
sealing ring
❑ Ensure correct position‐
ing on replacement.
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.

106 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3 Protective mouldings

3.1 Replacing protective side mouldings

Note

Protective mouldings cannot be removed without destroying

them.

– To remove, warm protective moulding with a hot-air blower

and detach from door.
– Surface to be bonded must be free from dust and grease.
– Clean outer panel with petrol, treat with silicone remover and
rub dry.

Note

Protective mouldings are only to be bonded on at room temper‐

ature. The vehicle and the protective moulding should be moved
to an area at room temperature at least 2 hours prior to start of
work.

– Detach backing -3- from double-sided adhesive strip -4- short‐

ly before fitting.

Note

Once backing has been removed, protective moulding must be

bonded on within 90 minutes.

– Fit protective moulding -1- or -2- at front and start bonding from
front to rear.
– Heat protective moulding with hot-air blower to approx. 40 °C
and firmly press or roll on.
– The vehicle must be left at room temperature for a further 4
hours after bonding on the moulding.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3.2 Removing permitted
and installing trim cover for sill panel
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. Protective mouldings 107

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Front trim cover

❑ To remove, unscrew
bolt
⇒ Item 2 (page 108) at
front and rear and press
trim cover with clip
⇒ Item 4 (page 108) to
rear out of fastener.
❑ Detach trim cover side‐
ways. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To install, insert trim permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

cover in door, slide for‐

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

wards into fastener and

secure with bolt
⇒ Item 3 (page 108) .
2 - Rear trim cover
❑ Remove in same man‐
ner as front trim cover.
3 - Bolt - 1 Nm
4 - Clip

108 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3.3 Removing and installing trim cover for sill panel (Allroad)
Front door

1 - Front door trim cover

❑ Unscrew bolts
⇒ Item 2 (page 109) at
front and rear from bot‐
tom of door.
❑ Pull decorative trim with
clips to rear out of elon‐
gated hole fasteners.
❑ Detach decorative trim
sideways from door.
2 - Combi bolt - 1 Nm
3 - Clip
4 - Combi bolt - 2 Nm

Rear door

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. Protective mouldings 109

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Rear door trim cover

❑ Unscrew bolts
⇒ Item 2 (page 110) at
front and rear from bot‐
tom of door.
❑ Pull decorative trim with
clips to rear out of elon‐
gated hole fasteners.
❑ Detach decorative trim
sideways from door.
2 - Combi bolt - 1 Nm
3 - Clip
4 - Combi bolt - 2 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.

110 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

4 Trim panels

4.1 Removing and installing B-pillar trim

1 - Combi bolt - 1.5 Nm

2 - B-pillar trim
❑ Removing:
– Detach cover
⇒ Item 9 (page 112)
downwards.

– Unscrew bolts
⇒ Item 1 (page 111) ,
⇒ Item 6 (page 112)
and
⇒ Item 10 (page 112)
and detach trim out‐
wards.
❑ Installing:
– Position trim as shown
in detail views at top and
bottom with rear door
closed.

– Tighten front combi bolt

⇒ Item 1Protected
(pageby111) . Copying for private or commercial purposes, in part or in whole, is not
copyright.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– The gap ofwith0.3 … 0.6
respect to the correctness of information in this document. Copyright by AUDI AG.
mm is produced on slid‐
ing up the trim until it
makes contact with the
cover.

– The outer lip of the rear

door window seal must
make full contact over
entire area of trim.

Note

Avoid over-compressing seal at trim

-arrow- as otherwise projecting lip
could cause wind noise.

– With rear door open, screw in combi bolt ⇒ Item 1 (page 111) .

– Press grommet ⇒ Item 8 (page 112) into trim.

– Attach cover ⇒ Item 9 (page 112) from underneath.

4. Trim panels 111

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

3 - Front expanding nut

4 - Rear expanding nut
5 - Cover
6 - Combi bolt - 1.5 Nm
7 - Expanding nut
8 - Grommet
9 - Cover for B-pillar
❑ Detach downwards to remove.
10 - Combi bolt - 1.5 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.

112 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

5 Rear lid decorative trim

5.1 Replacing rear lid decorative trim

Note

The decorative trim -1- cannot be removed without destroying it.

– Use plastic wedge to prise off decorative trim.

– Bonding surface must be free from dust and grease.
– To install, detach backing from adhesive strip -2-, align with
left side of rear lid -3- and clip consecutively onto pins -4-.

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. Rear lid decorative trim 113

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

6 Rear view mirror

6.1 Removing and installing rear view mirror

1 - Mirror housing
❑ Can be removed from
door without disman‐
tling entire rear view mir‐
ror ⇒ page 115 .
2 - Mirror adjustment unit
❑ Removing:
– Remove rear view mir‐
ror from door.

– Prise off mirror glass

⇒ Item 7 (page 114) .

– Unplug mirror heating

connectors.

– Unscrew cross-head
bolts
⇒ Item 6 (page 114)
and take mirror adjust‐
ment unit out of mirror
housing
⇒ Item 1 (page 114) .

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
On vehicles with seat memory, door permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
trim must be removed before de‐ with respect to the correctness of information in this document. Copyright by AUDI AG.

taching mirror adjustment unit.

3 - Door subframe
4 - Hexagon socket head bolt -
12 Nm
5 - Seal
❑ Ensure correct position‐
ing on installation.
6 - Cross-head bolt - 1 Nm
7 - Mirror glass
❑ Use pressing-off lever -80-200- to unclip.
❑ Mask top and bottom of mirror housing with fabric adhesive strip to prevent damage.
❑ Press off mirror glass at bottom and then at top.
❑ To install, insert mirror glass in guide lugs and friction pin in friction spring and press on.
❑ Only exert pressure on centre of glass. Always wear protective gloves.
8 - Friction pin
❑ Must be inserted in friction spring ⇒ Item 9 (page 114) in housing when fitting mirror glass.
9 - Friction spring

114 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

6.2 Replacing housing for exterior mirror

– Remove mirror glass ⇒ Item 7 (page 114) .
– Unscrew bolts -4- (2x).
– Squeeze retainer tabs -2- and detach cover -3- downwards.
– Unscrew (3x) bolts -1- at mirror adjustment unit.
– Lift off housing -5-.

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 Replacing electric mirror adjustment unit

– Remove mirror glass ⇒ Item 7 (page 114) .
– Unscrew bolts -1- (3x).
– Any mirror adjustment unit connectors are to be unplugged
prior to removal.

Note

If mirror adjustment units are provided with soldered wires, these

are to be disconnected individually directly at the housing.

– Fit wires in connector housing supplied with replacement part.

Note

♦ Take over wiring arrangement from old adjustment unit.

♦ Use applicable current flow diagram.

• Tightening torque 1 Nm

6. Rear view mirror 115

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

7 Protective sheeting for side panel

7.1 Bonding protective sheeting onto side

panel

Note

Before bonding, the temperature of the side panel and sheeting

must be between +20 and +60 °C in the bonding area.

– Use a lint-free cloth and naphtha to clean the bonding surface

on the body.
– Moisten the bonding surface with a mixture of alcohol and wa‐
ter with low surface tension (1:3).
– Detach backing from bonding surface of sheeting.
– Press on sheeting, working outwards from centre such that
water film beneath sheeting is pressed out.
– Take care to avoid any air inclusions.
– In the case of any air inclusions, pierce carefully with a needle
and press sheeting on again.

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.

116 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

8 Outer sill moulding

8.1 Replacing outer sill moulding

Note

Outer sill moulding cannot be removed without destroying it.

– To remove, unclip -arrow- sill moulding -1- from sill panel trim
-2- over entire length.
– Heat sill moulding with hot-air blower and lift off carefully.
– Clean area to be bonded with petrol, treat with silicone remov‐
er and rub dry.
– Heat areas to be bonded with a hot-air blower to approx. 40 °
C.
– On installation, detach backing from lower adhesive strip -3-.
– Clip sill moulding into sill panel trim -2- along the line of clips.
– Start pressing on sill moulding at lower bonding surface -3-.
– Detach backing from upper bonding surface and press on sill
moulding at top as well.

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. Outer sill moulding 117

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

9 Trim

9.1 Removing and installing sill panel trim

1 - Holder for sill panel trim

❑ Removing and installing
⇒ page 119
2 - Oval head bolt - 1 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Self-tapping screwpermitted
- 2 Nmunless 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 - Sill panel trim
❑ Removing:
– Remove outer sill
moulding ⇒ page 117 .

– Unscrew bolts
⇒ Item 2 (page 118) ,
⇒ Item 3 (page 118) ,
⇒ Item 6 (page 118)
and start by pulling sill
panel trim out of holder
⇒ Item 1 (page 118) .

– Then pull forwards out

of rear trim and detach.
❑ Installing:
– Start by fixing sill panel
trim in position at holder
⇒ Item 1 (page 118)
⇒ page 119

– Screw in bolts
⇒ Item 3 (page 118) ,
working from front to
rear.

– Screw in bolts
⇒ Item 2 (page 118) and
⇒ Item 6 (page 118) .

5 - Rear sill panel trim

❑ Removing and installing ⇒ page 119
6 - Self-tapping screw - 2 Nm
7 - Self-tapping screw - 1 Nm
8 - Wheel housing liner

118 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Removing holder for sill panel trim

• Sill panel trim removed
– Unscrew bolts at wheel housing liner (2x).
– Unscrew oval head bolts -2- and detach holder -1-.
– Expanding nut -3-
– When installing sill panel trim -4-, make sure it engages fully
in holder -1- as shown in detail view.

Rear sill panel trim

• Sill panel trim -1- removed
– Unscrew bolts -2- and -6- and detach rear sill panel trim -3-.
– Wheel housing liner -5-
– Rear wheel housing liner is additionally bonded with double-
sided adhesive strip.
– Bonding area must be free from dust and grease.

9.2 Removing and installing sill panel trim (Allroad)

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.

9. Trim 119
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Combi bolt - 2 Nm
2 - Sill panel trim
❑ Removing:
– Completely unclip sill
moulding from sill panel
trim ⇒ page 121 .

– Remove rear trim

⇒ Item 3 (page 120)
⇒ page 121
– Screw bolts
⇒ Item 1 (page 120) and
⇒ Item 4 (page 120) out
of rear trim.
– Pull out trim
⇒ Item 3 (page 120) to
rear.

– Screw bolts
⇒ Item 1 (page 120)
completely out of trim. 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
– Detach trim sideways. with respect to the correctness of information in this document. Copyright by AUDI AG.

3 - Rear sill panel trim

❑ Removing:
– Unclip sill moulding from
trim in rear area.

– Unscrew the bolts

⇒ Item 1 (page 120) and
⇒ Item 4 (page 120) un‐
derneath.

– Pull out sill panel trim to

rear.

4 - Combi bolt - 2 Nm
5 - Rear wheel housing liner
6 - Combi bolts - 1 Nm
7 - Front wheel cover
❑ Removing ⇒ page 126
8 - Front wheel housing liner
9 - Holder
❑ Removing ⇒ page 121

120 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Unclipping sill moulding

– Before removing sill panel trim -3-, unclip sill moulding -1- in
-direction of arrow-.
– To facilitate clipping in, moisten sill panel trim with soap solu‐
tion, for example, in clip area.

Removing and installing rear sill panel trim

– Unclip sill moulding in area of rear sill panel trim
⇒ page 123 .
– Unscrew bolts -2- and -4-.
– Pull rear sill panel trim -5- out of sill panel trim -1-.
– Before fitting new part, detach backing from double-sided ad‐
hesive strip -3-.
– Slide rear sill panel trim into front sill panel trim.
– Press rear sill panel trim firmly onto sill panel with double-sided
adhesive strip.
– Screw in bolts -2- and -4- and tighten to 2 Nm.
– Clip sill moulding in again in area of rear sill panel trim.

Holder for sill panel trim

• Sill panel trim removed
– Unclip front wheel cover from holder.
– Screw bolts -3- of holder -2- out of clips -1- and detach holder.

9.3 Removing and installing sill panel trim (RS6)

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.

9. Trim 121
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Combi bolt - 2 Nm
2 - Mount
❑ After painting, attach to
sill panel trim
⇒ Item 4 (page 122)
with clips
⇒ Item 13 (page 123) .
3 - Bolt - 2 Nm
❑ 10x
4 - Sill panel trim
❑ Removing:
– Completely unclip sill
moulding from sill panel
trim ⇒ page 123

– Screw out bolts

⇒ Item 1 (page 122) ,
⇒ Item 3 (page 122) ,
⇒ Item 5 (page 122) ,
⇒ Item 7 (page 122)
and
⇒ Item 9 (page 122) .

– Detach end piece

⇒ Item 10 (page 122) .

– Detach sill panel trim

sideways.
❑ Installing:
– After painting, attach
protective sheeting
⇒ Item 12 (page 122) .

– Attach mount
⇒ Item 2 (page 122) with
clips
⇒ Item 13 (page 123) to sill panel trim.

– First secure sill panel trim with bolts ⇒ Item 1 (page 122) , ⇒ Item 3 (page 122) and
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
⇒ Item 7 (page 122)to. the correctness of information in this document. Copyright by AUDI AG.
with respect

– With sill panel trim in position, detach backing from double-sided adhesive strip ⇒ Item 11 (page 122) .

– Attach end piece ⇒ Item 10 (page 122) .

– Secure sill panel trim and wheel housing liners ⇒ Item 6 (page 122) and ⇒ Item 8 (page 122) with bolts
⇒ Item 5 (page 122) and ⇒ Item 9 (page 122) .

5 - Bolt - 2 Nm
❑ 3x
6 - Front wheel housing liner
7 - Bolt - 2 Nm
8 - Rear wheel housing liner
9 - Bolt - 2 Nm
10 - End piece
11 - Double-sided adhesive strip
12 - Protective sheeting
❑ Bond on after painting.

122 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

13 - Clip
❑ 12x

Unclipping sill moulding

– Before removing sill panel trim -3-, unclip sill moulding -1- in
-direction of arrow-.
– To facilitate clipping in, moisten sill panel trim with soap solu‐
tion, for example, in clip area.

Holder for sill panel trim

• Sill panel trim removed
– Unclip front wheel cover from holder.
– Screw bolts -3- of holder -2- out of clips -1- and detach holder.
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.

9.4 Removing and installing sill moulding

– Unclip sill moulding -1- lengthways from sill panel trim -2-.
– Heat the bonded surfaces with a hot-air blower and detach sill
moulding from sill panel.
– Completely remove any residual adhesive.
– Before fitting new sill moulding, bonding surface must be com‐
pletely free from grease and dust.
– Detach lower backing from sill moulding.
– Use lubricant to facilitate clipping of sill moulding into sill panel
trim.
– Clip in sill moulding along sill panel trim.
– First press on sill moulding over entire area of lower sill panel
flange.
– Detach rest of backing and press on sill moulding over entire
area of upper sill panel flange.

9. Trim 123
 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

10 Wheel housing liner

10.1 Removing and installing front wheel housing liner

1 - Wing
2 - T25 Torx bolt - 1.5 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Front wheel
permittedhousing linerby AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
❑ Removing:
with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove front wheel.

– Release clamping pins
⇒ Item 6 (page 124) .

– Unscrew (13x) Torx

bolts
⇒ Item 2 (page 124) .

– Disengage wheel hous‐

ing liner from wing and
pull out downwards.

4 - Expanding nut
❑ 13x
5 - Sill panel trim
6 - Clamping pin

124 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

10.2 Removing and installing rear wheel housing liner

1 - Rear wheel housing liner

❑ Removing:
– Remove rear wheel.

– Unscrew bolts
⇒ Item 2 (page 125)
and cap nut
⇒ Item 4 (page 125) .

– Take out wheel housing

liner downwards.
2 - Self-tapping screw - 1.5 Nm
3 - Expanding nut
4 - Cap nut - 1.5 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.

10. Wheel housing liner 125

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

11 Covers

11.1 Removing and installing cover for front wheel housing (Allroad and RS6)

1 - Cover for front wheel hous‐

ing
❑ Removing:
– Remove front wheel.

– Remove wheel housing

liner.
– Unscrew bolts
⇒ Item 2 (page 126) of
cover.
– Detach cover sideways
from vehicle.

– If necessary, remove re‐

sidual adhesive from
sealing strip of cover at
wing.
❑ Installing:
– Bonding surface for
sealing strip must be
free from dust and
grease.

– Remove backing at
wing contact surface
-arrow- from cover.

– Insert guide lugs

-arrow- of cover in holes
at wing.

– Press cover onto wing

and secure with bolts.

– Perform further installa‐

tion operations in re‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
verse order of removal. 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.
– Following installation, detach adhesive strip liner from cover at top edge.

2 - Torx bolts - 1 Nm
3 - Front wheel housing liner
❑ Removed
4 - Front guide piece for bumper
5 - Front bumper

126 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

11.2 Removing and installing cover for rear wheel housing (Allroad)

1 - Cover for rear wheel hous‐

ing
❑ Removing:
– Remove rear wheel.

– Remove wheel housing

liner.

– Unscrew bolts at rear sill

panel trim ⇒ page 128 .

– Unscrew all bolts

⇒ Item 2 (page 127) of
cover.

– Detach cover sideways

from vehicle.

– If necessary, remove re‐

sidual adhesive from
sealing strip of cover at
body.
❑ Installing:
– Bonding surface for
sealing strip must be
free from dust and
grease.

– Remove backing from

double-sided adhesive Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
strip permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ Item 8 (page 127) at with respect to the correctness of information in this document. Copyright by AUDI AG.
cover and insert guide
lugs of cover in holes in
body.

– Press cover onto body

and secure with bolts.

– Perform further installation operations in reverse order of removal.

– Following installation, detach backing from adhesive strip liner ⇒ Item 9 (page 127) .

2 - Torx bolts - 1 Nm
3 - Rear sill panel trim
❑ To remove when working on rear wheel cover, unscrew the two bolts in the area of the wheel housing
liner and press trim aside until bolt ⇒ Item 5 (page 127) is accessible.
4 - Rear guide piece
5 - Torx bolts - 1 Nm
❑ Bolts are only accessible after pressing off cover ⇒ Item 3 (page 127) in area of wheel housing liner
⇒ page 128
6 - Wheel housing liner
❑ Remove before taking out wheel housing cover.
7 - Torx bolts - 1 Nm
8 - Adhesive strip
9 - Adhesive strip liner

11. Covers 127

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

Rear sill panel trim

– To remove rear wheel cover, unscrew bolts -4- at top and bot‐
tom.
– Press aside trim -5- in area of wheel housing liner and unscrew
the bolts beneath for securing wheel cover.

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.

128 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

12 RS6 rear spoiler

12.1 Removing and installing Saloon rear spoiler

Note

Rear spoiler cannot be removed without damaging it.

1 - Rear spoiler
❑ Removing ⇒ page 129
❑ Installing:
– Rear lid paintwork in
rear spoiler bonding
area must be free from
dust and grease.

– Check whether sealing

washers
⇒ Item 2 (page 129)
have been attached to
studs.

– Remove backing from

double-sided adhesive
strip
⇒ Item 4 (page 129) at
rear spoiler and insert
studs of rear spoiler in
holes in rear lid.

– Tighten collared nuts

⇒ Item 3 (page 129) .

2 - Sealing washer
3 - Collared nut - 4 Nm
4 - Double-sided adhesive strip

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.

12.2 Removing rear spoiler

Special tools and workshop equipment required

12. RS6 rear spoiler 129

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

♦ Cutting tool -V.A.G 1351-

♦ Parting tool for bonded windows -V.A.G 1474 A-

♦ Fabric-reinforced adhesive strip

♦ Plastic wedge
Procedure
– Remove hazard warning triangle with holder.
– Remove rear lid lining ⇒ General body repairs, interior; Rep.
Gr. 70 . 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
– Unscrew hexagon with
collared nuts
respect to from studs
the correctness at spoiler.
of information in this document. Copyright by AUDI AG.

– Mask rear lid with fabric-reinforced adhesive strip -2- all round
spoiler -1-.

– Use felt-tip pen to mark position of outer studs as shown

-arrow- on spoiler -1-.
2 - Fabric-reinforced adhesive strip

130 Rep. Gr.66 - Exterior equipment

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

– Insert cutting wire -1- beneath spoiler at side.

– Secure cutting wire in two handles from cutting tool -V.A.G
1351- .
– Cut out spoiler as far as outer mark.

– Slide plastic wedge -2- beneath spoiler at side to act as a

spacer.
– Insert cutting wire -3- through bond at position of stud (outer
mark) beneath spoiler -1-.

– Pull cutting wire in -direction

Protected by copyright.of arrow-
Copying through
for private bond purposes,
or commercial as far as
in part or in whole, is not
centre screw connection.
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.
– Proceed in the same manner from the other side and com‐
pletely cut out spoiler -1-.
– Detach spoiler from rear lid.
2 - Fabric-reinforced adhesive strip

12.3 Removing and installing Avant rear spoiler

Note

Rear spoiler cannot be removed without damaging it.

12. RS6 rear spoiler 131

 Audi A6 1998 ➤
General body repairs, exterior - Edition 11.2004

1 - Collared nut - 4 Nm
2 - Rear spoiler
❑ Removing:
– Remove upper rear lid
trim ⇒ General body re‐
pairs, interior; Rep. Gr.
70 .

– Unscrew collared nuts

⇒ Item 1 (page 132) .
– Grasp hold of rear edge
of rear spoiler and pull to
rear out of bond.
❑ Installing:
– Rear lid paintwork in
rear spoiler bonding
area must be free from
dust and grease.

– Before fitting rear spoil‐

er in position, guide out
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
the tabs of the backing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ Item 3 (page 132) of
the double-sided adhe‐
sive strips
⇒ Item 4 (page 132) to
the side.

– Insert studs of rear

spoiler in holes in rear
lid.

– After positioning rear

spoiler, detach backing
by way of tabs.

– Tighten collared nuts

⇒ Item 1 (page 132) .

3 - Backing for double-sided adhesive strip

❑ Guide out to the side before positioning rear spoiler.
4 - Double-sided adhesive strip

132 Rep. Gr.66 - Exterior equipment