Audi A8 1994 Body Repair Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Body repairs
Audi A8 1994 ➤
Edition 10.1998
Service
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Repair Group overview for Body Repairs
Re pa ir G ro up
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A004DKI0120
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.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Type plate and vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Body - Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Foam-filled cavities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Floor group, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Floor group, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Floor group, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.5 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.6 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1 Wing mounting flange - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Front wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Front longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Closure plate for strut holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5 Longitudinal member front section - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Roof - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 A-pillar trim - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Outer B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Inner B-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Inner side member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8 Top part of cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Rear cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Audi A8 1994 ➤
Body repairs - Edition 10.1998
Contents i
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 Rear cross panel/side panel - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 Luggage compartment floor/side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Rear longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
5 Side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6 Rain channel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Audi A8 1994 ➤
Body repairs - Edition 10.1998
ii Contents
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00 – Technical data
1 Vehicle identification data
1.1 Type plate and vehicle identification
number
The type plate -A- is located on the lock carrier at the front right.
Vehicles for certain export countries have no type plate.
The vehicle identification number -B- (chassis number) is stam‐
ped on the rear bulkhead in the engine compartment. Detach the
seal in the area of the marking.
1.2 Vehicle data sticker
The vehicle data sticker is located in the spare wheel well at the
rear of the vehicle.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
1. Vehicle identification data 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 Body - Bonded joints
2.1 Body - centre
• The following body areas are bonded
– Roof to roof frame
– Inner roof frame to outer roof frame
Audi A8 1994 ➤
Body repairs - Edition 10.1998
2 Rep. Gr.00 - Technical data
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2.2 Body - rear
– Rear wheel housing liner to rear wheel housing
Audi A8 1994 ➤
Body repairs - Edition 10.1998
2. Body - Bonded joints 3
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with respect to the correctness of information in this document. Copyright by AUDI AG.
3 Foam-filled cavities
The following areas of the body are foam-filled for acoustic rea‐
sons:
a = A-pillar
b = Inner B-pillar
c = Outer side panel
d = D-pillar
Use foam D-000-111-A 2.
Alternatively, use can also be made of a 2-component foam which
does not absorb moisture.
a = Foam-filling hole
Audi A8 1994 ➤
Body repairs - Edition 10.1998
4 Rep. Gr.00 - Technical data
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A = A-pillar
B = Inner B-pillar
C = Outer side panel
An aluminium wire mesh is inserted at the bottom to stop the foam
running through.
D = D-pillar
Prior to foam filling, spray the pillar with wax from inside to stop
the surface being damaged during the foam filling process.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
3. Foam-filled cavities 5
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4 Corrosion protection
The following body areas are flooded with hot wax:
A = Outer side member.
B = Front and rear doors.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
6 Rep. Gr.00 - Technical data
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Bonnet
A = Front frame.
B = Front frame reinforcement.
Audi A8 1994 ➤
Body repairs - Edition 10.1998
4. Corrosion protection 7
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with respect to the correctness of information in this document. Copyright by AUDI AG.
5 Body dimensions
5.1 Floor group, front
Distance between front attachment points of front axle
Distance between rear attachment points of front axle
Distance between front attachment points of front axle
Diagonal distance between attachment points of front axle
Audi A8 1994 ➤
Body repairs - Edition 10.1998
8 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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5.2 Floor group, centre
Distance between rear attachment points of front axle and rear
axle mounting
Diagonal distance between rear attachment points of front axle
and rear axle mounting
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 9
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with respect to the correctness of information in this document. Copyright by AUDI AG.
5.3 Floor group, rear
Distance between front attachment points of rear axle
Distance between rear attachment points of rear axle
Distance between attachment points of rear axle
Diagonal distance between attachment points of rear axle
Audi A8 1994 ➤
Body repairs - Edition 10.1998
10 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Distance between production mountings
Distance between rear longitudinal members
Distance between rear axle rear attachment point and rear lon‐
gitudinal member
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 11
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5.4 Body - front
Distance between front longitudinal members
Audi A8 1994 ➤
Body repairs - Edition 10.1998
12 Rep. Gr.00 - Technical data
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Distance between wing panel mountings
Distance between front attachment points of strut holder
Distance between rear attachment points of strut holder
Distance between front hinge attachment points
Diagonal distance between hinge attachment points and wing
panel mounting
Diagonal distance between attachment points of strut holder
Distance between front hinge attachment points and wing panel
mounting
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
5.5 Body - centre
5.5.1 Front door opening
Height of door opening
Distance between A-pillars
Distance between B-pillars
Distance between A-pillar and B-pillar
Audi A8 1994 ➤
Body repairs - Edition 10.1998
14 Rep. Gr.00 - Technical data
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5.5.2 Rear door opening
Distance between C-pillars
Distance between B-pillar and C-pillar
Height of door opening
Audi A8 1994 ➤
Body repairs - Edition 10.1998
5. Body dimensions 15
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5.6 Body - rear
Distance between side panels (top)
Distance between side panels (bottom)
Distance between rear cross panel flange and window cross
member flange
Audi A8 1994 ➤
Body repairs - Edition 10.1998
16 Rep. Gr.00 - Technical data
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6 Straightening jig
Note:
♦
The item numbers in the illustrations are identical with the end numbers on the alignment bracket mountings.
♦
The item numbers of the alignment bracket mountings for checking the body with and without mechanical
units are marked with a circle.
♦
The required basic set size is given for the alignment bracket mountings.
♦
The following illustrations show the right side of the vehicle.
Alignment bracket set Audi A8 -V.A.G 2008- incl. quattro
Audi A8 1994 ➤
Body repairs - Edition 10.1998
6. Straightening jig 17
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2 - MZ 142 and TV 400
3 - Spacer
36 - MZ 142, TV 400 and
mounting -2-
4 - MZ 260, TV 400
6 - Spacer bolt
8 - MZ 602
12 - Mounting for bar
10 - MZ 602 and alignment
bracket mounting -8-
15 - Bar in place of steering
box
14 - Mounting for steering
18 - Mounting for steering
16 - Mounting for steering
(right-hand drive vehicles only)
18 - MZ 140
20 - Bracket without MZ and
front production mounting -21-
22 - MZ 200 (quattro only)
24 - MZ 260 and TV 400. No
longer to be used. Instead,
make use of -VAS 5007- to‐
gether with -VAS 5007/1- .
26 - MZ 260
6 - Spacer bolt
28 - MZ 602 and attachment
plate - CD.25-.
30 - MZ 260
32 - MZ 140
34 - MZ 200 and TV 400
Audi A8 1994 ➤
Body repairs - Edition 10.1998
18 Rep. Gr.00 - Technical data
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with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Mounting for subframe
40 - Sill panel mounting
Audi A8 1994 ➤
Body repairs - Edition 10.1998
6. Straightening jig 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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2 - Front longitudinal member
When checking, bolt on MZ
last, as the longitudinal posi‐
tion of the impact absorber
mounting can vary by
several mm due to production
tolerances - if necessary do not
bolt down.
3 - Spacer
36 - Front longitudinal mem‐
ber / top of wheel housing
Overview of front alignment brackets
Audi A8 1994 ➤
Body repairs - Edition 10.1998
20 Rep. Gr.00 - Technical data
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Overview of front alignment brackets
Audi A8 1994 ➤
Body repairs - Edition 10.1998
6. Straightening jig 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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11 - Bar in place of steering
box
Lubricate bar with oil and take
care to avoid damage.
14 - Mounting for steering
15 - Mounting for steering
6 - Mounting for subframe
6 - Spacer bolt
8 - Mounting for alignment
brackets -10- and -12-
Do not insert pin until after fit‐
ting body on jig.
10 - Strut holder
12 - Mounting for bar
Audi A8 1994 ➤
Body repairs - Edition 10.1998
22 Rep. Gr.00 - Technical data
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Overview of centre alignment brackets
Audi A8 1994 ➤
Body repairs - Edition 10.1998
6. Straightening jig 23
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20 - Bracket
21 - Front production mounting
May have been forced up‐
wards by handling vehicle in
factory: when checking dimen‐
sions, pack with spacer up to 4
mm if necessary.
39 - Drilling in sill panel
40 - Drilling in sill panel
18 - Mounting for subframe
6 - Spacer bolt
Audi A8 1994 ➤
Body repairs - Edition 10.1998
24 Rep. Gr.00 - Technical data
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