AUDI A4 1997 B5 / 1.G Front End Workshop Manual

50-1


Body, front Lock carrier with attachments, removing
and installing

1 -
Hex bolt (6x)
45 Nm (33 ft lb)
2 -
Hex bolt 45 Nm (33 ft lb)
3 -
Hex bolt (4x) 10 Nm (7 ft lb)
4 -
Hex bolts (2x) 10 Nm (7 ft lb)
5 -
Access hole for special tool For service position, attach special tool
3369 here
6 -
Cowl attachment hole Attachment for service position
Pa
ge 1 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1

50-2


Repair Manual, Heating & Air Conditioning,
Repair Group 87

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

50-3


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

50-4


Installing:
- Install in reverse order of removal.
- Adjust headlights.
Adjusting:
- Center lock carrier -7- between fenders.
- If fenders and hood are also being
replaced, center them in relation to one
another before adjusting lock carrier.
8 -
Hood seal
9 -
Hood lock cable
Disconnecting page 55
-10
10 -
Hole in side panel
Pa
ge 4 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1

50-5


Fig. 1 Disconnecting hydraulic fluid cooler
- Remove screws for cooling line (for power steering) at engine support
and transmission.

Repair Manual, General, Engine, Repair Group 19 Fig. 2 Disconnecting coolant hose
- Drain coolant from radiator.
- Pull out locking element for coolant line connecting flange at bottom of
radiator and remove connecting flange.
- Bleed coolant system.
Pa
ge 5 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1

50-6


Fig. 3 Disconnect hose for charge air cooler
- On vehicles with charge air cooler, loosen bolt on hose clamp (arrow).
- Remove hose.
- Unscrew air duct to air cleaner at cowl and lift out.

- Disconnect harness connectors for headlights, headlight height
adjustment and blinkers.
- Disconnect harness connector for coolant system temperature sensor
for coolant fan at lower coolant hose area at radiator (left).
Pa
ge 6 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1

50-7


Lock carrier service position

Notes:

Do not remove noise insulation. Loosen only
front quick-release screws page 50
-18
.
Bumper removed
1 -
Combination bolt
45 Nm (33 ft lb)
2 -
Combination bolt 45 Nm (33 ft lb)
3 -
Combination bolt 10 Nm (7 ft lb)
4 -
Combination bolt 10 Nm (7 ft lb)
5 -
Access hole for special tool For service position, attach special tool
3369 here
6 -
Cowl attachment hole Attachment for service position
Pa
ge 7 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1

50-8


Note:
After assembly of the lock carrier, check headlight
positioning and adjust if necessary. 7 -
Lock carrier
For service position
- Screw special tool 3369 into threaded
bore -5- on left side Fig. 1

- Remove left and right mounting screws -
1-.
- Remove mounting bolts -3- and -4- and
pull lock carrier -7- forward.
- Secure lock carrier Fig. 2
.
8 -
Hood seal
9 -
Hood lock cable
10 -
Hole in side panel
Pa
ge 8 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1

50-9


Fig. 1 Screw in special tool 3369
- Screw special tool 3369 in at left and right as shown.
- Pull lock carrier forward until rear hole in lock carrier aligns with front
threaded hole in fender flange.

Fig. 2 Secure lock carrier
- Secure lock carrier with screws at left and right as shown.
Pa
ge 9 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1

50-10


Front fender ( VIN 8D XA 200 000),
assembly overview

1 -
Combination bolt
4.5 Nm (40 in. lb)
2 -
Threaded rivet Threaded rivet is inserted using VAG1618A
3 -
Combination bolts (2x) 7.5 Nm (66 in. lb)
4 -
Phillips head screw 4.5 Nm (40 in. lb)
5 -
Metal nut (2x)
6 -
Fender Remove bumper page 63
-1 .
Remove wheelhousing liner page 66
-
31
.
Remove end plate Fig. 1
.
Remove headlights Repair Manual,
Electrical Equipment Disconnect electrical connectors for side
blinkers
- Remove bolts -1-, -3-, -4-, -7-, and -11-.
Pa
ge 10 of 19 Bod
y, front
11/20/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.BD01.50.1