Audi 80-90 B3 (1986-1991) Service manual

 E-1
B-pillar trim
m assembly 66.4
Front license plate bracket
E installing 66:16
Mirror glass
ë removing/installing 66.3
Outside mirror
8 removing/installing 66.3
Protective moldings
= assembly 66.5
uw removing/instaling 66.7 -
Radiator grille
uw removing/installing 66.2
Rear spoiler
® changing gas strut 66.15
æ installing on replacement lid 66.12
E removing installing 66.12
Rocker panel moldings
B assembly 66.8
Roof trim molding
E assembly 66.9
m installing 66.11
® removing 66.10
Side window exterior molding
®B removing/installing 66.11
Wheel house liner
= removing/installing 66.2
#
r
a
| |
Body Accessories - Exterior
7
=
Index
Coupe
A-pillar trim
-B assembly 66.20
« removing/installing 66.21
B-pillar trim
= assembly 66.22
E removing/instaling 66.23
Door sill trim
E assembly 66.28
Front license plate trim
® assembly 66.29
Outside mirror
E instaliing 66.18
E removing 66.17
Outside mirror glass
® installing 66.19
B® removing 66.18
Protective moldings
= assembly 66.26
Radiator grille
= removing/installing 66.17
Rocker panel moldings
E assembly 66.27
Roof trim moldings
® assembly 66.24
+ # removing/installing 66.25
>
, . Wheel house liner В
= removing/installing 66.17 -
de
1
E
ho
!
À
66.1
Body Accessories — Exterior
Radiator grille, removing/installing
> Removing’
m remove Phillips screws 1
® push down retaining clips (arrows) with
screwdriver ©
® pull radiator grille up and away from front
panel 2
‘Installing
install in reverse order of removal. Note the
following:
Bm retaining tabs from radiator grille must fit
behind front panel 2
wT
I | Wheel house liner, removing/installing
7 | > Removing
® unclip comers of bumper from guides at
side (see Repair Group 63)
B® pry out expanding nut 1 -
® remove bracket 2 on one side
® remove plastic nut 3
m remove Phillips screws, note clip 4
on fender flange
E pull fender away slightly at bottom
E pull wheel housing liner over studs
® press wheel housing liner inwards and oft
fender flange
® remove wheel house liner
Installing
‚m insert wheel housing lining towards A pillar
- and press over fender flange
® reinstall all components in reverse ‘order of
removal
- ——_
E-2
Radistor grille, removing/nstalling 66. |
Wheel house liner, removing/installing. ad
Body Accessories — Exterior
Outside mirror, removing/installing
> Removing
в tum mirror (arrow C) to expose Phillips
Screws ’
® holding mirror, remove both screws (arrows
A, B)
` ® disconnect electrical plug
Installing
Install in reverse order of removal
Outside mirror glass, removing/installing
| | > Removing
CAUTION
Wear protective gloves to prevent injury
if glass breaks.
Hold dlass to prevent falling out.
»
u tape upper/lower edge of mirror housing
E using tool 80-200, pry mirror glass off at
bottom 1 and top 2
w hold mirror, unplug electrical connector
> Installing |
CAUTION
Apply pressure only at center of mirror
glass. |
~ mreconnect electric connector
| - 9 = fit mirror onto guide pins (arrow)
- o BB press into mirror housing
"= check mirror for proper function
E-3
Е — Outside mirror, removing/installing 66 |
a Outside mirror glass, removing/installing e 3
Body Accessories — Exterior
Trim for
B-piilar trim
Gap between B- pillar trim
and roof trim is
0.5mm (approx. 1/64 in.)
Adjust gap by moving
mounting.
Mounting with
expanding clips
% | Expanding clip: +
Es”
Body Accessories — Exterior
A = distance between body side
crease and protective molding
approx. 10.0mm (13/32 in.)
Protective moiding,
_ rear side panel
В adhesive strip width
4.0mm (5/32 in.)
Protective molding a
rear door >
adhesive strip width >
4.0mm (5/32 in.)
tront tender 4.0mm (5/32 in.)
adhesive strip width N
4.0mm (5/32 M.)
cal
E-5
50 S a | | protectiva molings azomy OO «5 -
Body Accessories — Exterior
Protective molding, rear side panel
adhesive strip: a = 4.0mm (5/32 in.) width
Protective molding, front fender
adhesive strip: a = 4.0mm (5/32 in.) width
b = 8.0mm (5/16 in.) width
ii
*
= €
Protective molding, rear door
adhesive strip: a = 4.0m (5/32 in.) width
N E A Protective molding, front door
adhesive strip: a = 4.0mm (5/32 in.) width
*
- . #
| . . 3 - 1 4
B B o
> ъ
- = co wl"
a e a
Pa
'
wu
A= between body side +” -
approx. 10.0mm (13/32 in.) “e | | |
- . a | | | - N | + | . . : : + | E-6 . .
| EX race mole assembly 6 6 в 6
Body Accessories — Exterior
WARNING Protective moldings, removing/
installing
Follow all application and
safety instructions on labels. Removing
Protective moldings cannot be removed
without being damaged. -
CAUTION 9 camag
m heat molding with hot air gun
Part numbers are for reference ° в carefully pry off old molding
2 only. Always check with your
Parts Department for latest . Installing
parts information. - Installing molding on repainted sheet metal:
Em clean adhesive areas on sheet metal with
3M® General Purpose Adhesive Cleaner or
equivalent |
a prime with primer from Adhesive kit
D 004 300 03 or equivalent, and
allow primer to dry for 10 minutes
=
Installing moulding on plastic surface:
® clean adhesive areas with 3M* General
Purpose Adhesive Cleaner or equivalent
° M rub dry with lint free cloth
m prime area with primer from Adhesive kit
: D 004 300 03 or equivalent, and allow to
3 dry for 10 minutes
Mm Cut back any remaining adhesive to depth
of approximately 1.0mm (3/64 in.) 2
~ ® do not cut into paint or primer
æ clean remaining adhesive with 3M*
General Purpose Adhesive Cleaner or
equivalent
m apply adhesive D 009 100.03 or equivalent
® position molding
® press firmly to body
e take special care at ends of moldings
® apply strips of fabric (cloth) tape to hold
molding in position. a
w allow to dry 4 hours at 20°C (68°F)
remove tape
m ciean any residual adhesive from metal or
— plastic with dry cloth, followed by mineral
spirits
® allow residue on plastic to harden
‘2-3 hours before removing
. Ч
Protective moldings, removing/installing 66 ol
e
Body Accessories — Exterior
Moiding rear door
Puil out end cap, pull
molding toward back, out of clips
End cap, rear
Retaining clip points toward molding
wider side downwards
2
Molding front door
Pull out end cap and pull molding
to the back from the clips.
4
End cap, front
. - Retaining clip points toward molding,
wider side downwards
‚о.
#
ER 66.5
ía
{7
E-9
Body Accessories — Exterior
Clip
roof trim molding is installed to
D-pillar with clips
Pop rivet
E
NN
Do not remove end cap
when replacing or removing
the roof trim molding.
— Drip rail molding, reer
clipped to roof trim molding
removal, page 66.10
Roof trim molding
-. removing, page 66.10
Pop rivet В — —— Orip rail.molding, front
"clipped to roof trim molding
| | | —E-10
. TF_-
Root trim molino assembly 66 9
Body Accessories — Exterior
Roof trim molding, removing
s remove trim for outer B-Pillar
® pry drip rail molding 1 front and rear out of
roof trim molding 2 and pull out
Note
Do not remove end cap when replacing or
removing the roof trim molding.
® begin to pull out gap covering 1 on C-pillar
here
® bore out rivet heads with 8.0mm (5/16 in.)
diameter drill and push remaining rivet
through to the inside
® pull roof trim molding 4 upwards along
D-pillar approximately 30mm (1.1 in.), until
the retaining straps of the roof trim molding
are released from the clips 6
Note
~ Paint damage may occur by the rivets turning
when being drilled out.
The appearance and area of paint damage
will determine the type of paint refinishing
application: brush, spray can or spray gun.
”
~ EY
Roof trim moldina. removina/instailing 66 «10 |
Body Accessories — Exterior
Roof trim molding, installing
Note -
To avoid paint damage, guide the roof trim
molding along D-pillar during installation with |
aid of a helper.
D = install roof trim molding through end cap
a push roof trim molding along D-pillar under
the retaining clips, until the perforation
pattern on the roof frame matches the
perforation pattern on the roof trim molding
E install pop rivet |
E install drip rail molding 1 first in direction of
arrow 2, then press in roof trim strip in
direction of arrow 3
Side window exterior molding,
removing
m remove side window (see Repair Group 64)
> в Боге ош! rivet heads and push remaining
| rivet through to the inside
| Note
Paint damage may occur by the rivets turning
when being drilled out. т
The appearance and area of paint ‘damage
will. determine the type of paint refinishing
66-2078 application: brush, spray can or spray gun.
E heat molding with hot air gun ~~ °
s carefully pull off molding from top
s clean adhesive areas on sheet metal with
3M® General Purpose Adhesive Cleaner or
equivalent | |
Side. window molding, installing
a pull of paper from adhesive strip
m_ press molding to body sheet metal .
=m install pop rivet |
° ® reinstall side window, trim and rear - seat
bench
——
E12 |
- Side window exterior molding, removing/installing 66
` Root trim molding, removing/installing «11
Body Accessories — Exterior
CAUTION | "Rear spoiler, removing/installing
Use care not to damage paint finish. J
7 Removing J
Prime damaged areas with anti- 3
comasion primer, and refinish as a tape area immediately above spoiler
required. '
зо
п
pron
+P = open lid and remove nuts on back of *
spoiler
m gently pull spoiler away from lid at both
sides
® insert knife between spoiler and lid
separate spoiler from lid with knife
E remove any remaining adhesive from
spoiler and lid with 3M* General Purpose
Adhesive Cleaner or equivalent
installing
Install in reverse order, note the following:
E stick adhesive strip on spoiler
® remove paper backing from adhesive strip
m put spoiler on lid
E install and tighten spoiler nuts
e side areas may be made to fit flush by
warming spoiler corners with hot air
blower, pressing tightly to lid .
LY
Rear spoiler, installing on
replacement rear lid
CAUTION - | ВЕ e
Prime drilled holes with anti-corrosion | к
primer and refinish as required.
> Mm mark spoiler mounting hole positions on
replacement lid (as shown)
e M = middle of lid
e ali dimensions in mm, + 1.0 mm,
tolerance |
a center punch and drill small starter holes
in lid о о
® drill 8 mm (5/16 in.) holes
® put spoiler on lid 1
m check fit, rework holes as required
: install spoiler nuts and tighten
g
. EN
* .
| | Rear spoiler, removing/instaliing 606 -
| 80 Quattro I on replacement lid ' À 0 2
Body Accessories — Exterior
| Rail |
Part No. 893 827 959A/960A
Part No. 893 827 971/972 . Part No. 893 827 981
van fl - °
~ Sealing ring
A Hex head bolt
"U torque 5 Nm (4 ft Ib). .
Mounting ..
Part No. 893 827 203
- E-14 |
90 Quattro
Rear spotier, ое; 66 1 3 ‘
Body Accessories — Exterior
CAUTION
Prime all drilied holes and cut sheet
metal with anti-corrosion primer and
refinish as required. >
Rear spoiler, installing on
replacement lid
® mark spoiler mounting hole positions on
replacement lid (as shown)
e all dimensioris in mm
=
m center punch and drill. small starter holes
in lid
” m drill 7.0 mm holes
“ = put spoiler on lid
® check fit, rework and refinish holes as
required,
8 cover with adhesive strip in center bracket
area |
Em put spoiler on lid, fasten down with outer
bolts
® using soft pencil, copy outline of center
brackets onto adhesive strip
am remove spoiler, place base 5 on outline
drawn on adhesive strip
® outer edges of base should just cover
outline
mark bolt holes
drilf small starter holes
drill 7.0 mm holes
check fit, rework holes as required
drill and enlarge holes to 15.0 + 0.5 mm
refinish holes as required -
e
E15
| Ч я ler, instaili
90 Quattro | Rear spor, installing 66.14
\ [m2] _
STO
Кос
y Cut along dashed line
21 Nm (15.5 ft Ib)
>
Body Accessories — Extérior
E using air saw, cut inner rear lid, as shown
E refinish edges .as required
Rear spoiler, aftermarket installation
— E installation procedures are identical, noting
“the following:
- © install stronger rear lid gas filled struts,’
Part No. 893 827 552A =
Rear lid gas filled strut, adjusting
A place stops in upper most position
a lightly tighten hex head bolts
m carefully push rear lid into lock
m open rear lid, tighten hex head bolts
o 21 Nm (15.5 ft Ib)
E-16
90 Quattro | ‘Rear spoiler, installing on replacement lid 66 1 5
Changing gas filled strut:
Body Accessories — Exterior
> - Front license plate bracket, installing
® drill two 8mm (9/16 in.) diameter holes in
bumper cover (arrows)
® drill points are pre-marked
4" Mount license plate bracket with M5 x 22
screws Part No. N 014 155.1 or equivalent
>
CAUTION
Part numbers are for reference only.
Always check with your Parts
Department for latest information.
E17
—
Pp
CONTINUED IN THE
LA
— BEGINNING OF NEXT ROW
ta
E-i8 о -
|
——
DD
—
=
‚же но
т о
‘Body Accessories — Exterior
x pape т“. =
FPS
7H
>
yr
Radiator grille, removing
® remove Phillips screws 1
Mm push down retaining clips (arrows) with
screwdriver
Mm pull radiator grille up and away from front
panel 2
Radiator grille, installing
Install in reverse order of removal. Note the
following:
m retaining tabs from radiator grille must fit
behind front panel 2.
Wheel house liner, removing
® unclip and remove expanding clips, screws
and nuts
1 — plastic nut =
2 — self tapping screw
removing:
® remove screw/washer 6
© pull fender away
3 — expanding clip “
4 — clip
5 — self tapping screw
6 — screw/washer
e 6 NM (53 in Ib)
7 — self tapping screw
Wheel house liner, installing
*
A. ~ ZZ
Tn
ei ` ``
fry ``
@) à. с
- + 0
= ` 4
* X +
` y
` 1 à 4
A in
t #
+.
Reinstall all components in reverse order of
removal.
p Outside mirror, removing
m turn mirror 90 (arrow C) to expose Phillips
screws A, B
m holding mirror, remove both screws
(arrows A, B)
m disconnect electrical plug at base of mirror
F-2
Coupe
Radiator grille, removing/installing
Wheel house liner, removing/instailing 66 |
| Outside mirror, removing In 1 7
Coupe
Body Accessories — Exterior
Outside mirror, installing ;
J Ho
Reinstall mirror in reverse order of removal
noting the following:
Left side
E mount mirror (arrows) as shown
e arrow A points to front of vehicle
Note
Do not alter mounting position as this will
change viewing angle.
`
Right side
B mount mirror (arrows) as shown
e arrow A points to front of vehicle
Note
Do not alter mounting position as this will.
change viewing angle.
p O Outside mirror glass, removing
CAUTION
Wear protective gloves to prevent injury
if glass breaks.
Hold glass to prevent falling out.
ta
® tape upper/lower edge of mirror housing to
prevent damage
m using tool 80-200, pry mirror glass off at
bottom 1 and top 2
® hold mirror, unplug electrical connector
су»
F-3
0 Outside mirror, installing 66
Outside mirror glass, removing m 1 8
Outside mirror glass, installing
CAUTION
— Apply pressure only at center of mirror
glass.
> E reconnect electric connector
E fit mirror onto guide pins (arrow)
© | } = press into mirror housing
EM check mirror for proper function
a A,
owt
F-4
Coupe | Outside mirror glass, instaiing 66 „19
He
THIS FRAME INTENTIONALLY LEFT
BLANK
ia
F-5
Body Accessories — Exterior
A-pillar trim —
windshield
Gap cover
A-pillar trim
gap dimension
a=05+ 02mm
(1/2 + 13/64 in.)
pop-rivet
gap dimension
а = 0.5 + 0.2 mm
(1/2 + 13/64 in.)
bracket ——
support
remove protective film first
. before installing
a:
pop-rivet
bracket
— support
remove protective film
before installing
bracket
A-pillar trim
gap dimension
а = 0.5 + 0.2 mm
(12 + 13/64 in.)
of
root .
gap cover
support |
remove protective
film before installing
DA pop-rivet.
3 wl
A-plilar trim
gap dimension
a=05+ 02mm
(12 + 13/64 in.)
waa] |
€,
Coupe
F-6
© A-piliar trim, assembly 66. 20
Body Accessories — Exterior
A-pillar trim, removing
a remove door seal at area of A-pillar
№ bore out rivet heads with 8.0 mm (5/16 in.)
diameter drill and push remaining rivet
through to the inside :
Note
Paint damage may occur by the rivet turning |
when being drilled out.
The appearance and area of paint damage
will determine the type of paint refinishing
application: brush, spray can or spray gun. 4
A-pillar trim, installing
Install in reverse order of removal, noting
the following:
® remove protective film from supports
prior to installing
m set A-pillar gap dimension, |
а = 0.5 + ох ул (1/2 + 13/64 in.)
7
Coupe A-piliar trim. removing/instaliing 66 а 21
Body Accessories — Exterior
| pop rivet— a (=== \—/
support
B-pillar trim
F-
E
bracket À.
side window
Ра
| ‘
F-8 .
ab
| Coupe B-pillar trim, assembly 66 „22
Body Accessories — Exterior
* B-pillar trim, removing
m remove door seal at area of B-pillar! — ,
M bore out rivet heads with 8.0 mm (5/16 in.)
diameter drill and push remaining rivet
through to the inside
Note
Paint damage may occur by the rivet turning
when being drilled out.
The appearance and area of paint damage
will determine the type of paint refinishing
application: brush, spray can or spray gun.
{ A
i
* B-pillar trim, installing
, Install all components in reverse order of
removal
— lo 4
* ss . . x -
ый
я | a. В | | о
Coupe E-piltar trim. removing/Installing "66. 23
Body Accessories — Exterior
Support —]
A-pillar trim—
Roof trim molding
Pop rivet
Plug
~ Roof trim molding |
Sealing washer
remove protective
film before
installing
A
=
'F-10
e,
a
Body Accessories — Exterior
Roof trim-molding, removing
m remove door seat at door glass area
m remove B-pillar trim
m remove side window
m remove side window seal along roof
mM bore out rivet heads with 8.0 mm (5/16 in.)
diameter drill and push remaining rivet
through to the inside
Note
Paint damage may occur by the rivets turning
when being drilled out.
The appearance and area of paint damage
will determine the type of paint refinishing
application: brush, spray can or spray gun.
Roof trim molding, installing
Install molding in reverse order of removal,
noting the following:
Note | ‘ей
To avoid paint damage, guide the roof trim
molding in place with aid of heiper.
a remove protective fiim from support prior to
installing
FIT
Coupe | Roof trim molding, removing/installing- 66 «25
. Body Accessories — Exterior
Protective molding, rear
install gasket first
| Gasket
protective ,
. molding, rear /
protective |
molding, door
Protective molding, door
install gasket first
# - | 7
"Protective molding, front ~ 7 4— Protective molding, front
- _ : В | Support. “ В
- Nut- , remove protective
25 Nm (22 in Ib) a — paper first ;
F-12
Coupe | protective moldings. assembly 66 «26
Body Accessories + Exterior
à
!
Fender, front
Moiding, door Doo
pull out end cap
and pull molding
toward back
' Side panel
>
Molding, rear
pull out end cap
and pull molding
toward back
from the clips trom the clips >
Molding, front
Clip
Ww
Nut —— , Molding, rear
; 1.0 Nm (8 in. Ib) pull out end cap
and pull molding
—— Molding, door
- pult out end cap
-and pull molding
toward back
from the clips
toward back
Washer
from the clips
“Molding, front
чл
R13
Rocker panel moldings, assembly 6 6 = 27 |
i Body Accessories — Exterior
Clip |
install before , .
mounting sill-trim
SHI trim
secured with adhesive
remove protective film
before installing
Y
ov
Coupe | poor sit trim, assembly 66.28
Body Accessories — Exterior
+
D Front license plate trim, assembly
1 = nut
e 4 Nm (35 in Ib)
. 2 = split rivet
3 = license plate trim
e remove protective film before installing
4 = screw/washer
® 4 Мт (35 in Ib)
® secures license plate
= — ——
e € F-15
Co upe 1 Front license plate trim, assembly 66 . 29