Audi 80/Avant (B4)

since 1991-1995 release

Repair and operation of the car



Audi 80/Avant
+ Technical specification
+ Engines
+ System of production of the fulfilled gases
+ Cooling system
+ Fuel tank and fuel pump
+ Air filter and airintaking channels
+ System of injection
+ Coupling
+ Transmission and transmission
+ Suspension bracket and steering
+ Brake system
+ Anti-blocking system of brakes
+ Wheels and tires
+ Body electrical system
+ System of ignition
+ Lighting
+ Signaling devices
+ Devices and auxiliary devices
+ Heating and ventilation
- Body elements
   Front bumpers
   Forward part of the car
   Cowl
   Wings
   Moldings
   Doors
   External rear-view mirrors
   Forward and back flew down
   Trunk lid at the sedan
   Back door of the versatile person
   Rear bumper
   Movable hatch
   Clearing of openings for a water drain
   Control of anticorrosive protection of the bottom of a body
   Salon
   Seats
+ Search of malfunctions
+ Specifications





Doors

Feature of Audi 80 are doors, two-piece. An internal part of doors, a framework for a hinge plate of mechanisms, it is fixed on an external part, a basic element of a door, four bolts. Thanks to it at small damage to road accident it is possible to replace an external part, without spending time for shift of mechanisms of window regulators and unblocking.

Care of door laying

External door laying in Audi 80 demands special leaving as sealing laying with cracks not only is not tight, but also causes strong noise from an air pressure during a trip. The best laying care product are a cervine fat. It has one more useful effect: to prevent freezing of laying to a body in the winter.

Removal of a door

Sleva: bolts of a door loop – on an illustration a back door:

1 – fixing bolts of a door;
2 and 3 – adjusting bolts.

On the right: the locking bolt can be regulated in all directions (arrow) to provide faultless closing of a door.


The top element of an armrest of a door (1) 4-and 5-cylinder models – the version without switch – is fastened to a covering in four places. The mechanism of regulation of rear-view mirrors (2) is removed, adjusting castors (3 and 4) are disconnected.


On this illustration removal of an armrest (2) on 6-cylinder model is shown. In total it is necessary to turn out three bolts with an internal hexagon then it is possible to remove an armrest from holders. To carefully take out the block of switches (1) from a support.

Sleva: the panel (1) of the handle of a window regulator (2) can be removed after pressing a fixing uvula (3).

On the right: from a reverse side of the mechanism of opening of a door it is necessary to remove before removal of a covering of a door porolonovy laying (1). Then to remove a bracket (2) and to disconnect the end of a cable (3).


 PERFORMANCE ORDER

  1. On models with the loudspeakers installed in the doorway, electric adjustment or electrowindow regulators for separation of cable shtekerny connections it is necessary to remove a door covering. As to make it, it is described in the following section. The same needs to be made with wires and hoses of system of locks with the central management.
  2. To turn out two six-sided bolts from the top and lower loop, to remove a door. Hinges remain on a body.
  3. After installation to level a new door (see the following section).

Correct installation of a door

 PERFORMANCE ORDER

  1. For installation and adjustment of a door the car has to stand horizontally on the earth all four wheels. If the car is raised, then the body can warp slightly because of what as a result the door will be warped.
  2. Adjustment is made by the following criteria:
    width of a gap of the first and rear edge of doors has to make 5–6,5 mm. Otherwise to move doors.
  3. The contour of a body has to be coordinated: check on all perimeter whether there passes the middle line at height of door handles exactly, without steps, and whether the door too low or too highly is established.
  4. It is necessary to take care of a noise isolation. It can achieve by the correct installation of doors: a first line back doors come on an average rack. On this place the rack/door distance at the closed door is measured. It has to make 14,5 mm. Proceeding from this gap other edges of doors are exposed: the first line of a forward door has to be 0,5-1 mm more deeply, than a forward wing. The rear edge of a forward door has to act 0,5-1 mm further rather first line of a back door. And the rear edge of a back door has to act on the same distance over a back wing.

Alignment of a door

 PERFORMANCE ORDER

  1. Regulation across for installation of a door gap: to turn out a back bolt on connection of a loop and body, and then to turn out a little the carving plug located behind it.
  2. To weaken a little a forward bolt on connection of a loop and body, so that it was possible to shift a door.
  3. To close a door and to expose a door gap.
  4. It is careful to open a door and to tighten forward bolts of a loop.
  5. To screw the carving plug to a prileganiye, to tighten a back bolt.
  6. Regulation down (contour): to weaken bolts between a loop and a body (as already became), to shift a door up or down.
  7. Again to tighten bolts.
  8. Regulation sideways, first line of a door (noise isolation): to weaken bolts between a loop and a doorframe.
  9. To close a door and to shift it in a door opening according to the standard sizes.
  10. To open a door, to tighten bolts.
  11. Regulation sideways, rear edge of a door (noise isolation):
  12. To weaken a little locking bolt which the door lock enters.
  13. To close a door and to shift it in a door opening according to the standard sizes.
  14. To open a door, to tighten the locking bolt.
  15. Check from within the car whether the door adjoins to rubber sealing laying evenly.
  16. Installation of a frame of a window: when the basic element of a door is adjusted correctly, it is necessary to check a window frame arrangement in a door cut. At the same time external door sealing laying should not support a roof lath.
  17. If it is necessary to regulate, then remove a covering of a door and weaken four fixing bolts of a frame of a window.
  18. To close a door.
  19. Ask the assistant to press a frame into a door cut – better to press a little stronger – the elastic band will soften.
  20. If installation is right, to tighten bolts from within (at first top). Inhaling moment: 20 N • m.

Removal of a covering of a door

Screws which need to be unscrewed for removal of a covering of a door

1, 2 – screws above at end faces;
3, 4 – fixing screws of the top panel of an armrest;

5 – screws of the lower panel of an armrest;
6 – window regulator handle screw; the screw in the mechanism of opening of a door is not visible.


At the removed door covering become visible

1 – window regulator drive mechanism screws;
2, 5 – screws of the directing tire;

3, 6 – threaded connections of both elements of a door.
4 – screw of fastening of the door handle.

Below removal of a covering of forward doors is described. Removal of a covering of back doors happens in the same way.

 PERFORMANCE ORDER

  1. Removal of the handle of a window regulator: to enter near a handle axis the screw-driver under a decorative slip and to press a fixing uvula. To remove a covering towards an axis. To turn off the bolts which are under it with crosswise shliyets.
  2. Models with 4-and 5-cylinder engines: the driver's door with switches in a covering: to remove switches (see the description Switches).
  3. Forward doors without switches: to turn out two screws with crosswise shliyets and to remove the lower insert of a polokotnik.
  4. Now access to four screws for removal of the top element opened. To turn out.
  5. To take out (up) both castors from the longitudinal nakatky button of regulation of provision of rear-view mirrors (mechanical regulation). If necessary to help itself the screw-driver.
  6. With the extending effort to give the top insert to the rear edge of a door and to rasfiksirovat latches on a first line of a door (goes very hard).
  7. Now to extend an insert upward.
  8. To raise a little plastic collars of the removed insert and to take out in the direction down the mechanism of regulation of rear-view mirrors.
  9. Models with the 6-cylinder engine: to weaken three screws with an internal hexagon of 4 mm on the lower party of an armrest.
  10. To remove an armrest, to disconnect switches.
  11. To turn off the holder of an armrest.
  12. All models: in the mechanism of opening of a door to pull for the opening lever and to insert the screw-driver into an opening in a cup of the mechanism of opening of a door. To unscrew the screw with crosswise shliyets.
  13. To pull a cup of the mechanism of opening of a door forward and to take out it from clamps.
  14. On a reverse side of the mechanism of opening of a door to remove a bracket and to disconnect a cable.
  15. To turn out on one screw with crosswise shliyets behind and in front on outer side to a door covering.
  16. To remove rubber a sealant in front and behind on a window frame fringing.
  17. The button of locking of a door remains established from within.
  18. Now slightly to knock with edge of a palm (a thumb eminence) from below on a door covering to raise it up and by that to disconnect latches on a reverse side of a covering from a door framework.
  19. To remove a covering.
  20. Before installation to insert rubber crackers into openings of fastenings on a door framework.
  21. In order that it was easier to insert fastenings, crackers should be greased with vaseline or silicone paste.
  22. At installation to watch that the button of locking of a door correctly entered an opening on a covering.
  23. If the new door or a new covering is established, it is possible to adjust the adjusting provision of a covering: for this purpose it is necessary to roll or turn out the adjusting screw above on door inside. Correct situation: the screw head has to be 21 mm below than the sealing laying of a window located opposite.

Removal of the external panel of a door

After receiving small damage of the external panel of a door there can be a need to separate the external panel of a door from a box for the built-in door elements. In this case before installation it is recommended to paint the new external panel of a door. However in this case it is necessary to work especially carefully.

 PERFORMANCE ORDER

  1. To remove a door covering.
  2. To remove a door and to put outer side on soft laying (foam rubber, warm blankets).
  3. To unhook the hummock drive of the mechanism of opening of a door from fixing latches inside to the lock.
  4. To unscrew 4 fixing screws on the face parties of a door (see an illustration above).
  5. To remove in the direction up the external panel of a door.

Removal of the door lock

Removal of the door lock

1 – the lever to a cable of opening of a door (4);
2 – the lever to the mechanism of locking of a door from within (6);

3 – the lever to driving draft from the external door handle (5).

External door handle in unassembled form

1 – the forward fixing screw with a star-shaped key;
2 – driving draft of the mechanism of opening of a door;
3 – door handle;

4 – a level with the lock;
5 – driving draft of the mechanism of locking of a door.


 PERFORMANCE ORDER

  1. To turn out two screws with an internal hexagon of 6 mm.
  2. To slightly pull the lock back, at the same time the connected cables and drafts of drives become visible.
  3. To disconnect cables and drafts from inside of the mechanism of opening of a door and the mechanism of locking of a door.
  4. For a detachment of drafts of the drive from the external handle of a door to turn the lock on 90 °.
  5. For installation of the lock to remove an internal covering to have an opportunity better to bring drives.
  6. For removal of a cable of the mechanism of opening of a door to take away a lock rychazhok the screw-driver from within and to hold it.

Removal of the external handle of a door

 PERFORMANCE ORDER

  1. To remove an internal covering of a door.
  2. To turn out through an opening in door inside the screw with a star-shaped head T25 width (to buy the corresponding key).
  3. At height of the locking cylinder to grope a small latch through a door framework and to turn it on 65 ° to the rear edge of a door.
  4. Now it is possible to remove the door handle inside.
  5. To take out outside the locking cylinder and an external level. At the same time slightly to turn a level.
  6. To disconnect the drive lever from the door lock.

Removal of the locking cylinder

 PERFORMANCE ORDER

  1. To remove the external handle of a door.
  2. To insert a key into the lock cylinder in order that at taking out of the cylinder locking plates and springs at the same time did not drop out.
  3. To remove a lock ring on the back end of the locking cylinder.
  4. To remove capture and an elastic element, at the same time to notice their situation for repeated installation.
  5. To take out from a level the lock cylinder in the direction forward.
  6. To apply the spray isolating and deleting a rust on the new cylinder of the lock.

Removal of window regulators

 PERFORMANCE ORDER

  1. To remove a door covering.
  2. To disconnect a box for the built-in door elements. The external panel of a door remains connected to the car.
  3. To wring out a lock ring of fastening of a window regulator and glass. To remove lining washers, to disconnect glass.
  4. To turn out fixing screws of the drive and a window regulator; at the power window it is necessary to weaken nuts instead of screws.
  5. The window regulator and the driving mechanism or the electric motor of a window regulator represent the uniform block and can be removed or replaced only in a set.

Removal of door glass

 PERFORMANCE ORDER

  1. To remove the window regulator mechanism (see the previous section).
  2. To remove caps from a glass guide.
  3. To extend glass from a guide in the direction down.
  4. After glass installation from below to insert a cap into a guide. The distance between bottom edge of a cap and bottom edge of a guide of glass has to make 25 mm.
  5. Again to establish a window regulator.

Moldings

Moldings on doors are pasted. Removal and installation are described above in this chapter.








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