Audi A4, S4

since 2000 release

Repair and operation of the car

General information and security measures when carrying out body works

General information

The body is executed in the form of the bearing design. The bottom, sidewalls, a roof and back wings are welded among themselves.

The cowl, trunk lid, doors and forward wings are fixed on bolts and can be replaced. At installation of elements of a body it is necessary to sustain a uniform gap through their interface since otherwise there is a knock of doors or in the course of the movement there is increased wind resistance. The gap has to have identical value on perimeter of a prileganiye of elements of a body. Gap width deviations no more than 1 mm are allowed.

If within carrying out body works it is also necessary to carry out any works with electric equipment, it is necessary to disconnect surely a negative cable (-) of the battery. For this purpose it is necessary to examine materials of the Section Replacement of the Battery. As works with electric equipment it is necessary to consider even disconnection of an electric wire from any conclusion.

Many covers and facings have fastening by means of clips. The damaged or lost clips need to be replaced. Removal and installation of razzhimny and lock clips are considered in appropriate section.

Security measures when carrying out body works

At repair of a body it is necessary to apply spot welding. Only if it is impossible to bring electrodes to a place of welding, it is necessary to apply welding in the environment of inert gases.

· When carrying out the welding works or any other works connected with formation of sparks surely switch-off the battery (positive and negative cables) and carefully isolate both plugs (-) and (+). When working near the battery, it needs to be removed.

At removal of the battery the memories given from electronic blocks, in particular, a radio receiver code are erased. Without code the radio receiver can be switched on only by his manufacturer or HUNDRED. Study remarks in the Section Replacement of the Battery.

· Models with the conditioner: It is not allowed to make welding and the soldering soft or solid solders of the elements of the conditioner filled with coolant. It belongs also to production of welding and the soldering of elements of the car if it can lead conditioner elements to heating.

· When welding galvanized sheets poisonous oxide of zinc is formed. Therefore it is necessary to watch good ventilation of a workplace.

· Increase welding current by 10, at most 30%.

· Apply electrodes from solid copper with high thermal resistance (above + 400 °C).

· Clear electrodes more often and process them to diameter of a contact surface of 4 mm.

· Increase pressure upon an electrode.

· Increase welding time. Time is chosen truly if welding ends are put without splashes.

· It is not necessary to open a contour of cooling of the conditioner since coolant at hit on skin can cause frostbite.

· At casual hit of coolant on skin it is necessary to wash out an affected area cold water within not less than 15 min. Coolant evaporates at an external temperature. Coolant has no color and a smell, and also it is heavier than air. As availability of coolant is not felt, around the bottom of the car and in a viewing hole there is a danger of suffocation.

Drying of a paint and varnish covering: When carrying out painting works in the course of repair drying in furnaces should not be made at a temperature over + 70 °C. Otherwise electronic devices of the car can be damaged. Besides, thus in the conditioner pressure that will lead to destruction of system can increase.

Removal of a polyvinylchloride sheeting of the bottom of the car: For protection against corrosion the polyvinylchloride sheeting is applied on the bottom of the car and wheel arches. The sheeting is removed the rotating steel brush or hot air temperature to + 180 °C by means of the pallet. Owing to heating of a covering from PHV up to the temperature over 180 °C there is a chemical reaction and the hydrochloric acid promoting active corrosion is formed, besides, unhealthy couples are formed.