Audi Workshop Service and Repair Manuals

Door seals Special tools and workshop equipment required

t  Roller -3356-

t  Adhesive strip remover -VAS 6349-

Removing and installing inner door seal

1 -	Inner door seal

q	Remove trim for window frame → Rep. gr.70.

q	Detach door arrester from A-pillar.

q	Fitted on body flange all around

q	To remove, detach from body flange.

q	When installing, align seal with vulcanised butt joint on lower hinge and press onto vehicle body flange by hand.

2 -

Door

Renewing outer door seal

t	The complete outer door seal is bonded on and can only be renewed.

t	The vehicle and the outer door seal must be at room temperature.

t	Bonding surfaces must be free of dust and grease (clean with cleaning solution -D 009 401 04-).

t	Apply primer -D 355 205 A2- to bonding surfaces on body using applicator -D 009 500 25- and allow to flash off.

t	The water drain holes are positioned correctly when they are on the underside of the door.

1 -	Outer door seal

t	Prior to removal, mark position of seal on door e.g. with adhesive tape.

t	To prevent any residual adhesive from remaining on door, first stretch seal lengthwise and only then pull seal off door.

q

Removing

–	Pull seal slightly off door at top of window frame and cut through with scissors or similar (commercially available).

–	Stretch seal lengthwise and then gradually pull off upwards → Anchor.

q	Installing

–	Bonding surfaces must be free of dust and grease. Clean bonding surfaces with cleaning solution -D 009 401 04-; if necessary use adhesive strip remover -VAS 6349- to remove any adhesive residue.

–	Apply primer -D 355 205 A2- to bonding surface using applicator -D 009 500 25- and allow to flash off.

–	Detach door arrester from body → Anchor.

–	Fasten outer door seal behind door arrester.

–	Secure door arrester again.

t	Align marking on outer door seal with top corner at B-pillar.

t	Secure outer door seal to window frame (top, front and rear) with adhesive tape → Item.

t	When positioned correctly, the water drain holes (3x) in the outer door seal are located on the underside of the door.

t	When pressing on outer door seal, start in centre at bottom and gradually continue towards front and rear.

–	Peel off protective film in area of underside of door.

–	Press outer door seal onto underside of door in centre and continue outwards to both sides.

–	Gradually peel protective film off further on both sides and press on outer door seal.

–	Press on outer door seal upwards along A-pillar and B-pillar.

–	Finally press on outer door seal at top along window frame.

Caution t  When installing, do not stretch or compress door seal. t  If the outer door seal is stretched or compressed on the underside, at the A-pillar or at the B-pillar, the seal could become detached. t  The outer door seal can only be stretched or compressed in the area of the window frame at the top (in this area the seal is secured in place by the window frame cover).

–	Press on base of outer door seal → Item using roller -3356-.

Caution To prevent the outer door seal from becoming detached or misaligned, it is important that the door is not closed for at least two hours; the vehicle must be stationary at room temperature.

2 -

Door

Detaching door arrester –  Unscrew bolt -arrow- for door arrester. –  Fasten seal behind door arrester and tighten bolt to specified torque → Item. Marking position of seal

–  Mark position of seal at window frame and...

–  ...around door lock with adhesive tape.

Detaching seal   Note By stretching the outer door seal lengthwise, the adhesive is separated from the door and the seal can be detached from the window frame without leaving any adhesive. –  Gradually stretch outer door seal -1- lengthwise -arrow-, as shown, and detach. –  Proceeding step-by-step, pull outer door seal off all around door shell. –  Remove any residual adhesive from window frame with adhesive strip remover -VAS 6349-.

Installing outer door seal (on new door)

t	The front section of the seal must be positioned on the window frame at the transition area of the radius -arrow- and pressed on.

t	To make installation easier, mark position according to dimensions and press on seal.

1 -	Outer door seal

q	After making marks at transition areas between radius and straight sections, perform the remaining installation steps as described previously → Anchor.

q	From the door lock upwards to the lower door hinge, the rear edge of the seal must be positioned at the transition point of the inside radius to the straight section, as shown.

q	From the lower door hinge on the underside of the door to the door lock, the front edge of the seal must be positioned at the transition point of the outside radius to the straight section.

–	Press seal into place all around door shell using roller -3356- → Anchor.

2 -

Door

Bonding area for outer door seal l  In the area -A- from the door lock to the lower door hinge, the rear edge of the seal must be positioned at the transition point of the inside radius to the straight section. l  In the area -B-, the front edge of seal must be positioned at the transition point of the outside radius to the straight section.

Pressing on outer door seal

1 -	Front door

2 -	Outer door seal

–	When installing outer door seal, first secure it to top of window frame -arrows-.

Caution Only press on base of outer door seal using roller -3356-.

–	Fold outer door seal upwards, as shown in detail view, and press base on firmly all around using roller -3356-.