Audi Workshop Service and Repair Manuals

Working instructions: Filling with foam Replacement parts t  2 x 2-pack rigid epoxy foam -D 506 110 A3- t  Accessories 8T0 898 803 A t  18 x pop rivet N 910 197 01 t  Body sealant Special tools and workshop equipment required t  Drill -VAS 5830- t  Twin cartridge gun -VAS 6453-

t  Pneumatic pop rivet tool -V.A.G 2003A-

t  Pop rivet nut pliers -VAS 5073-

–	Heat the rigid epoxy foam cartridge for 30 minutes in a water bath with a constant temperature of approx. 60 °C.

If available, the cartridge can be heated at 60° C in a stove.

1 -	2-pack structural foam cartridge

–	Open the cap

2 -	Static mixer

3 -	Extension hose

4 -

Adapter

The adapter is required for applying the foam.

5 -

Union nut

–	Screw with the static mixer -2 - onto the structural foam cartridge -1 -.

Steps 1-6 of the foam filling operation using the twin cartridge gun -VAS 6453-

Preparing the extension hose

–	Mark the hose at 20 mm, 60 mm and 100 mm.

–	Mask the adjacent rivet holes with commercially available adhesive tape.

–	Use a Ø 6 mm bit to drill off the clinch bolt.

–	Seal the hole.

To avoid the need for a top coat, apply a thin layer of one-pack wash primer LLS MAX 101-104 (use a brush if applicable) and allow to dry for 10 -15 minutes. Forced drying with a hairdryer or infrared dryer is not permissible.

Then apply two-pack filler LLS MAX 201.

On completion of the flash-off time, harden under an infrared lamp at 60° C for approx. 5 minutes.

–	Start with the foam filling operation, perform steps 1 - 3 as shown.

–	Mark the hole for the foam filling operation (95 mm -5 mm from the rivet for the decorative roof trim) and mark the centre of and centre punch the hole - a -.

–	Use a Ø 6 mm bit to drill the hole.

–	Countersink the hole with a 90° cutter.

–	Seal the hole.

To avoid the need for a top coat, apply a thin layer of one-pack wash primer LLS MAX 101-104 (use a brush if applicable) and allow to dry for 10 -15 minutes. Forced drying with a hairdryer or infrared dryer is not permissible.

Then apply two-pack filler LLS MAX 201.

On completion of the flash-off time, harden under an infrared lamp at 60° C for approx. 5 minutes.

–	Start with the foam filling operation, perform steps 4 -6 as shown.

Step 1

To facilitate insertion between the outer and inner panels, flatten the extension hose -arrows-.

–	Insert approx. 100 mm of the extension hose vertically into the opening for the clinch bolt at the front.

–	Start with the foam filling operation and apply foam as far as the first mark (graduation 11).

Step 2

–	After reaching the first mark, the hose must be pulled out by approx. 40 mm.

–	Proceed with the foam filling operation as far as the second mark (graduation 16).

Step 3

–	After reaching the second mark, the hose must be pulled out by approx. 40 mm.

–	Proceed with the foam filling operation as far as the third mark (graduation 23).

Pull the extension hose out of the opening.

–	Use a cloth to wipe off any surplus rigid epoxy foam.

To ensure that the decorative roof trim can be inserted, the two-pack rigid epoxy foam must be removed from the holes for the rivet.

Insert the clinch bolt using the pop rivet nut pliers -VAS 5073-.

Step 4

–	Insert approx. 100 mm of the extension hose vertically into the opening of the drilled hole at the rear.

–	Start with the foam filling operation and apply foam as far as the fourth mark (graduation 31).

Step 5

–	After reaching the mark, the hose must be pulled out by approx. 40 mm.

–	Proceed with the foam filling operation as far as the fifth mark (graduation 37).

Step 6

–	After reaching the mark, the hose must be pulled out by approx. 40 mm.

–	Proceed with the foam filling operation and use up the whole cartridge.

–	Use a cloth to wipe off any surplus rigid epoxy foam.

–	Coat the pop rivet nut and the hexagon socket head bolt (M4) with body sealant, e.g. Terolan Hell.

–	Insert the M4 pop rivet nut using the pop rivet nut pliers -VAS 5073-.

–	Screw in the M4 hexagon socket head bolt as far as it will go and fill the hole with body sealant.

–	Use a cloth to wipe off any surplus Terolan Hell body sealant.

Note After filling the first side with foam, fit the decorative roof trim and then start with the next side.   Note t  After applying the foam fill, the vehicle must be left standing on a flat surface for 24 hours at an ambient temperature of 15° C to allow the rigid epoxy foam to harden (curing time). t  The decorative roof trim and side window can only be re-installed on the vehicle following completion of the curing time.