SM 21

Service
Workshop Manual
Audi A3 2004 ➤
General body repairs, exterior
Edition 09.2015
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
58 - Rear doors, door components
60 - Sunroof
63 - Bumpers
64 - Glazing
66 - Exterior equipment
Technical information should

Protected always
by copyright. Copyingbefor private
available to the
or commercial foremen
purposes, in part or inand mechanics,
whole, is not because their
careful and constant adherence to the instructions is essential to ensure vehicle
road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt A0050306220

Audi A3 2004 ➤
General body repairs, exterior - Edition 09.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Notes on repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Routing and attaching pipes/hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Bonding surfaces for adhesive strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Self-locking bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Exploded view - lock carrier with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Exploded view - wing (RS 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Removing and installing trim cover (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Removing and installing closureProtected plate by.copyright.
. . . . . Copying
. . . . .for. private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. in. .whole,
. . . is. not
. 13
2.5 Removing and installing wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 14
2.6 Removing and installing wing bracket (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Removing and installing noise insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Removing and installing cable for bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3 Lining for bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.4 Bonnet seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.5 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 Rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Removing and installing rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Removing and installing rear lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Removing and installing gas strut for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.5 Removing and installing rear lid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.6 Adjustment dimensions for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.8 Removing and installing handle trim for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3 Tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Removing and installing tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Tank flap unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.1 Removing and installing window frame and window regulator . . . . . . . . . . . . . . . . . . . . . . 39
1.2 Removing and installing window regulator and door window . . . . . . . . . . . . . . . . . . . . . . . . 43
1.3 Removing and installing window guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.4 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.5 Adjusting door (vehicles with 3 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.6 Making adjustments using template T40038/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.7 Adjusting front door (vehicles with 5 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Contents i
Audi A3 2004 ➤
1.9 Renewing inner window slot trim strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

1.10 Renewing outer window slot trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.11 Exploded view - front door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.12 Removing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.13 Removing and installing outer door handle trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.14 Removing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.15 Removing and installing cover for door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2 Central locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.1 Overview (vehicles with 3 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.2 Overview (vehicles with 5 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.3 Removing and installing convenience system central control unit . . . . . . . . . . . . . . . . . . . . 66
2.4 Removing and installing tank filler flap locking motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.5 Removing tank filler flap locking motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

1 Rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.1 Removing and installing window frame and window regulator . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Removing and installing window regulator and door window . . . . . . . . . . . . . . . . . . . . . . . . 73
1.3 Removing and installing window guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.4 Removing and installing outer window slot trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.5 Removing and installing window regulator motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.6 Adjusting rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.8 Adjustment dimensions for rear door window frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.9 Exploded view - rear door handle and door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.10 Removing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.11 Removing and installing outer door handle trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.12 Removing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
60 - Sunroof . . . . . . . . . . . . . . . . . . . . . . . .Protected
. . . . by. .copyright.
. . . .Copying
. . . .for. private
. . . or. commercial
. . . . . purposes,
. . . . .in.part
. .or in87
whole, is not
1 Sliding/tilting sunroof (vehicles with 3 doors)with .respect . . . .to. the
. . correctness
. . . . . . .of.information
. . . . . .in. this
. . document.
. . . . . . Copyright
. . . . . by AUDI
87 AG.
1.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Manual operation of electrical glass sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.4 Removing and installing sliding sunroof motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.5 Adaption for sunroof motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.6 Checking zero position for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.7 Adjusting zero position for sliding/tilting sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.8 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.9 Removing and installing glass sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.10 Adjusting glass sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.11 Removing and installing seal for glass sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.12 Removing and installing sunroof headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.13 Removing and installing frame for sunroof operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2 Water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2 Cleaning water drain hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3 Sliding/tilting sunroof (vehicles with 5 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Removing and installing roof module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.2 Minimum drying times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.3 Assembly parts (exterior) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.5 Removing and installing sunroof panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.6 Removing and installing cable guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.7 Exploded view - cross strut and sunroof sun blind (front) . . . . . . . . . . . . . . . . . . . . . . . . . . 122
ii Contents
Audi A3 2004 ➤
3.8 Removing and installing sunroof sun blind (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

3.9 Removing and installing sliding sunroof motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1 Bumper (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Removing and installing bumper (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Attachment points for bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.3 Removing and installing trim grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.4 Installing brackets for parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2 Bumper (front) - RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.1 Exploded view - bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.2 Removing and installing bumper cover (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
2.3 Removing and installing closure plate for bumper cover (front) . . . . . . . . . . . . . . . . . . . . . . 148
2.4 Removing and installing spoiler (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.5 Removing and installing bumper cover mounting (front) . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.6 Removing and installing impact absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.7 Removing and installing cover for headlight washer jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.8 Removing and installing air intake grille and trim strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.9 Exploded view - impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.10 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
2.11 Removing
Protected andCopying
by copyright. installing connecting
for private or commercialpiece
purposes, .in.part
. . or. .in.whole,
. . . .is.not .......................... 153
2.12 Removing
permitted and installing
unless authorised by AUDI AG.mounting
AUDI AG does fornotimpact
guaranteebar
or accept. . .any. .liability
........................... 154
3 Bumper (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.1 Exploded view - bumper cover (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.2 Removing and installing bumper cover (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.3 Removing and installing guides (side/rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.4 Removing and installing bumper cover trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.5 Removing and installing bumper cover (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . 160
3.6 Removing and installing bumper cover mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.7 Removing and installing impact bar (vehicles without towing bracket) . . . . . . . . . . . . . . . . 161
3.8 Removing and installing impact bar (vehicles with towing bracket) . . . . . . . . . . . . . . . . . . 161
3.9 Installing brackets for parking aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4 Bumper (rear) - RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.1 Exploded view - bumper cover (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.2 Removing and installing bumper cover (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.3 Removing and installing bumper cover trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.4 Removing and installing guide (rear) for bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.5 Removing and installing guide (side) for bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.6 Removing and installing bumper cover mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.7 Removing and installing bumper cover (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.8 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1 Flush-bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
1.1 Removing and installing flush-bonded windows - general comments . . . . . . . . . . . . . . . . 174
1.2 Repairing windscreen using special tool VAS 6092 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
1.4 Minimum drying times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.1 Exploded view - windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.2 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.3 Preparations before installing a new windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
2.4 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
2.5 Removing and installing rain sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.6 Installing fastening strip for water deflector strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Contents iii
Audi A3 2004 ➤
3 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

3.1 Exploded view (vehicles with 3 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.3 Removing undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.4 Removing damaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.5 Preparations before installing a new rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.6 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4 Removing and installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.2 Removing undamaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.4 Removing undamaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.5 Removing damaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.6 Preparations before installing a new window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.7 Installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

1 Strips and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.1 Removing and installing trim panel for B-pillar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
1.2 Renewing protective side strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
1.3 Trim cover on door (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
1.4 Renewing sill panel trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2 Strips and panels - RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.1 Exploded view - outer sill panel trim, side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
2.2 Removing and installing sill panel trim (front and rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.3 Removing and installing side member trim for wing panel . . . . . . . . . . . . . . . . . . . . . . . . . . 217
2.4 Removing and installing side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3 Removing and installing roof rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4 Exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.1 Exploded view - exterior mirror - vehicles up to 05.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.2 Installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.3 Removing and installing mirror adjustment motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.4 Removing and installing mirror housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
223
4.5 Exploded view - exterior
with respect mirror of(vehicles
to the correctness from
information in 06.2009
this document. onwards)
Copyright by AUDI AG. .................... 225
4.6 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
4.7 Removing and installing housing for exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.8 Removing and installing cover for mounting for mirror adjustment unit . . . . . . . . . . . . . . . . 228
4.9 Removing and installing mounting for mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . 228
4.10 Removing and installing mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
5 Radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.1 Exploded view - radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.2 Exploded view - radiator grille, RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.3 Removing and installing RS 3 emblem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
5.4 Removing and installing radiator grille - RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
5.5 Removing and installing Audi rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
6 Spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
6.1 Exploded view - spoiler for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
6.2 Removing and installing wheel spoiler (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
6.3 Removing and installing wheel spoiler (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
6.4 Exploded view - wheel spoiler, RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
6.5 Removing and installing wheel spoiler (front) - RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
6.6 Removing and installing wheel spoiler (rear) - RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
7 Underbody trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
7.1 Exploded view - heat shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
iv Contents
Audi A3 2004 ➤
7.2 Removing and installing heat shield for floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

7.3 Removing and installing heat shield for propshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
7.4 Removing and installing heat shield for tunnel (centre) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
7.5 Removing and installing heat shield for rear silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
7.6 Removing and installing cross member for underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
7.7 Removing and installing Cd underbody panelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
8 Wheel housing liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
8.1 Removing and installing wheel housing liner (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
8.2 Removing and installing wheel housing liner (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
8.3 Exploded view - wheel housing liner, RS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
8.4 Removing and installing front section of wheel housing liner (front) - RS 3 . . . . . . . . . . . . 245
8.5 Removing and installing rear section of wheel housing liner (front) - RS 3 . . . . . . . . . . . . 245
8.6 Removing and installing wheel housing liner (rear) - RS 3 . . . . . . . . . . . . . . . . . . . . . . . . 246
9 Brand emblems and model badges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.1 Emblems and badges on rear lid (vehicles with 3 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . 247
9.2 Emblems and badges on rear lid (vehicles with 5 doors) . . . . . . . . . . . . . . . . . . . . . . . . . . 249
9.3 Emblems and badges on rear lid (S3, RS 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Contents v
Audi A3 2004 ➤
vi Contents
Audi A3 2004 ➤
00 – Technical data
1 Notes on repairs
(ARL004417; Edition 09.2015)
⇒ “1.1 Routing and attaching pipes/hoses and wiring”,
page 1 ⇒ page 1
⇒ “1.2 Contact corrosion”, page 1 ⇒ page 1
⇒ “1.3 Bonding surfaces for adhesive strips ”, page 1
⇒ page 1
⇒ “1.4 Self-locking bolts”, page 2
1.1 Routing and attaching pipes/hoses and

wiring
Make sketches or take photographs when unfastening or remov‐
ing and installing hydraulic and pneumatic lines or electrical wires.
This ensures that you can re-install them at the original location.
1.2 Contact corrosion

Contact corrosion can occur if unsuitable fasteners (bolts, nuts,
washers etc.) are used on the vehicle.
For this reason, only fasteners with a special surface coating are
fitted.
In addition, all rubber or plastic parts and all adhesives are made
of non-conductive materials.
Should you have any doubts whether certain parts can be re-
used, use new parts (refer to Electronic parts catalogue).
Please note:
♦ We recommend using genuine replacement parts only, as
these have been checked and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by the
warranty.
1.3 Bonding surfaces for adhesive strips

♦ The vehicle must be at room temperature before fitting e.g.
self-adhesive covers or door seals with adhesive stripstoetc.
with respect the correctness of information in this document. Copyright by AUDI AG.
♦ Bonding surfaces on the body must be free of dust and grease.

♦ Clean bonding surfaces with cleaning solution - D 009 401
04- .
♦ Apply primer - D 355 205 A2- to bonding surfaces on body
using applicator - D 009 500 25- and allow to flash off.
♦ Heat bonding surfaces with a hot air blower to around 40℃.
♦ After installation, press covers attached with adhesive strips
on again using a roller.
♦ Subsequently, check that components are attached securely
by pulling them with your hand.
1. Notes on repairs 1
Audi A3 2004 ➤
1.4 Self-locking bolts

If bolts secured with microencapsulation have been removed,
they must be renewed, and the threaded holes must be cleaned
with a suitable tap.
2 Rep. gr.00 - Technical data

Audi A3 2004 ➤
50 – Body - front
1 Body - front
⇒ “1.1 Tools”, page 3
⇒ “1.2 Exploded view - lock carrier with attachments”, page 3
⇒ “1.3 Removing and installing plenum chamber cover”,
page 7
1.1 Tools
Special tools and workshop equipment required
♦ Guide pins - T10093-
1.2 Exploded view - lock carrier with attachments

Vehicles up to 06.2008
1. Body - front 3
Audi A3 2004 ➤
1 - Lock carrier
❑ Take off bumper cover
before removing
⇒ page 134
Note
Lock carrier can be removed with

headlights and radiator installed.
❑ If radiator is also re‐
moved, drain coolant
beforehand.
❑ Unplug electrical con‐
nectors for headlights.
❑ Unplug connection for
headlight washer sys‐
tem and disconnect wir‐
ing.
❑ Bonnet lock must be re‐
moved ⇒ page 18 or
Bowden cable for bon‐
net release switch must
be unplugged from cou‐
pling unit
⇒ Item 1 (page 22) .
❑ To remove, unscrew
bolts -3- and -8-.
❑ Detach lock carrier to
front.
2 - Torx bolt
❑ 10 Nm
3 - Torx bolt
❑ 23 Nm
4 - Bracket for bumper
❑ Can remain installed when removing lock carrier.
❑ Removal ⇒ page 6
5 - Washer
6 - Hexagon nut
7 - Bumper
❑ Removing ⇒ page 134
8 - Hexagon bolt
❑ 60 Nm
Note
Service position: Screw guide pins -

T10093- into top outer bolt holes for
brackets securing the bumper. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Vehicles from 06.2008 onwards
4 Rep. gr.50 - Body - front

Audi A3 2004 ➤
1 - Foam section
❑ Pressed onto bumper
2 - Bumper
– To remove, unscrew
bolts -3- and detach
bumper forwards, pull‐
ing it out of brackets.
3 - Bolt
❑ 28 Nm
4 - Bolt
❑ 16 Nm
5 - Lock carrier
❑ Bumper cover removed
⇒ page 134
Note
Lock carrier can be removed with

headlights and radiator installed.
❑ If radiator is also re‐

moved, drain coolant

beforehand.
nectors for headlights.
❑ Unplug connection for
headlight washer sys‐
tem and disconnect wir‐
ing.
❑ Bonnet lock must be re‐
moved ⇒ page 18 or
Bowden cable for bon‐
net release switch must
be unplugged from cou‐
pling unit ⇒ Item 1 (page 22) .
❑ To remove, unscrew bolts -4- and -6-.
❑ Detach lock carrier to front.
6 - Bolt
❑ 50 Nm
Note
Service position: Screw guide pins -

T10093- into top outer bolt holes for
brackets securing the bumper.
7 - Bracket for bumper

8 - Bolt
❑ 5 Nm
9 - Nut
❑ 28 Nm
10 - Cross brace
❑ Only on Cabriolet
11 - Bolt
❑ 8 Nm
1. Body - front 5
Audi A3 2004 ➤
12 - Pop rivet nut

❑ If necessary, press into lock carrier with pop rivet nut pliers - V.A.G 1765C- .
Removing and installing headlight mounting

– Insert headlight housing -2- into mounting -1-; guide rails on
headlight housing should engage in guides on mounting
-arrows-.
– Position mounting with headlight housing between lock carrier

and wing and hand-tighten bolts.
– Install bumper cover (front).
– Align so that correct gap widths are attained between head‐
light housing and body contours.
– Tighten bolts in sequence -1 ... 4- (see illustration).
Note
When tightening bolts -2- and -3-, the nuts of the adjuster ele‐
ments automatically turn towards the mounting points of the
headlight housing to lock the headlight housing in place.
Removing bracket (left-side) for bumper

– Bumper cover removed
– Unscrew hexagon bolts -2-.
– Unscrew Torx bolts -arrow- and detach bracket from bumper.
– When installing, tighten hexagon bolts -2- to 60 Nm.
– Tighten Torx bolts to 8.5 Nm.
Note
Note change in tightening direction and torque on vehicles from
06.2008 onwards ⇒ Item 8 (page 5)

Audi A3 2004 ➤
Removing bracket (right-side) for bumper

– Unscrew hexagon bolts -2-.
– Unscrew Torx bolts -arrow- and detach bracket from bumper.
– When installing, tighten hexagon bolts -2- to 60 Nm.
– Tighten Torx bolts to 8.5 Nm.
1.3 Removing and installing plenum chamber cover

Exploded view
1 - Windscreen
2 - Plenum chamber seal
3 - Plenum chamber cover Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Before removal, lift off

plenum chamber seal
-2- and detach washer
jets.
– To remove cover -3-, lift

it up at front and use a
suitable tool (e.g. tyre
iron) to prise cover out in
direction of -arrow-,
starting from the outside
and staying as close as
possible to surround
-4-.
Caution
When prising out the
cover, make sure you do
NOT push up the sur‐
round -4-. This would
push the surround off the
windscreen, leading to
leaks in this area.
– Support the tyre iron e.

g. with a wooden block
(approx. 4 cm high)
placed on the top of the
suspension turret.
– When installing, do not

"hammer on" the cover,
but gradually push it into
the surround.
1. Body - front 7
Audi A3 2004 ➤
– The surround could otherwise be pressed off the windscreen, which would lead to leaks in this area.
4 - Surround for cover

– No spare part available; must not be pressed off windscreen when installing plenum chamber cover.

Audi A3 2004 ➤
2 Wing
⇒ “2.1 Removing and installing wing”, page 9
⇒ “2.2 Exploded view - wing (RS 3)”, page 11
⇒ “2.3 Removing and installing trim cover (left-side)”, page 13
⇒ “2.4 Removing and installing closure plate”, page 13
⇒ “2.5 Removing and installing wing”, page 14
⇒ “2.6 Removing and installing wing bracket (bottom)”,
page 15
2.1 Removing and installing wing

1 - Wing panel brace permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - Torx bolt
❑ 10 Nm
3 - Torx bolt
❑ 10 Nm
4 - Wing
❑ Take off bumper cover
and wheel housing liner
before removing
⇒ page 134 .
❑ Remove closure plate
⇒ page 10 .
❑ Removing wing panel
cover ⇒ page 11
bolts -3- at wing mount‐
ing flange.
❑ Unscrew bolt -5- with
door open.
❑ Slacken off bolt -6- with
shim.
❑ Unscrew panel bolts
-10- from brace for wing
panels, as well as panel
bolts -8- beneath the
closure plate and de‐
tach the wing panels to
2. Wing 9
Audi A3 2004 ➤
the side.
5 - Bolt with washer
❑ 7.5 Nm
6 - Bolt with washer and shim
❑ 4.5 Nm
❑ When removing the
wing panel, only slacken off the bolt and pull the wing panel out to the side (elongated hole in the tab).
❑ 5 Nm
❑ 5 Nm
❑ Accessible beneath closure plate
9 - Speed nut
❑ 2x
❑ 10 Nm
11 - Cover for wing panel
Removing and installing closure plate

– Wheel housing liner removed ⇒ page 242 .
– Unscrew bolts -1- and take closure plate -3- out of wheel
housing.
– Washer -2-
– Clip -4- fitted in body. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Wing panel -5- with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A3 2004 ➤
Removing wing panel cover

– Unscrew bolts for wheel housing liner in the area of the cover.
– Press wheel housing liner to one side and unscrew bolts -2-.
– Compress retainers -arrows- and pull cover -3- outwards off
wing panel.
– Clip -1- fitted in body.
– Wheel housing liner -4-
Seal for wheel housing liner

– Seal is self-adhesive; remove protective paper and press seal
-1- onto the inner side of the wing panel -2- as shown.
– If necessary, the seal can be be broken out at the perforation
to feed through various wires.
2.2 Exploded view - wing (RS 3)
2. Wing 11
Audi A3 2004 ➤
1 - Fastener
❑ 2x
2 - Trim cover (left-side)
❑ Removing and installing
⇒ page 13
3 - Sealing piece
❑ On inside of wing
4 - Bolt
❑ 2x
❑ 10.5 Nm
5 - Bolt
❑ 3x
❑ 10.5 Nm
6 - Sealing piece (front)
❑ Can only be renewed af‐
ter wing panel has been
removed
7 - Sealing piece (rear)
❑ Can only be renewed af‐
ter wing panel has been
removed
8 - Bolt
❑ 10.5 Nm
9 - Wing
⇒ page 14
10 - Bolt
❑ 2x
❑ 10.5 Nm
11 - Bolt
❑ 4.5 Nm
12 - Washer Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
13 - Nut with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 2x
❑ 3 Nm
14 - Bracket (bottom)
❑ For wing
❑ Removing and installing ⇒ page 15
15 - Bolt
❑ 2x
❑ 4.5 Nm
16 - Closure plate
17 - Bolt
❑ 2x
❑ 1.8 Nm

Audi A3 2004 ➤
2.3 Removing and installing trim cover (left-

side)
Removing
– Remove rear section of wheel housing liner (front)
⇒ page 245 .
– Remove spreader rivets -2 and 3-.
– Take out trim cover (left-side) -1-.
Installing
Install in reverse order of removal; note the following:
– Install rear section of wheel housing liner (front)
⇒ page 245 .
2.4 Removing and installing closure plate

Removing
⇒ page 245 .
– Remove trim cover (left-side) ⇒ page 13 .
– Remove bolts -1 and 3-.
– Pull out closure plate -2- towards front.
Installing
• Tightening torque ⇒ page 11
– Install trim cover (left-side) ⇒ page 13 .
⇒ page 245 .
2. Wing 13
Audi A3 2004 ➤
2.5 Removing and installing wing

Removing
– Remove bumper cover (front) ⇒ page 148 .
– Remove closure plate ⇒ page 13 .
– Remove bumper cover mounting (front) ⇒ page 149 .
– Remove side member trim for wing panel ⇒ page 217 .
– Remove bolts -1, 2, 3-.
– Unscrew bolts -2, 3- and nuts -4-.

– Detach wing panel -1-.
Installing
– Sealing piece (front and rear) must be between wing
permitted unless mounting
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
flange and wing panel. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Install bumper cover mounting (front) ⇒ page 149 .

– Install closure plate ⇒ page 13 .

Audi A3 2004 ➤
2.6 Removing and installing wing bracket

(bottom)
Removing
– Remove wing panel ⇒ page 14 .
– Loosen bolt (top) -4-.
– Unscrew bolts -1 and 2- after removing sealing compound.
– Detach bracket (bottom) -3-.
Installing
– Carry out corrosion protection measures

with respect to and apply sealing
the correctness of information in this document. Copyright by AUDI AG.
compound again ⇒ Audi Paintwork Guide .
– Install wing panel ⇒ page 14 .
2. Wing 15
Audi A3 2004 ➤
3 Noise insulation
⇒ “3.1 Removing and installing noise insulation”, page 16
3.1 Removing and installing noise insulation
1 - Noise insulation
Note
Microencapsulated bolts must be

renewed, and the threaded holes
must be cleaned with a suitable tap.
bolts -2- from subframe
or unscrew bolts -3- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
from wheel housing liner permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
and detach noise insu‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
lation towards rear.
❑ When installing, make
sure that the noise insu‐
lation is inserted at the
front as illustrated in de‐
tail view ⇒ page 16 .
❑ 6 Nm
3 - Panel bolt
❑ 2 Nm
4 - Wheel housing liner
5 - Subframe
6 - Lock carrier
Inserting noise insulation at bottom of lock carrier

– Insert noise insulation -3- into bottom of lock carrier -2- as il‐
lustrated.
– The narrow tabs -arrow a- must be inserted below and the wide
tabs -arrow b- must be inserted above the edge of the lock
carrier -2-.
– The catches on the bigger tabs must engage in the holes of
the lock carrier.

Audi A3 2004 ➤
55 – Bonnet, rear lid

1 Bonnet
⇒ “1.1 Removing and installing bonnet”, page 17
⇒ “1.2 Removing and installing cable for bonnet lock”,
page 22
⇒ “1.3 Lining for bonnet”, page 23
⇒ “1.4 Bonnet seal”, page 24
⇒ “1.5 Removing and installing plenum chamber cover”,
page 25
1.1 Removing and installing bonnet

Exploded view
WARNING
After installing the bonnet check that arrester/bonnet lock close

correctly.
Bonnet must fall into bonnet lock from equilibrium position and
engage fully.
1. Bonnet 17
Audi A3 2004 ➤
1 - Bonnet
nectors before remov‐
ing.
❑ To remove, disengage
gas strut -9- from bonnet
⇒ page 19
❑ Unscrew hexagon bolts
from bonnet hinge (on
bonnet side) and re‐
move bonnet.
2 - Buffer
❑ The two outer buffers
can be used to adjust
height of permitted
bonnet. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Screw in the two inner
buffers as far as possi‐

ble and then slacken off
half a turn.
3 - Cable for bonnet
4 - Bonnet hinge
❑ Before removing, de‐
tach bonnet.
❑ Unscrew hexagon bolt
-6- and then detach bon‐
net hinge.
❑ 21 Nm
6 - Bonnet lock
7 - Lock carrier
8 - Arrester
9 - Gas strut
❑ To remove, slightly raise retaining clip -4- with screwdriver and detach gas strut from ball head stud.
Removing bonnet lock

– Unplug electrical connector and unscrew bolts -3- and -4-.
– Remove bonnet lock -2- from lock carrier -1-.
– Disengage cable from lock.
Only on right-hand drive vehicles
18 Rep. gr.55 - Bonnet, rear lid

Audi A3 2004 ➤
– Unclip cable -2- from bonnet lock -1-.
– Disengage cable from release lever -arrow- in bonnet lock.

– Install in reverse order of removal.
Removing arrester
– Tounless
permitted remove, unscrew
authorised by AUDI AG.cap nuts
AUDI -3- not
AG does and detach
guarantee arrester
or accept -2- from
any liability
bonnet
with respect -1-.
to the correctness of information in this document. Copyright by AUDI AG.
– When installing, tighten cap nuts to 11 Nm.
Removing bonnet hinge

– Bonnet -1- must be removed or securely supported.
– To remove hinge -2- unscrew hexagon nuts -4- and bolts -3-.
Removing and installing gas strut
1. Bonnet 19
Audi A3 2004 ➤
1 - Gas strut
❑ Prop up and secure
bonnet in open position.
– Use screwdriver to
slightly lift retaining clips
-2- off gas strut -arrow-
at both ends of gas strut;
detach gas strut from
ball head studs.
– To install, press gas

struts onto ball head
studs -3- and make sure
they engage.
– The cylinder end of the

gas strut must be instal‐
led on the body side.
2 - Retaining clips
❑ To remove gas strut
merely lift slightly with a
screwdriver.
3 - Ball-head pin
❑ When installing, tighten
to 14 Nm.
4 - Bonnet Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Make sure gas strut with respect to the correctness of information in this document. Copyright by AUDI AG.
does not fall down dur‐
ing removal (secure it
accordingly).
Releasing gas from gas strut

– Clamp gas-filled section -x = 50 mm- of gas strut in a vice.
WARNING
Only the section -x= 50 mm- of the gas strut may be clamped
in the vice (accident risk).
– Saw open the first third of the cylinder part of the gas strut
(measured from the piston rod end of the cylinder).
Note
♦ Protective goggles must be worn during sawing process.

♦ Cover area of separating cut with a cloth.

Audi A3 2004 ➤
Adjusting height of bonnet on vehicles with 5 doors
Note
The bonnet must be adjusted as described in the following in order to avoid wind noises.
1 - Trim frame for radiator grille

2 - Radiator grille
4 - Bonnet
❑ To avoid wind noises set
bonnet height at dis‐
tance -a = 1.5 mm- to
trim frame.
Adjusting height of stop buffers

– With bonnet closed, stop buffers -1-, -2- and -3- must rest
lightly on lock carrier.
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
You can also use the stop buffers to adjust the height.
1. Bonnet 21
Audi A3 2004 ➤
1.2 Removing and installing cable for bonnet lock
1 - Coupling unit for cable

❑ To separate Bowden
cable, fold coupling unit
open in opposite direc‐
tion of arrow.
❑ Disengage cable from
coupling unit.
❑ When installing, push
coupling unit together in
direction of arrow.
2 - Cable, lock carrier side
❑ When removing, dis‐
connect lock carrier at
coupling unit.
❑ Routing (passenger
compartment side
⇒ page 22 ).
3 - Cable clip
❑ Pressed into subframe.
4 - Clip
❑ Secure cable in lock car‐
rier using clip.
5 - Mounting
❑ Engage cable in bonnet
lock.
❑ Make sure that the ball
engages in the tube
mounting.
6 - Bonnet lock
Cable (passenger compartment)

– Separate cable at coupling unit -4-.
– Unfasten grommet -arrow- from bulkhead, pull cable -2- out
from under the seal -3- and into the passenger compartment.
– To remove release lever -3- unscrew bolts -2-.

Audi A3 2004 ➤
– When installing, make sure you press grommet for cable -1-
into bulkhead correctly.
– When installing, tighten bolts to 2 Nm.
– Clip -4- fitted in A-pillar (bottom).
1.3 Lining for bonnet with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Bonnet
2 - Bonnet lining
❑ Pull all retaining clips
out of lining, and detach
lining from bonnet.
3 - Retaining clip
❑ 18x
1. Bonnet 23
Audi A3 2004 ➤
1.4 Bonnet seal
1 - Lock carrier seal

❑ Position seal in centre of
lock carrier (note mark‐
ing for centre) and push
seal from side onto
flange at lock carrier and
wing panels.
2 - Profiled seal (left-side)
❑ Self-adhesive
❑ Before installing make
sure bonding surface is
free of dust and grease.
❑ Remove protective pa‐
per, and press seal on
firmly.
3 - Protected
Plenumby chamber seal
copyright. Copying for private or commercial purposes, in part or in whole, is not
❑permitted
Position moulded
unless authorised ends
by AUDI AG. AUDI AG does not guarantee or accept any liability
onto wing mounting
flange from side (see

-detail view-) and press
seal onto flange from
top, working from out‐
side to inside.
4 - Profiled seal (right-side)
❑ Self-adhesive
❑ Before installing make
sure bonding surface is
free of dust and grease.
❑ Remove protective pa‐
per, and press seal on
firmly.

Audi A3 2004 ➤
1.5 Removing and installing plenum chamber cover
1 - Windscreen
2 - Plenum chamber seal
3 - Plenum chamber cover
4 - Surround for cover
– Before removal, lift off
plenum chamber seal
-2- and detach washer
jets.
– To remove cover -3-, lift

it up at front and use a
suitable tool (e.g. tyre
iron) to prise cover out in
direction of -arrow-,
staying as close as pos‐
sible to surround -4- and
starting from the out‐
side.
Caution
When prising out the
cover, make sure you do
NOT push up the sur‐
round -4-. This would
push the surround off the
windscreen, leading to
leaks in this area.
– Support the tyre iron e.

g. with a wooden block
(approx. 4 cm high)
placed on the top of the
suspension turret.
– When installing, do not

"hammer on" the cover,
but gradually push it into the surround.
– The surround could otherwise be pressed off the windscreen, which would lead to leaks in this area.
1. Bonnet 25
Audi A3 2004 ➤
2 Rear lid
⇒ “2.1 Removing and installing rear lid”, page 26
⇒ “2.2 Removing and installing rear lid hinge”, page 27
⇒ “2.3 Removing and installing gas strut for rear lid”, page 28
⇒ “2.4 Adjusting rear lid”, page 29
⇒ “2.5 Removing and installing rear lid seal”, page 31
⇒ “2.6 Adjustment dimensions for rear lid”, page 32
⇒ “2.7 Removing and installing rear lid lock”, page 32
⇒ “2.8 Removing and installing handle trim for rear lid”,
page 34
2.1 Removing and installing rear lid
1 - Protected
Gas strut
by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ withRemoving
respect to the ⇒ page 29
correctness of information in this document. Copyright by AUDI AG.
❑ Locations for engaging

gas strut on rear lid vary
depending on whether it
is a vehicle
with 3 or 5 doors.
2 - Cap
3 - Adjusting buffer
4 - Pop rivet nut
❑ Riveted into body
❑ When installing, pop riv‐
et nut must rest flat
against body
5 - Rear lid
❑ Removing:
❑ Remove rear lid trim. ⇒
Rep. gr. 70
nectors and disconnect/
detach hose for rear
window washer system.
❑ Remove gas strut.
❑ A second person is re‐
quired to support and lift
off the rear lid.
❑ Unscrew bolts at rear lid

Audi A3 2004 ➤
hinge ⇒ page 27 .
❑ Remove rear lid.
6 - Handle trim
7 - Stop
8 - Torx bolt
❑ 8 Nm
9 - Rear lid seal
10 - Hexagon nut
❑ 20 Nm
11 - Striker
❑ Note different versions.
❑ Rigid version
12 - Striker
❑ Plastic-coated version
2.2 Removing and installing rear lid hinge

Removing
– Detach cover -1- from rear lid hinge -2-.
– Unclip outer roof frame trim -1-.

– Unclip trim -2- from retaining clips -3- and remove trim.
– Remove D-pillar trim. ⇒ Rep. gr. 70
Note
Prop up and secure rear lid to avoid damaging paintwork.
2. Rear lid 27
Audi A3 2004 ➤
– Unscrew nuts -arrows-.
Rear lid hinge on vehicles with 3 doors

– Unscrew bolts -1- and -4- and nut -3-.
– When installing, tighten bolts -1- and -4- as well as nut -3- to
21 Nm.
Rear lid hinge on vehicles with 5 doors

– Detach gas strut at ball head pin (on rear lid side).
– Unscrew ball head stud -1-, hexagon bolt -2- and hexagon nut
-5-.
– Renew seal -4- when re-installing hinge.
– When installing ball head stud, tighten hexagon bolt and hex‐
agon nut to 21 Nm.
– Adjust rear lid ⇒ page 29 .
2.3 Removing and installing gas strut for

rear lid
Caution
Please note that gas struts are installed in different positions

depending on whether it is a vehicle with 2 or 4 doors.
Removing
– Open and prop up rear lid.

Audi A3 2004 ➤
– Use screwdriver to lift retaining spring -3- as shown and lift gas
strut -1- off ball head stud -2- (top).
Note
♦ If gas strut has been completely removed make sure it is re-

installed in the correct position.
♦ On vehicles with 2 doors, damping element must be engaged
on body.
♦ On vehicles with 4 doors, damping element must be engaged
on rear lid.
Installing
Installation is carried out in reverse order; note the following:
– When installing, gas strut is merely pressed onto ball-head
pins.
– Tightening torque for ball-head pin: 20 Nm-1 Nm.
2.4 Adjusting rear lid
Note
Gas struts must be fitted before adjusting new rear lid.
– Remove rear cross panel trim. ⇒ Rep. gr. 70

– Unfasten nuts with washers -1- and -3-; it must be possible to
move striker plate -2-.
– Note different versions.
Note
Ensure correct installation position when fitting striker plate (lug

-arrow- must face rear).
Adjusting buffer for vehicles with 3 doors

– Remove protective cap -1- from adjusting buffer.
– Completely screw in upper part of adjusting buffer -2-, width
across flats: 20 mm.
2. Rear lid 29
Audi A3 2004 ➤
Adjusting buffer for vehicles with 5 doors

– Adjusting buffer is secured with bolts on body side.
– When installing, tighten bolts -3- to 8 Nm.
– Bolts -3- are supplied with adjusting buffer.
– Height adjustment is performed via adjuster screw -arrow- as
on vehicles with 3 doors.
Adjusting buffer with respect to the correctness of information in this document. Copyright by AUDI AG.
– -1- Protective cap (clipped on).

– -2- Adjusting buffer (top section).
– -3- Adjusting buffer (bottom section, with thread).
– When installing for first time, tighten bottom section to 15 Nm
( Torx - (T30)- ).
– Before adjusting rear lid, screw top section of buffer all the way
in.
– Hand-tighten nuts -1- and -3-.

– Close rear lid and align with body contour.
– Rear lid lock must be engaged in main catch (2nd stop).
– Open rear lid in this position and tighten nuts -1- and -3- to
21 Nm.
– Check that rear lid closes easily and without play at lock.
– Repeat adjustment if necessary.
– Unscrew top sections -3- of adjusting buffers until stop buffers

-2- of closed rear lid -1- make contact with adjusting buffers.
– Bottom section of adjusting buffer -3- is screwed into side pan‐
el -4- (15 Nm; Torx - T30- ).

Audi A3 2004 ➤
– Make sure that rear lid has no play by pressing or pulling on

side edges of rear lid beneath rear window.
– If necessary, unscrew adjusting buffers at hexagon flats.
– Check whether rear lid still closes easily. Repeat adjustment
procedure if necessary.
– If rear lid does not close easily, screw in adjusting buffers
slightly at hexagon flats.
– Check adjustment dimensions ⇒ page 32 .
2.5 Removing and installing rear lid seal
1 - Seal for rear lid

❑ Removing:
– Unclip trim at C-pillar
and at roof.
– Open rear lid and de‐

tach seal at C-pillar to
side.
– Detach seal from body

flange at roof and rear
cross panel (bottom),
pulling itpermitted
in longitudinal
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
direction. with respect to the correctness of information in this document. Copyright by AUDI AG.
– When installing, vulcan‐

ised butt joint of seal
must be positioned in
centre of vehicle.
– Press seal -1- onto body

flange as shown.
2 - Rear lid
2. Rear lid 31
Audi A3 2004 ➤
2.6 Adjustment dimensions for rear lid

– Align rear lid in body opening so that gap widths are the same
on right and left.
– Make sure that body surface beneath rear window is flush with
body surface of side panels (rear) -arrows a-.
– Check that rear lid is flush with roof or slightly higher.
♦ Dimension b = 0 to 0.5 mm
2.7 Removing and installing rear lid lock

Exploded view

Audi A3 2004 ➤
1 - Rear lid actuator

❑ Remove together with
mounting plate -3-.
2 - Operating rod
❑ To remove, pivot hinged
lever -8- out of rear lid
lock -6- and disengage
operating rod from rear
lid lock.
❑ When dismantling first
remove actuator.
3 - Mounting plate
❑ Remove with actuator.
❑ Operating rod disen‐
gaged at rear lid lock.
❑ Slacken off bolts -4- and
push mounting plate
with actuator out of elon‐
gated holes.
❑ Disengage actuator with
mounting plate and op‐
erating rod from rear lid.
4 - Torx bolt
❑ 1.7 Nm
❑ For securing mounting
plate to rear lid.
❑ Only slacken bolts for Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
removal. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - Torx bolt
❑ For securing actuator to
mounting plate
❑ 1.7 Nm
6 - Rear lid lock
❑ Remove rear lid interior trim. ⇒ Rep. gr. 70 ; Trim panels
7 - Lock cover
❑ When installing, cover must engage audibly in rear lid lock.
8 - Hinged lever
❑ To remove, pivot operating rod -2- by 90° and disengage operating rod.
9 - Release element
❑ Fitted to side of lock lever
2. Rear lid 33
Audi A3 2004 ➤
Removing rear lid lock

– Rear lid interior trim removed.
– Operating rod for actuator removed.
– Unscrew hexagon nuts -3- and detach rear lid lock -2- from
rear lid -1-.
– When installing tighten nuts to 21 Nm.
Removing actuator
– Unplug electrical connectors.
– Operating rods -2- disengaged at rear lid lock.
– Slacken off bolts -5- and push actuator -1- with mounting plate
-3- out of elongated holes on rear lid.
– Detach actuator with mounting plate -3- from rear lid.
– Unscrew bolts -4- and detach actuator.
– To remove, pivot operating rod -2- 90° out of clip in opposite
direction of arrow.
– When installing, insert operating rod in actuator.

– Pivot operating rod 90° in direction of arrow.
– Operating rod must engage securely in clip of actuator.
2.8 Removing and installing handle trim for rear lid
Removing
– Unplug electrical connector on inside of handle trim -4-.

Audi A3 2004 ➤
1 - Fastener
❑ Unscrew nuts on fasten‐
ers -1- (left and right) as
well as nuts -2-.
– Take fasteners out of
rear lid.
– Tightening torque: 8 Nm
❑ Release retaining hooks
on handle trim and de‐
tach it from rear lid.
Releasing retaining hooks for handle trim

– Press down both retaining hooks -arrows- above number plate
lights and detach handle trim -1-.
Installing
Install in reverse order of removal.
2. Rear lid 35
Audi A3 2004 ➤
3 Tank flap
⇒ “3.1 Removing and installing tank flap”, page 36
⇒ “3.2 Tank flap unit”, page 37
3.1 Removing and installing tank flap

Exploded view
1 - Tank flap cup

❑ When installing, note
markings on tank flap
cup and side panel
-arrow-.
2 - Tank flap unit
Note
Before taking out tank flap unit, re‐

move tank filler flap locking motor -
V155- ⇒ Item 1 (page 68) .
❑ Removing:
– Unscrew tank cap and
remove bolt -4-.
– Pull tank flap unit out of

side panel slightly (on Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
side with bolt).

– Pull tank flap unit fully

out of side panel at an
angle and towards rear.
❑ Installing:
– Insert drain hose in tank
flap cup.
– Press tank flap cup into

cut-out in side panel.
– Align markings on tank

flap cup and side panel
-arrows-.
– Place tank flap unit in

opening and engage in
tank flap cup.
– Fasten tank flap unit with bolt -4- and tighten.
3 - Fuel filler flap

❑ Place flap on hinge arm and make sure it engages.
4 - Bolt
❑ 1 Nm
5 - Drain hose
❑ Drain hose with clamp on side panel (bottom) pushed onto flange.
6 - Clip

Audi A3 2004 ➤
Releasing tank flap

– Insert a screwdriver between flap -2- and flap mounting -1- as
shown to release retainer.
– Pull flap slightly towards rear out of retainer.
– Detach flap to the side.
Installing tank flap

– Insert flap into recesses on mounting.
– Press flap -2- towards front in direction of arrow until it engages
in retainer on mounting -1-.
3.2 Tank flap unit

Installation position
3. Tank flap 37
Audi A3 2004 ➤
1 - Tank flap
❑ Can be renewed sepa‐
rately.
2 - Tank flap unit
sure sealing lips are cor‐
rectly seated on tank
flap cup.
3 - Tank flap cup
❑ Insert into side panel as
shown.
4 - Drain hose
❑ Secured to wheel hous‐
ing beneath wheel
housing liner using re‐
taining clip.
5 - Tank cap

Audi A3 2004 ➤
57 – Front doors, door components, central locking

1 Front door
⇒ “1.1 Removing and installing window frame and window regu‐
lator”, page 39
⇒ “1.2 Removing and installing window regulator and door win‐
dow”, page 43
⇒ “1.3 Removing and installing window guide”, page 44
⇒ “1.4 Removing and installing window regulator motor”,
page 45
⇒ “1.5 Adjusting door (vehicles with 3 doors)”, page 45
⇒ “1.6 Making adjustments using template T40038/3 ”,
page 48
⇒ “1.7 Adjusting front door (vehicles with 5 doors)”, page 50
page 53
⇒ “1.9 Renewing inner window slot trim strips”, page 55
⇒ “1.10 Renewing outer window slot trim strip”, page 56
⇒ “1.11 Exploded view - front door handle and door lock”,
page 57
⇒ “1.12 Removing door handle”, page 58
⇒ “1.13 Removing and installing outer door handle trim”,
page 59
⇒ “1.14 Removing door lock”, page 60
⇒ “1.15 Removing and installing cover for door handle”,
page 63
1.1 Removing and installing window frame

and window regulator
Note
Before removing the window frame / door you must disconnect

the battery.
1. Front door 39
Audi A3 2004 ➤
1 - Window frame
Caution
There is a side airbag
sensor on the inside of
the door -arrow-; ob‐
serve the safety regula‐
tions for airbags ⇒ Rep.
gr. 69 .
❑ Removing:
❑ Remove door trim. ⇒
Rep. gr. 70
nectors.
❑ Remove window regula‐
tor motor ⇒ page 42
❑ Unscrew bolts -4- and
-6-.
-8- and lift window frame
with window regulator
out of door.
❑ Installing:
❑ Before installing, move
half of window glass into
window frame.
❑ Insert window frame
into door from above.
❑ Attach upper half of seal
(on door side) into win‐
dow frame (top).
Note
Slacken off longitudinal adjuster

screw -arrow a- (also ⇒ page 42 )
to adjust window frame to door.
❑ Fit fitted bolts -4- loosely and hand-tighten.
❑ Set adjuster screw -arrow a- so that it makes contact with door (9 mm hexagon socket).
❑ Screw in bolt -6- (rear).
❑ Press top of window frame -1- slightly inwards.
❑ Tighten fitted bolts -4- to 32 Nm.
❑ Unscrew adjustment bolts for longitudinal direction -arrow c- and for the angle -arrow b- as far as they
will go with an Allen key (width across flats: 9 mm).
❑ Tighten bolts -6- to 32 Nm.
❑ If longitudinal adjuster screw -arrow b- has been slackened, it must now be tightened to 32 Nm.
❑ Tighten lower bolts -7- for window regulator
Protected to 6 Copying
by copyright. Nm. for private or commercial purposes, in part or in whole, is not
❑ Tighten upper bolts -8- to 6 Nm. with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Check door adjustment with template - T40038/3- (on vehicles with 3 doors) or template - T40038/5- (on
vehicles with 5 doors).
Note
♦ When setting door angle, adjust‐

ment bush -arrow c- must only
make contact with door panel.
40 Rep. gr.57 - Front doors, door components, central locking

Audi A3 2004 ➤
♦ Do NOT adjust the window frame

via the adjustment bush. The
window frame must be pressed
into the correct position before
the adjustment bush makes con‐
tact with the inner door panel.
♦ Tighten all bolts in the specified
sequence.
2 - Window regulator
❑ Bolted to window frame for installation in door
3 - Front door
4 - Fitted bolt
❑ 32 Nm
Note
♦ Height of window frame is al‐

ready correctly set by fitted bolts
-4-.
♦ However, should it be necessary
to adjust the height of the window
frame, replace the fitted bolts
with standard bolts.
♦ This will enable you to adjust the
height of the window frame.
5 - Cap
6 - Torx bolt
❑ 32 Nm
7 - Flange bolt
❑ 6 Nm
8 - Torx bolt
Note
On vehicles with 3 doors there are 3

of these bolts at the top.
❑ 6 Nm
9 - Spacer
Adjuster screw for longitudinal direction
– After tightening fitted bolts, unscrew threaded sleeve -2- on
window frame -1- using a 9 mm Allen key as far as it will go.
– Then tighten the appropriate flange bolt to 32 Nm.
– Self-adhesive seal -3-.
1. Front door 41
Audi A3 2004 ➤
Screw for lateral adjustment

– Use adjustment bush -4- to make lateral adjustments and set
the angle of the window frame.
Note
♦ When setting the door angle, the adjustment bush -4- must
only make contact with the door panel.
♦ Do NOT adjust the window frame via the adjustment bush. The
window frame must be pressed into the correct position before
the adjustment bush makes contact with the inner door panel.
♦ Tighten all bolts in the specified sequence and to the specified
torque ⇒ page 39 .
– Use template - T40038/3- to check position of window frame

-1-.
– Only slacken off longitudinal adjuster screw -2- if it is neces‐
sary for longitudinal adjustment of the window frame in the
door.
– Self-adhesive seal -3-.
Removing and installing window regulator motor

– To remove, unscrew bolts -2- and detach window regulator
motor -1-.
– Installing window regulator motor ⇒ page 45 .
Door hinge (top)

– Torx bolt - T 45- -1- (fitted from inside vehicle): 32 Nm
– Door hinge (top) -2-
– Cap -3-
– Torx bolt - T 45- -4-: 32 Nm.
– Fitted bolt -5- Torx - T 45- : 32 Nm.

Audi A3 2004 ➤
Door hinge (bottom)

– Torx bolt - T 45- -1- (32 Nm) is secured to B-pillar from inside
of vehicle.
– Door hinge (bottom) -2-
– Cap -3-
– Torx bolt - T 45- -4-: 32 Nm.
– Fitted flange bolt Torx - T 45- -5-: 32 Nm.
– Re-grease lubrication points -arrows- at prescribed service in‐
tervals.
– Front door -6-
1.2 Removing and installing window regulator and door window
1 - Window frame
❑ Removing:
Rep. gr. 70
❑ Window frame removed
from front door together
⇒ page 39
❑ Door window -4- re‐
moved
countersunk-head bolts
-3- and detach window
regulator from window
frame.
❑ Installing:
sure that the two guide
rails run parallel.
❑ Tighten bolts -3- to
6 Nm.
from front door together
⇒ page 39
❑ Door window removed
countersunk-head bolts
1. Front door 43
Audi A3 2004 ➤
frame.
3 - Countersunk-head bolt
❑ 6 Nm
4 - Door window
❑ Removing:
❑ Lower door window.
❑ Unscrew bolts -5- and detach door window from window regulator.
❑ Installing:
❑ Insert window in window regulator.
❑ Screw bolts -5- into window regulator but do not tighten yet.
❑ Move door window upwards into window frame.
❑ Pull door window to rear into window guide on window frame at B-pillar and tighten bolts -5- to 4 Nm.
5 - Hexagon socket head bolt
❑ 4 Nm
1.3 Removing and installing window guide
1 - Window frame
❑ Removed ⇒ page 40
2 - Window guide
Note
♦ Seal must be pressed on to in‐

stall, do NOT "hammer" it on.
♦ Use soap solution to facilitate in‐
stallation of seal.
❑ Slide onto window
frame from side and
press into guide on A-
pillar.
❑ Use soapy water for
easier installation.
❑ You must hear the fas‐
tener in the corner
-arrow- engage; if nec‐
essary also use glue to
secure in correct posi‐
tion.
3 - Inner door seal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4 - Door window with respect to the correctness of information in this document. Copyright by AUDI AG.
5 - Door trim
❑ Removed
6 - Inner window slot seal

Audi A3 2004 ➤
1.4 Removing and installing window regula‐

tor motor
Removing
– Door trim removed ⇒ Rep. gr. 70
Note
♦ Window regulator motor can be removed or installed with mo‐

tor or side window in any position. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Unplug connectors before removing motor. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew Torx bolts -2- -T30- and detach motor.

Installing
– When installing, make sure threaded pins -3- are engaged in
inner door panel -arrows-.
– Push on window regulator motor -1- and secure with bolts
-2-.
– Tightening torque: 3.5 Nm
Note
♦ After installing the electric motor and attached wiring, first turn
the ignition on and then off again.
♦ Then raise door window as far as it will go and keep window
regulator switch pulled for approx. 2 seconds.
♦ The window regulator is now in the basic setting and the open‐
ing/closing function is activated.
1.5 Adjusting door (vehicles with 3 doors)
Note
♦ Make sure you use the correct template for adjusting the door.
There are two versions: one for vehicles with 3 doors and one
for vehicles with 5 doors.
♦ On vehicles with 3 doors use template - T40038/3- for precise
door adjustment (height, angle and gap) as described
⇒ page 48 .
Panel gaps
1. Front door 45
Audi A3 2004 ➤
♦ Template - T40038/3-
♦ Setting gauge - 3371-
Panel gaps
– Dimension -A- = 3.5 mm ± 0.5 mm
– Dimension -B- = 3.5 mm ± 0.5 mm.
– Flush dimension to side panel = 0 mm+1 mm with gap running
parallel to body.
Longitudinal adjustment

Audi A3 2004 ➤
– For longitudinal adjustment of the door, slacken hinge bolts

-arrow A- on A-pillar at door hinge (top and/or bottom) and
move door -2- within elongated holes in hinge or A-pillar.
– Door hinge -1-
– A-pillar -3-
– Door -2-
Note
Illustration shows
permitted door
unless hinge
authorised (bottom).
by AUDI AG. AUDI AG does not guarantee or accept any liability
Adjusting the door inwards/outwards
Note
♦ The door hinges (top and bottom) are secured with a fitted bolt
(one for each hinge; on door side).
♦ As a result, an adjustment is not usually required during repair
work.
♦ However, should adjustments be required after all, the fitted
bolts can be replaced by bolts of the same size, length and
strength, as offered in the Parts catalogue.
– The door can be adjusted relative to the centre of the vehicle

by slackening the door hinge bolts (top and/or bottom) -arrow
B- and moving the door within the elongated holes in the hinge.
Note
Adjust rear end of door by altering position of striker plate inwards

or outwards.
Adjusting door at striker plate
– Loosen bolts -2-.

– Use markings -arrows a- and -arrows c- for lateral adjustment.
– Move striker plate -1- until door is flush with body contour.
Note
Use this adjustment only to adjust door inwards or outwards, not

vertically.
– Use markings -arrows b- and -arrows d- for height adjustment.

– If adjustment is correct, striker plate should engage centrally
in door lock.
– Tighten bolts to 25 Nm.
1. Front door 47
Audi A3 2004 ➤
1.6 Making adjustments using template -

T40038/3-
– Use template - T40038/3- for checking (e.g. in the case of wind
noise) and adjusting door as described in the following:
– Use a regular bank card -1- or similar to check contact pres‐
sure of sealing lip on roof trim strip.
Checking contact of sealing lip on roof trim strip

– Move a regular bank card along the area of contact between
the sealing lip and the roof trim strip, applying light pressure.
– The card must not dip in between sealing lip -1- and roof trim
strip -2-.
Template - T40038/3-
– The template has a “min” and a “max” marking to check the

lateral adjustment of the doors.
Note
♦ The “min” and “max” markings refer to the min. / max. pre-
tension on the doors.
♦ In other words, the “max” marking signifies that the door is
adjusted with max. pre-tension (as far inwards as possible).
“Max” adjustment
– In this position (max) the door is set with max. pre-tension (as
far inwards as possible).

Audi A3 2004 ➤
– Position template at distance -a- = 200 mm and with “max.”

marking pointing towards the door window.
– Make sure points -1- and -3- make contact.
– A gap is permissible at point -2- of the template.
– If there is no gap at point -2- or if there is a gap at point -1-,
the window frame is positioned too far outwards (pre-tension
not sufficient) and must be adjusted.
Adjusting “min”
– In position “min.” the door is set with min. pre-tension (as far
outwards as possible).
– Position template at distance -a- = 180 mm and with “min.”

– Make sure points -2- and -3- make contact with door window.
– In position min. the door is set with min. pre-tension (as far
– If there is no gap at point -1- or if template contact cannot be
established at point -2-, window frame is positioned too far
outwards and must be adjusted.
Height adjustment of window frame
– If the height of the window frame has to be adjusted, replace

fitted bolts -1- with standard bolts.
– This will enable you to adjust the height of the window frame.
– Seals -2- and -3- are inserted into window frame.
– Place template on roof as shown, or on upper edge of rain
channel.
1. Front door 49
Audi A3 2004 ➤
– When correctly adjusted, bottom edge of window frame must

be located between markings -a- (line on template -arrow-) or
-b-.
– Check/adjust angle of window frame.
– The position of the door can be assessed using the lower side
of template - T40038/3- (illustration shows different template).
– The door must not be recessed relative to the side panel -2-.
– The front door -1- must not be recessed relative to the side
panel -2- (wind noise).
– The front door may protrude (max. 0.8 mm) relative to the side
panel in the area of the cut-out in the template -arrow-.
1.7 Adjusting front door (vehicles with

5 doors)
Checking the panel gaps Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment required permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi A3 2004 ➤
Note
Use template - T40038/5- for precise door adjustment (height,

angle and gap) as described ⇒ page 53 .
Use special tool -3371- to check panel gaps.

– Dimension -E- = 3.5 mm ± 0.5 mm
– Dimension -F- = 4.5 mm ± 0.5 mm
– Dimension -G- = 3.5 mm ± 0.5 mm
parallel to body.
1. Front door 51
Audi A3 2004 ➤
– For longitudinal adjustment of the door, slacken hinge bolts
-arrow A- on A-pillar at door hinge (top and/or bottom) and
move door -2- within elongated holes in hinge or A-pillar.
– Door hinge -1-
– A-pillar -3-
– Door -2-
Note
Illustration shows door hinge (bottom).permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note
work.
– The door can be adjusted relative to the centre of the vehicle

by slackening the door hinge bolts (top and/or bottom) -arrow
B- and moving the door within the elongated holes in the hinge.
Note

or outwards.

– Use markings -arrows a- and -arrows c- for lateral adjustment.
Note

vertically.

in door lock.

Audi A3 2004 ➤

T40038/5-

strip -2-.
Note
♦ Some of the illustrations show different templates; however,
this has no significance for the procedures for checking and
adjusting.
1. Front door 53
Audi A3 2004 ➤

Adjusting “min” permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– If the height of the window frame has to be adjusted, exchange

fitted bolts -1- for standard bolts (of the same length and
strength).
channel.

Audi A3 2004 ➤

-b-.
of template - T40038/5- .
1.9 Renewing inner window slot trim strips
1. Front door 55
Audi A3 2004 ➤
1 - Window frame
2 - Inner window slot trim strip
❑ After removing door trim
-5-, lift window slot trim
strip off window frame
-1-.
❑ To install new window
slot trim strip, press it
onto window frame.
3 - Seal on A-pillar
4 - Seal on B-pillar
5 - Door trim
❑ Removing ⇒ Rep. gr.
70
1.10 Renewing outer window slot trim strip

– Window frame removed.
– Window slot trim strip is additionally clipped onto B-pillar.
– Open clip and detach window slot trim strip -1- upwards from
door shell -2-.

Audi A3 2004 ➤
– When installing, position at distance -c- = 0...0.5 mm from rear

end of door and press on fully towards front.
– Clip into rear end of door.
– Door window -3-.
1.11 Exploded view - front door handle and door lock
1 - Door handle mounting

❑ Releasing ⇒ page 58 .
2 - Door lock
❑ Removing:
❑ Door trim removed
multi-point socket head
bolts -4- and take door
lock out downwards.
3 - Operating rod
❑ Clip into door lock
⇒ page 63
4 - Multi-point socket head bolt
❑ 20 Nm
5 - Cover for lock cylinder
❑ After removing lock cyl‐
inder, unclip cover
6 - Lock cylinder
7 - Door handle
❑ Prior to removal take out
window frame and win‐
dow regulator. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Operating lever
9 - Clip
❑ Hook operating rod into
clip, swivel clip through
90° and engage at oper‐
ating rod.
1. Front door 57
Audi A3 2004 ➤
Removing lock cylinder

– Open driver's door.
– Prise out cap -2-.
– Turn Torx bolt -arrow- anti-clockwise as far as it will go.
– This moves catch -1- to rear and releases lock cylinder.
– Pull lock cylinder out of door handle.
1.12 Removing door handle
1 - Door handle
– Door handle cover re‐
moved ⇒ page 61 .
2 - Clip
❑ When dismantling door
handle -1-, disengage
operating rod -3- at clip.
3 - Operating rod
❑ Before removing door
handle, disengage op‐
erating rod at clip -2-.
❑ After installing a new
door lock, first insert op‐
erating rod into locking
sleeve and lock operat‐
ing rod in place. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Then pull locating pin

-5- out of door lock.
4 - Locking sleeve
❑ To lock operating rod
-3- in place, push lock‐
ing sleeve -4- upwards.
5 - Locating pin
❑ Only fitted on replace‐
ment part
❑ After installing operating
rod -3-, pull out locating
pin.
6 - Door lock
Releasing door handle mounting

Audi A3 2004 ➤
1 - Locking slide
– Door trim, window frame
removed
– Insert screwdriver
through door panel and
lock the slide -1- in di‐
rection of arrow at lock‐
ing pin of door handle
-2-.
2 - Locking pin of door handle
1.13 Removing and installing outer door han‐

dle trim
Vehicles up to model year 2009
– To remove, pull up door handle -1- and use small screwdriver
to push out catch -3- in longitudinal direction.
– Disengage trim -2- at top to one side and detach downwards
from door handle.
– Install in reverse order.
1. Front door 59
Audi A3 2004 ➤
Vehicles from model year 2009 onwards

– Lift door handle -arrow A-.
– Release fastener -2- at door handle -3- -arrow B- and slide
outer door handle trim towards front -arrow C-.
– Detach outer door handle trim -1- from door handle.
Installing
– Lift door handle -1-.
– Position outer door handle trim -2- on door handle, as shown
in illustration.
• The retaining lugs must face guides -arrows A-.
– Slide outer door handle trim towards rear -arrow B- until fas‐
tener engages audibly.
1.14 Removing door lock

Audi A3 2004 ➤
1 - Cover
2 - Cover
M8
❑ 20 Nm
4 - Actuating arm
❑ When assembling door
lock, actuating arm of
door handle must be in‐
serted into mounting of
door lock.
5 - Door shell
6 - Door lock
nector at door lock.
❑ If same door lock is re-
installed, disengage op‐
erating rod at door han‐
dle.
❑ If you are renewing door
lock, disengage operat‐
ing rod at door lock
⇒ page 63 .
❑ Unclip operating rod
from door lock at locking
sleeve.
❑ Unscrew multi-point
bolts -1- and take out
door lock.
7 - Transmission module
❑ Is clipped into door han‐
dle
8 - Bowden cable for interior door handle
❑ To install, first insert vertically in release lever, then swivel cable 90° and secure it by clipping it into door
lock ⇒ page 62 .
❑ After installing door lock, pull Bowden cable through cover in direction of arrow.
❑ When installing, make sure cover is correctly seated in door shell, otherwise leaks may occur.
❑ Only use undamaged covers.
Cover for door handle

1. Front door 61
Audi A3 2004 ➤
1 - Cover for door handle

Rep. gr. 70
❑ To remove, first unclip
from door shell, then un‐
clip from mounting for
door handle and remove
towards the rear.
2 - Operating lever
3 - Door handle
4 - Operating rod
❑ Engage operating rod in
door lock ⇒ page 63
Bowden cable for interior door handle

– To install, insert Bowden cable vertically into release lever as
illustrated (detail view). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pivot Bowden cable -2- 90° in direction of arrow
with respectand
to the clip it intoof information in this document. Copyright by AUDI AG.
correctness
door lock -1-

Audi A3 2004 ➤
Engaging operating rod in door lock

– When installing a new door lock, clip operating rod -1- into
locking sleeve.
– To lock operating rod, push slide -2- of locking sleeve up‐
wards.
– Pull securing pin -3- out of door lock.
Installing door seal

– Align butt joint of door seal -1- with marking -arrow- in door
flange.
– Press door seal onto door flange along its entire length.
Installing side impact protection

– Unscrew bolts -3- and lift out impact protection.
1.15 Removing and installing cover for door handle
1. Front door 63
Audi A3 2004 ➤
1 - Cover for door handle

Rep. gr. 70
❑ Window frame and win‐
dow regulator removed
❑ To remove, first unclip
from door shell, then un‐
clip from mounting for
door handle and remove
towards the rear.
2 - Door handle
Clipping in cover for door handle

– Clip cover -4- onto mounting on door handle and let it engage.
– To install operating rod -1-, operating lever -2- must first be
pressed into release lever -3- of door handle.
– Then pivot operating lever -2- 90° and let it engage in operating
lever.

Audi A3 2004 ➤
2 Central locking system

⇒ “2.1 Overview (vehicles with 3 doors)”, page 65
⇒ “2.2 Overview (vehicles with 5 doors)”, page 66
⇒ “2.3 Removing and installing convenience system central con‐
trol unit”, page 66
⇒ “2.4 Removing and installing tank filler flap locking motor”, page
67
⇒ “2.5 Removing tank filler flap locking motor”, page 67
2.1 Overview (vehicles with 3 doors)
1 - Alarm horn - H 12-

❑ Fitting location under
wheel housing liner
(front right).
2 - Vehicle inclination sensor -
G384- -(J529)-Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Installation under centre
console (front).
3 - Front passenger door con‐

trol unit - J387-
❑ Integrated into window
regulator motor
4 - Tank filler flap locking motor
- V155-
5 - Convenience system cen‐
tral control unit - J393-
❑ Removing ⇒ page 66 .
⇒ Rep. gr. 70 ; Trim panels
6 - Rear lid release motor -

V139-
❑ Fitting location in rear
lid.
7 - Driver door control unit -
J386-
regulator motor
8 - Bonnet contact switch -
F266-
❑ Fitting location: in lock
carrier
2. Central locking system 65

Audi A3 2004 ➤
2.2 Overview (vehicles with 5 doors)
1 - Alarm horn - H 12-

❑ Fitting location under
wheel housing liner
(front right).
2 - Vehicle inclination sender -
G384- / anti-theft and tilt sys‐
tem control unit - J529-
❑ Installation under centre
console (front).
3 - Front passenger door con‐
trol unit - J387-
regulator motor
4 - Rear right door control unit
- J389-
regulator motor
- V155-
6 - Convenience system cen‐
tral control unit - J393-
❑ Removing ⇒ page 66 .
7 - Rear lid release motor -
V139-
❑ Fitting location in rear
lid.
8 - Rear left door control unit -
J388-
regulator motor
9 - Driver door control unit -
J386-
regulator motor
10 - Bonnet contact switch - F266-
❑ Fitting location: in lock carrier
2.3 Removing and installing convenience

system central control
Protected unit
♦ Removal lever - 80-200-

Removing:
– Fitting location at rear right of luggage compartment beneath
side trim.
– Rear right luggage compartment trim removed.

Audi A3 2004 ➤
– Unplug electrical connectors -1- and -2-.

– Unscrew nuts -arrows- and remove retaining plate from control
unit.
– When installing, tighten nuts to 4.5 Nm.
– Move wiring harness clear at retaining plate using removal
lever 80-200.
– Unplug electrical connectors -1- to -3-.

– Press retaining clip -arrow- to side and remove control unit
from retaining plate.
– Re-attach all cable ties at the same locations when re-instal‐
ling.
2.4 Removing and installing tank filler flap

locking motor
♦ Hexagon socket screwdriver - T10010-
2.5 Removing tank filler flap locking motor

Exploded view

Audi A3 2004 ➤

- V155-
❑ Removing:
– Trim for rear cross panel
removed ⇒ Rep. gr. 70
– Release luggage com‐

partment side trim
(right-side) in area of
tank filler flap locking
motor - V155- and press
to the side.
– Unplug electrical con‐

nector for motor.
– Slacken off bolts
-arrows- using hexagon
socket screwdriver -
T10010- in clockwise di‐
rection, and push motor
out of elongated holes.
– Before installing motor,

eye of manual release
must be pushed over
locking pin.
– When installing, tighten

bolts anti-clockwise to
2 Nm.
2 - Locking rod
❑ Engaged in guide on
motor.
3 - Cable for manual release
❑ Routing cable
⇒ page 68
Routing cable for manual release with respect to the correctness of information in this document. Copyright by AUDI AG.
– Before installing motor -1- cable must be pushed over locking

pin.
– Route cable as shown.
– Guide cable -2- through side trim in luggage compartment
-5- and clip into cover -3-.

Audi A3 2004 ➤
Removing tank filler flap locking motor - V155-

– Unplug electrical connector.
Note
Slacken off bolts for securing actuator in clockwise direction.
– Slacken off bolts -arrows- in clockwise direction using hexa‐

gon socket screwdriver - T10010- ; then push lock actuator
-1- forwards and remove.
– Before installing actuator, manual release -3- must be slipped
over locking pin.
– When installing, tighten bolts in anti-clockwise direction.
– Locking pin of actuator must move smoothly into closed tank
flap -2-.

Audi A3 2004 ➤
58 – Rear doors, door components

1 Rear door
⇒ “1.1 Removing and installing window frame and window regu‐
lator”, page 70
⇒ “1.2 Removing and installing window regulator and door win‐
dow”, page 73 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.3 Removing and installing window guide”, page 74
⇒ “1.4 Removing and installing outer window slot trim strip”, page
74
⇒ “1.5 Removing and installing window regulator motor”,
page 75
⇒ “1.6 Adjusting rear door”, page 75
page 78
⇒ “1.8 Adjustment dimensions for rear door window frame”, page
80
⇒ “1.9 Exploded view - rear door handle and door lock”,
page 82
⇒ “1.10 Removing door handle”, page 83
⇒ “1.11 Removing and installing outer door handle trim”,
page 84
⇒ “1.12 Removing door lock”, page 84
1.1 Removing and installing window frame and window regulator
70 Rep. gr.58 - Rear doors, door components

Audi A3 2004 ➤
1 - Window frame
❑ Removing:
Rep. gr. 70
nectors.
❑ Remove window regula‐
tor motor ⇒ page 72
-8-.
❑ Unscrew fitted bolts -3-
as well as bolts -5- and
-6- and then lift window
frame with window reg‐
ulator out of door.
❑ Installing:
❑ Insert window frame
into door from above.
❑ Attach upper half of seal
(on door side) into win‐
dow frame (top).
❑ Position seals between
door and window frame.
❑ Loosely screw in fitted
bolts -3- at front and
rear.
❑ Screw in bolt -8-.
❑ Hand-tighten fitted bolts
-3-.
❑ Press top of window
frame -1- slightly in‐
wards.
❑ Unscrew adjustment
bushes (front and rear)
-arrows a- until they make contact (9 mm Allen key).
❑ Screw in bolt -5-.
❑ Tighten fitted bolts -3- to 32 Nm.
❑ Tighten bolts -5- (front
Protected andCopying
by copyright. rear) for
toprivate
32 Nm.or commercial purposes, in part or in whole, is not
❑ Tighten bolt -8-with to 10 toNm.
respect the correctness of information in this document. Copyright by AUDI AG.
❑ Tighten locking bolt -arrow b- in window frame to 32 Nm.
❑ Attach lower half of door seal to inner door panel.
❑ Attach window regulator rail to inner door panel with bolts -7-.
❑ Press threaded pins of window regulator drum through inner door panel until they engage.
2 - Rear door
3 - Fitted bolt
❑ 32 Nm
4 - Cover
❑ After tightening bolts with washers -5- to 32 Nm press covers into door trim.
❑ 32 Nm
❑ Before tightening the bolts with washers to the specified torque you must use an Allen key (A/F: 9 mm)
to position the adjusting bushes so that they make contact.
6 - Flange bolts
❑ 3.5 Nm
1. Rear door 71
Audi A3 2004 ➤
7 - Flange bolts
❑ 6 Nm
8 - Bolt
❑ 6 Nm
Removing window regulator motor

– To remove, unscrew bolts -2- and detach window regulator
motor.
– Installing window regulator motor ⇒ page 75 .
Door hinge (top)

– Torx bolt -T 45- -1- (2x; fitted from inside vehicle): 32 Nm
– Door hinge (top) -2-
– Fitted bolt -3- -T 45- : 32 Nm.
Door hinge (bottom)

– B-pillar trim removed
– Torx bolts -T 45- -1- (32 Nm) secured to B-pillar from inside of
vehicle
– Door hinge (bottom) -2-
– Cap -3-
– Torx bolt -T 45- -4-: 32 Nm
– Fitted bolt -T 45- -5-: 32 Nm
– Re-grease lubrication points -arrows- at prescribed service in‐
tervals.
– Front door -6-

Audi A3 2004 ➤
1.2 Removing and installing window regulator and door window
1 - Window frame
❑ Removing:
Rep. gr. 70
from door together with
window regulator
⇒ page 70
❑ Door window -4- re‐
moved
countersunk-head bolt
frame.
❑ Installing:
sure guide rail
-arrow A- runs parallel
with guide -arrow B-.
❑ Tighten bolts -7- to 6
Nm.
2 - Triangular trim Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Before removing, take

out window frame and
window regulator
❑ Unscrew bolt -3- and de‐
tach trim panel to side
❑ 4 Nm
❑ 6 Nm
5 - Door window
❑ Removing:
❑ Lower door window.
❑ Unscrew bolts -5- and detach door window from window regulator.
❑ Installing:
❑ Insert window in window regulator.
❑ Screw bolts -5- into window regulator but do not tighten yet.
❑ Move door window upwards into window frame.
❑ Pull door window forwards into window guide on window frame at B-pillar and tighten bolts -5- to 4 Nm.
6 - Hexagon socket head bolt
❑ 4 Nm-0.5 Nm
❑ Window frame removed from door together with window regulator ⇒ page 70
❑ Door window removed
❑ To remove, unscrew countersunk-head bolt -4- and detach window regulator from window frame.
1. Rear door 73
Audi A3 2004 ➤
1.3 Removing and installing window guide
1 - Window frame
2 - Inner window slot seal
❑ Door trim removed ⇒
Rep. gr. 70
3 - Window guide
Note
♦ Seal must be pressed on to in‐

stall, do NOT "hammer" it on.
♦ Use soap solution to facilitate in‐
stallation of seal.
❑ Push window frame
from side. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Use soapy water for permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
easier installation. with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ You must hear the fas‐

tener engage in the cor‐
ners -arrows-, if neces‐
sary also use glue to
secure in correct posi‐
tion.
4 - Inner door seal
5 - Door window
6 - Door trim
❑ Removed
1.4 Removing and installing outer window

slot trim strip

Audi A3 2004 ➤
– Window regulator and window frame removed ⇒ page 70 .

– Unclip tabs from door -2- and pull window slot trim strip -1-
upwards off door flange.
– When installing, press window slot trim strip onto door flange
so that it is flush with rear edge of door, starting at C-pillar and
working forwards.
– Press tabs on window slot trim strip into door from side.
1.5 Removing and installing window regula‐

tor motor
Removing
Note
Window regulator motor can be removed or installed with mo‐
♦permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
tor or side window in any position.
♦ Unplug connectors before removing motor.
– Unscrew Torx bolts -2- -T30- and detach motor.

Installing
– When installing, make sure threaded pins -arrows- are engag‐
ed in inner door panel.
– Push on window regulator motor -1- and secure with bolts
-2-.
– Tightening torque: 3.5 Nm
Note
♦ After installing the electric motor and attached wiring, first turn
the ignition on and then off again.
♦ Then raise door window as far as it will go and keep window
regulator switch pulled for approx. 2 seconds.
♦ The window regulator is now in the basic setting and the open‐
ing/closing function is activated.
1.6 Adjusting rear door

Checking the panel gaps
1. Rear door 75
Audi A3 2004 ➤
Use setting gauge -3371- to check panel gaps.

– Dimension -E- = 3.5 mm ± 0.5 mm
– Dimension -F- = 4.5 mm ± 0.5 mm
– Dimension -G- = 3.5 mm ± 0.5 mm
parallel to body.

Audi A3 2004 ➤
– For longitudinal adjustment of the door slacken hinge bolts
-arrow A- on B-pillar at door hinge (top and/or bottom) and
move door -2- within elongated holes in hinge or B-pillar.
– Door hinge -1-
– A-pillar -3-
– Door -2-
Note
Illustration shows door hinge (bottom).
Note
work.
– The door can be adjusted inwards or outwards by loosening

the top and/or bottom door hinge bolts -arrow B- and moving
the door within the elongated holes in the hinge.
Note

or outwards.

– Use markings -arrowspermitted
a- andunless
-arrows c- for lateral adjustment.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note

vertically.

in door lock.
1. Rear door 77
Audi A3 2004 ➤

T40038/5-

Note
Some of the illustrations show different templates; however, this

has no significance for the procedures for checking and adjusting.

strip -2-.

Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi A3 2004 ➤

Adjusting “min”
– If the height of the window frame has to be adjusted, replace

fitted bolts -1- with standard bolts.
channel.
1. Rear door 79
Audi A3 2004 ➤

-b-.
of template - T40038/5- (illustration shows different template).
1.8 Adjustment dimensions for rear door window frame

Audi A3 2004 ➤
1 - Window frame
❑ If door is adjusted cor‐
rectly, sealing lip must fit
flush with contours of
roof frame and B-pillar
(see -arrows-).
2 - Door window
❑ Adjust door to achieve
dimension -c- = 4 mm in
area -b- = 320 mm
❑ Dimension -a- meas‐
ured from front edge of
door at B-pillar = 90 mm
Note
Use template - T40038/5- to check

dimension -c-.
3 - Window frame
❑ Door window -2- must fit
into window frame at B-
pillar (dimension -d- =
7.5 mm -1 mm).
1. Rear door 81
Audi A3 2004 ➤
1.9 Exploded view - rear door handle and door lock
1 - Door handle mounting

❑ Releasing ⇒ page 83 .
2 - Door handle
❑ Prior to removal take out
window frame and win‐
dow regulator.
3 - Operating rod
❑ Clip into door lock
⇒ page 82
4 - Clip
❑ Hook operating rod into
clip, swivel clip through
90° and engage at oper‐
ating rod.
5 - Handle trim
6 - Multi-point socket head Protected
bolt by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 20 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7 - Door lock
❑ Removing:

⇒ page 70
multi-point socket head
bolts -6- and take door
lock out downwards.

locking sleeve -2-.
– To lock operating rod, push slide -3- of locking sleeve -2- up‐
wards.

Audi A3 2004 ➤
1.10 Removing door handle
1 - Door handle
2 - Clip
❑ When dismantling door
handle -1-, disengage
operating rod -3- at clip.
3 - Operating rod
❑ Before removing door
handle, disengage op‐
erating rod at clip -2-.
❑ After installing a new
door lock, first insert op‐
erating rod into locking
sleeve and lock operat‐
ing rod in place.
❑ Then pull locating pin
-5- out of door lock.
4 - Locking sleeve
❑ To lock operating rod
-3- in place, push lock‐
ing sleeve -4- upwards.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Locating pin
❑ Only fitted on replace‐
ment part
❑ After installing operating
rod -3-, pull out locating
pin.
6 - Door lock
Releasing door handle mounting

– Door trim, window frame and window regulator removed
– Insert screwdriver through door panel and release slide -2-
from door handle -1- in direction of -arrow-.
1. Rear door 83
Audi A3 2004 ➤
1.11 Removing and installing outer door han‐

dle trim
Vehicles up to model year 2009
– To remove, pull up door handle -1- and use small screwdriver
to push out catch -3- in longitudinal direction.
– Disengage trim -2- at top to one side and detach downwards
from door handle.
– Install in reverse order.
Vehicles from model year 2009 onwards

– Lift door handle -arrow A-.
– Release fastener -2- at door handle -3- -arrow B- and slide
outer door handle trim towards front -arrow C-.
– Detach outer door handle trim -1- from door handle.
Installing
– Lift door handle -1-.
– Position outer door handle trim -2- on door handle, as shown
in illustration.
• The retaining lugs must face guides -arrows A-.
– Slide outer door handle trim towards rear -arrow B- until fas‐
tener engages audibly.
1.12 Removing door lock


Audi A3 2004 ➤
1 - Rear door
2 - Grommet
3 - Backing plate
4 - Door lock
nector at door lock.
❑ If same door lock is re-
installed, disengage op‐
erating rod at door han‐
dle.
❑ If you are renewing door
lock, disengage operat‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ing rod at door lock permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ page 86 . with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Unscrew multi-point
bolts -6- and take out
door lock.
5 - Bowden cable for interior
door handle
❑ Installing ⇒ page 85
M8
❑ 20 Nm
Engaging Bowden cable in door lock

– To install, first insert Bowden cable -2- vertically into release
lever -3- as shown in detail view, then swivel 90° and clip into
door lock -1- to secure.
1. Rear door 85
Audi A3 2004 ➤

locking sleeve.
– To lock operating rod, push slide -2- of locking sleeve up‐
wards.

Audi A3 2004 ➤
60 – Sunroof
1 Sliding/tilting sunroof (vehicles with
3 doors)
⇒ “1.1 Exploded view ”, page 87
⇒ “1.2 Manual operation of electrical glass sunroof”, page 89
⇒ “1.3 Removing and installing wind deflector”, page 90
⇒ “1.4 Removing and installing sliding sunroof motor”,
page 91
⇒ “1.5 Adaption for sunroof motor”, page 92
⇒ “1.6 Checking zero position for sliding/tilting sunroof”,
page 93
⇒ “1.7 Adjusting zero position for sliding/tilting sunroof”,
page 94
⇒ “1.8 Removing and installing bellows”, page 95
⇒ “1.9 Removing and installing glass sunroof panel”, page 95
⇒ “1.11 Removing and installing seal for glass sunroof panel”,
page 96
⇒ “1.12 Removing and installing sunroof headliner”, page 97
⇒ “1.13 Removing and installing frame for sunroof operation”,
page 98
1.1 Exploded view
1. Sliding/tilting sunroof (vehicles with 3 doors) 87

Audi A3 2004 ➤
1 - Sunroof motor
❑ Manual operation
⇒ page 89
⇒ page 91
2 - Nut with washer
❑ 8 Nm
❑ Self-locking
❑ Renew
3 - Water drain hose (front)
4 - Spring
❑ For wind deflector
5 - Wind deflector
⇒ page 90
6 - Sunroof headliner
⇒ page 97
7 - Bellows
⇒ page 95
8 - Bolt
❑ 4.5 Nm
❑ Apply locking fluid when
fitting
❑ Locking fluid ⇒ Parts
catalogue
9 - Glass sunroof panel
88 Rep. gr.60 - Sunroof

Audi A3 2004 ➤
⇒ page 95
❑ Adjusting ⇒ page 96
10 - Seal
❑ For glass sunroof panel
11 - Cross-head screw
❑ 1 Nm
12 - Slide
❑ For sunroof headliner
❑ Removing and installing ⇒ Removing and installing sunroof headliner ⇒ page 97
13 - Frame
❑ For operation of sliding/tilting sunroof
14 - Water drain hose (rear)
15 - Bolt
❑ 8 Nm
❑ Self-locking
❑ Renew
16 - Bolt
❑ 3.5 Nm
1.2 Manual operation of electrical glass sun‐

roof
Special tools and workshop equipment required Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Front-end hook - 3370- with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
If sunroof motor is defective, glass sunroof can be operated using

manual crank from vehicle tool set.

Audi A3 2004 ➤
Removing
– Use special tool -3370- to carefully pull off lens for interior light.
– Insert manual crank -1- into recess in sunroof motor -arrow-;

press beyond first stop.
– Turn manual crank, at the same time keep pressing crank up‐
wards.
– After manual operation, check and, if applicable, adjust the
zero position ⇒ page 93 and ⇒ page 94 .
1.3 Removing and installing wind deflector

Removing
– Open sliding sunroof fully.
– Pull rear end of air deflector out of joint in direction of arrow.
Note
Spring for air deflector is relieved when it is disengaged.
– Repeat procedure on opposite side of vehicle and take air de‐

flector out of roof opening towards the rear.
Installing
– Guide uncoiled end of spring -2- for air deflector into groove
of joint -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi A3 2004 ➤
– Push contact -arrow 1- of air deflector forwards under the roof

opening.
– Insert spring -arrow 2- into groove in air deflector and press
retaining peg into joint -arrow 3-.
– Repeat procedure on opposite side of vehicle.
1.4 Removing and installing sliding sunroof

motor
♦ Front-end hook - 3370-
Removing
– Close glass sunroof; if necessary use manual operation
⇒ page 89 .
– Carefully remove cover for reading lamp using special tool
-3370-.

Audi A3 2004 ➤
– If applicable, unplug electrical connector -1- for hands-free

microphone.
– Remove bolts -arrows-.

– Swivel down interior light/reading light (front) and remove from
opening in moulded headliner.

– Remove sunroof motor -2- from opening in headliner.
– Unplug electrical connector -1-.
Installing
– Adjust sunroof motor to zero position ⇒ page 94 .
Tightening torque
Component Nm
Sunroof motor to body 3.5
1.5 Adaption for sunroof motor

Performing adaption
Note
♦ An adaption must be performed after the sunroof motor has

been renewed or if a motor is installed in a new sunroof frame.
♦ The adaption procedure adjusts the zero position for the motor
and sets a defined force for the roll-back function.
♦ The exact steps described below must be followed for an ac‐
curate adjustment.

Audi A3 2004 ➤
– Install motor in sunroof frame.

– Connect rotary switch to electric drive.
– Plug in connector for power supply at sunroof motor.
– Remove sliding/tilting sunroof fuse, wait at least 10 seconds
and then re-insert.
– Turn rotary switch -1- in direction of -arrow- and open sunroof.
– Turn rotary switch -1- in direction of -arrow- and close sunroof

again.
– Within the next 5 seconds, pull rotary switch -1- in

-direction of arrow-.
– Hold rotary switch in this position until sunroof tilts open,
closes, slides to fully open position and closes again.
WARNING
♦ After pulling the rotary switch, it takes approx. 8 ... 10 sec‐

onds for the roof to start moving.
♦ The subsequent adaption is performed without roll-back
function.
♦ On new motors the adaption is started immediately (no
waiting time).
– This completes the adaption and the sliding/tilting sunroof can

then be operated in the normal manner.
1.6 Checking zero position for sliding/tilting

sunroof
Note
Zero position can be checked with sunroof panel fitted.

Audi A3 2004 ➤
– Remove bellows ⇒ page 95 .

– Close sunroof.
– Push sunroof headliner completely to rear.
– If zero position is correct, guide pin -1- must be centrally
aligned with mark on slotted guide -2-.
1.7 Adjusting zero position for sliding/tilting

sunroof
Note
♦ Zero position must be adjusted if:

♦ the sunroof motor was not removed in zero position.

♦ the sliding/tilting sunroof was opened or closed manually.

♦ parts of sliding/tilting sunroof were removed and re-installed.

– Close sunroof.
– Remove sunroof motor ⇒ page 91 .
– Align guide pins -1- (left and right), so that they are centrally
aligned with marks -2- on slotted guides (mechanical zero po‐
sition).
Note
Glass sunroof panel has been removed in illustration.

Audi A3 2004 ➤
– Plug in electrical connector -4- for voltage supply at removed

sunroof motor.
– Plug in electrical connector -1- at switch for sunroof operation
(in interior light).
– Use rotary control to select “roof opened” or “roof tilted”.
♦ Motor automatically goes into end position.
– Move rotary control to “roof closed” position.
♦ Motor automatically moves to electrical zero position and
switches off - markings -2- and -3- must then be opposite one
another.
– Install motor in this position with sunroof closed (mechanical
zero position).
1.8 Removing and installing bellows

Removing
– Open sunroof topermitted
tilt position.
– Pull bellows off frame and glass sunroof panel -arrows-, be‐
ginning at bottom.
Installing
– Press bellows into mountings on glass sunroof panel.
– Press bottom part of bellows onto retaining strip on frame for
sunroof operation.
Note
Make sure that the bellows are correctly seated in the rear mount‐
ing on the glass sunroof panel.
1.9 Removing and installing glass sunroof

panel
Removing

Audi A3 2004 ➤
– Remove bolts -1- and -3-.

– Slacken off bolt -2- several turns.
– Lift glass sunroof panel out of roof opening.
Installing
– Adjust glass sunroof panel ⇒ page 96 .
Tightening torque
Component Nm
Glass sunroof panel to frame for sunroof opera‐ 4.5 1)
tion
1) Apply locking fluid when fitting bolts; locking fluid ⇒ Parts catalogue
1.10 Adjusting glass sunroof panel

Checking adjustment
– To avoid wind noise, adjust the height of the sunroof panel at
the front and rear as shown in illustration.
– Check the height adjustment at the points where the rounded
corners merge with the straight parts of the roof cut-out at the
front and back.
– The sunroof panel should not be higher than the roof at any
point at the front or lower than the roof at any point at the rear.
– For height adjustment, always close sunroof from open (non-
tilted) position.
Adjusting
– Loosen bolts -1 ... 3- several turns.

– Adjust panel.
1.11 Removing and installing seal for glass

sunroof panel
Removing
– Remove glass sunroof panel ⇒ page 95 .

Audi A3 2004 ➤
– Pull seal -2- out of glass sunroof panel -3-.

1 - Roof opening
Installing
Note
To facilitate installation of seal, apply soapy water to edge of sun‐

roof panel.
– Press new panel seal -2- into groove on reverse side of glass
sunroof panel -3-, starting in the middle.
1 - Roof opening
1.12 Removing and installing sunroof head‐

liner
Removing
– Remove glass sunroof panel ⇒ page 95 .
– Pull sunroof headliner forwards until bolts for rear slides are
accessible.

Audi A3 2004 ➤
– Push front slides -1- forwards -arrow- until they can be re‐
moved.
– Push rear slides towards rear.
– Push sunroof headliner forwards out of frame for sunroof op‐
eration.
– Remove rear slides.
Installing
Note
Make sure that the side contact surfaces for the sunroof headliner
are free of grease.
– Insert rear slides into guide on frame.

– Insert sunroof headliner into frame and push sunroof headliner
towards rear.
– Insert front slides into guide on frame. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Tightening torque
Component Nm
Sunroof headliner to slide 1
1.13 Removing and installing frame for sun‐

roof operation
Removing
– Remove moulded headliner. ⇒ Rep. gr. 70
– Unplug electrical connector -arrow-.
– Detach water drain hoses -arrow- (front and rear) from frame.

Audi A3 2004 ➤
– Unscrew nuts and bolts -arrows-.
Note
A 2nd mechanic is required for removing the frame for sunroof

operation.
– Remove frame for sunroof operation.

Installing
Note
Renew self-locking nuts and bolts when performing assembly

work.
– Insert frame for sunroof operation into body and hand-tighten

bolts on left and right.
– Align centring holes of frame for sunroof operation and body

at front -arrow- ...
– ... and rear -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Tighten nuts and bolts permitted
inwith
the specified sequence.
respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Front centre, side, rear
– Adjust glass sunroof panel ⇒ page 96 .
Tightening torque
Component Nm
Frame for sunroof operation to body 8 2)
2) Renew bolts/nuts.

Audi A3 2004 ➤
2 Water drain hoses

⇒ “2.1 Overview”, page 100
⇒ “2.2 Cleaning water drain hoses”, page 100
2.1 Overview
1 - Water drain hose (front)

❑ Water drain hoses
(front) are located in A-
pillars and end in wheel
housing above wheel
housing liner.
❑ Cleaning ⇒ page 100
2 - Frame
❑ For operation of sliding/
tilting sunroof
3 - Water drain hose (rear)
❑ Water drain hoses (rear)
are located in C-pillars
and end in wheel hous‐
ing above wheel hous‐
ing liner.
❑ Cleaning ⇒ page 100
2.2 Cleaning water drain hoses
Note
For cleaning it is recommended to use an improvised tool approx.

2300 mm long and made from speedometer drive cable core.

Audi A3 2004 ➤
Water drain hose (front)

– Water drain hoses (front) are located in A-pillars and end in
wheel housing above wheel housing liner -arrow-.
♦ To clean, access hose from sunroof opening.
Water drain hose (rear)
– Water drain hoses (rear) are located in C-pillars and end in

wheel housing above wheel housing liner -arrow-.
♦ Clean from lower end of hose.
– Remove wheel housing liner (rear) ⇒ page 243 .
2. Water drain hoses 101

Audi A3 2004 ➤
3 Sliding/tilting sunroof (vehicles with

5 doors)
⇒ “3.1 Removing and installing roof module”, page 102
⇒ “3.2 Minimum drying times”, page 112
⇒ “3.3 Assembly parts (exterior)”, page 112
⇒ “3.4 Removing and installing wind deflector”, page 113
⇒ “3.5 Removing and installing sunroof panel”, page 114
⇒ “3.6 Removing and installing cable guide”, page 119
⇒ “3.7 Exploded view - cross strut and sunroof sun blind (front) ”,
page 122
⇒ “3.8 Removing and installing sunroof sun blind (rear)”,
page 124
⇒ “3.9 Removing and installing sliding sunroof motor”,
page 132
3.1 Removing and installing roof module
Note
The complete roof module is bonded to the body; to remove it,

use the electric cutter - V.A.G 1561A- and various blades or cut‐
ting cord.
Tools for removing:

♦ Electric cutter - V.A.G 1561A-
♦ Blade (58 mm) - V.A.G 1561/2-
♦ Blade (110 mm) - V.A.G 1561/24-

Audi A3 2004 ➤
♦ Universal blade - V.A.G 1561/11-
♦ Blade (L-shaped, 25.4 mm) - V.A.G 1561/22-
♦ Blade (L-shaped, 38 mm) - V.A.G 1561/23-

♦ 2 x pull handle - V.A.G 1351/1-
Tools for installing:
Note
♦ As the adhesive has to be processed very quickly (within a

total time of 10 minutes) you need 2 adhesive sets
DA 004 600 A2 and 2 double cartridge guns - VAS 5237- as
well as 2 people to apply the adhesive on the remaining bead
on the body. The two people must start at one point and then
work in opposite directions.
♦ To ensure that there are no leaks there must be no gap be‐
tween the start and end of the adhesive bead.

Audi A3 2004 ➤
♦ 2 x double cartridge gun - VAS 5237-
♦ Tensioning strap - T10038-
Material required for installing:
Note
You will require two sets of window adhesive DA 004 600 A2 for
installing the roof module.
♦ 2-component window adhe‐ DA 004 600 A2 1), 2)

sive
♦ Glass primer/paint primer Protected

permitted unlessD 009 200
authorised 02 AG. AUDI AG does not guarantee or accept any liability
by AUDI
♦ Cleaning solution D 009 401 04
♦ Primer applicator D 009 500 25
♦ Adhesive remover D 002 000 10
3) Note minimum drying time.
Removing roof module

Audi A3 2004 ➤
1 - Panel -1-
❑ Supplied together with
roof module
❑ Cannot be removed un‐
damaged without re‐
moving the windscreen.
Note
If the windscreen is removed, the

complete roof module -11- can be
removed without damaging the pan‐
el -1-.
❑ Removing
Protected and for
by copyright. Copying instal‐
private or commercial purposes, in part or in whole, is not
permittedling
unless⇒ page by
authorised 114
AUDI. AG. AUDI AG does not guarantee or accept any liability
2 - Panel -2-
non-bonded panel
⇒ page 118
3 - Panel -3-
❑ In the case of a new roof
module it is already bon‐
ded to the roof module.
❑ Removing and instal‐
ling ⇒ page 114 .
❑ Dimension -a = 5 mm-
between rear edge of
glass panel and front
edge of sheet-metal
panel
4 - Panel (rear)
❑ Sheet-metal panel
❑ Is damaged irreparably
when removed
Note
Before removing panel, protect

paintwork at top of rear lid in area of
panel using e.g. double-sided adhe‐
sive tape.
❑ Use pliers to bend rear edge of sheet-metal panel approx. 90° upwards.
❑ Use blade (L-shaped, 25.4 mm) - V.A.G 1561/22- to cut through adhesive beads on side -6- on both
sides of sheet-metal panel in longitudinal direction.
❑ Use universal blade - V.A.G 1561/11- to cut through rear adhesive bead -6- horizontally (along width of
vehicle).
❑ Bend sheet-metal panel up approx. 90° and use universal blade - V.A.G 1561/11- to cut through front
adhesive bead -6- horizontally (along width of vehicle).
❑ Dimension -b = 4.5 mm- between rear edge of sheet-metal panel and rear lid (when rear lid is closed)
5 - Rear lid
6 - Felt strip
❑ Self-adhesive, stick on in same place ⇒ page 110
7 - Adhesive bead for sheet-metal panel
❑ Before installing a new panel you must cut back adhesive bead.
– Use electric cutter - V.A.G 1561- and blade, offset - V.A.G 1561/10- to cut remaining adhesive sealant
on flange to make it level. However, never fully remove the sealant.

Audi A3 2004 ➤
– The remaining sealant is required as a base for better adhesion of the new adhesive sealant.
❑ Apply in centre of remaining adhesive sealant
8 - Butyl adhesive sealing cord
❑ After detaching panel remove remains of butyl adhesive sealing cord and apply a new cord in the same
place.
Note
♦ The butyl adhesive sealing cord

seals the panel on the body and
must be absolutely leak-proof.
For this reason, ensure that
there is no gap between the ends
of the cord.
♦ Diameter of butyl adhesive seal‐
ing cord = 8 mm
9 - Supporting beads
Note
The supporting beads are no longer

applied on vehicles from chassis
number »8 P5A 126 517« onwards.
❑ Before installing roof module, cut back adhesive beads.
❑ Do not bond new roof in these positions.
❑ Instead, make self-adhesive felt strip ⇒ Parts catalogue (dimensions
Protected 100formm
by copyright. Copying x1
private mm x 10purposes,
or commercial mm) and in part or in whole, is not
bond it on in the same position. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Adhesive bead for roof module
❑ Before installing roof module, cut back adhesive beads.
❑ Apply adhesive on body in same place.
11 - Sliding sunroof module
Removing:
Note
When the complete sunroof module

is removed it is unavoidable that the
panel -1- will be damaged irrepara‐
bly when the moulding is removed.
❑ Do not remove headliner; only lower it ⇒ Rep. gr. 70 .
– To do so, remove A-pillar trim panels, sun visors, grab handles, roof end trim and interior lights.
– Unclip headliner (rear centre).
– Pull headliner forwards out of trim for C- and D-pillars and lay it down in the vehicle.
❑ Remove cross member for sunroof ⇒ page 131 .
❑ Remove roof trim strip ⇒ page 111 .
❑ To make sure that paint is not damaged, cover all body surfaces near sunroof module well with fabric-
backed adhesive tape.

Audi A3 2004 ➤
Caution
When removing the
moulding on the panel
-1-, make sure you do
not damage the mould‐
ing on the windscreen.
❑ Use sharp knife to remove moulding, cutting along glass edge at panel -1- (front) and at sides.
❑ Insert blade (L-shaped, 38 mm) - V.A.G 1561/23- into electric cutter - V.A.G 1561A- and cut through
adhesive beads on roof module (on side in area of panel).
❑ Then replace blade (L-shaped, 38 mm) - V.A.G 1561/23- with blade (L-shaped, 25.4 mm) - V.A.G
1561/22- and cut through adhesive at front of roof module.
❑ Cut through adhesive bead -9- on side right along roof module up to sheet-metal panel.
❑ Protect seal at rear of panel -3- to ensure it is not damaged.
❑ Cut through adhesive bead for roof module between panel 3 and sheet-metal panel.
Note
♦ On vehicles with support beads,

cut through these first.
♦ To improve access unscrew
bolts from cable guide
⇒ page 119 and push cable
guide slightly away from roof.
❑ Cut through support beads at left and right using universal blade - V.A.G 1561/24- .
❑ Screw bolts for cable guide back in.
❑ Lift complete roof out of vehicle (requires four people).
Note
If necessary cut right through adhe‐

sive which has not yet been cut us‐
ing cutting cord (Part No.
357 853 999 A) and two pull handles
- V.A.G 1351/1- ⇒ page 111 .
❑ Lift sunroof module out of vehicle (requires four people).
Installing:
Note
♦ If you are re-installing the same

roof, the remaining sealant bead
must not be cut back until just
before installation.
♦ Use electric cutter -
V.A.G 1561A- and blade, offset -
V.A.G 1561/10- to cut back the
adhesive sealant on the roof
module and the body flange.
However, never remove the
sealant completely.
♦ The remaining sealant is re‐
quired as a base for better adhe‐
sion of the new adhesive seal‐
ant.

Audi A3 2004 ➤
♦ If the windscreen flange has

been repaired or renewed, the
paintwork must be restored ac‐
cording to specifications in the
"Assessment of vehicle paint‐
work" manual and corrosion pro‐
tection must, if necessary, be
applied according to the "Sur‐
face Treatments/Chemical Ma‐
terials" manual.
♦ First clean repaired area with
D 009 401 04, then apply primer
D 009 200 02.

WARNING
Keep bonding surface
clean and free from
grease. Do not cut back
bonding surface until
shortly before installa‐
tion. Do not apply primer
to bonding surface and
do not use cleaning sol‐
ution.
Note
♦ To apply the adhesive you re‐

quire two people and two car‐
tridge guns.
♦ You require two sets of wind‐
screen adhesive DA 004 600 A2.
♦ Four people are required to lift
the module into the vehicle and
align it.
♦ Insert spacers for new module in
same position as on roof which
has been removed
⇒ page 109 .
❑ If you are installing a new roof module, remove protective paper on spacers.
❑ Peel off tape covering bonding surfaces on roof module.
❑ Clean bonding surfaces with cleaning fluid D 009 401 04.
❑ On a new roof module, apply glass/paint primer D 009 200 02 on bonding area on roof module.
❑ Allow glass/paint primer to flash off for 10 minutes.
❑ Apply adhesive on remaining bead on body (requires two people).

Audi A3 2004 ➤
Caution
Make sure there is a little
overlap where the adhe‐
sive beads merge (start
and end of beads), oth‐
erwise there might be
leaks in these areas.
The sunroof must be in‐
stalled in the vehicle
within 10 minutes after
applying the adhesive,
otherwise the adhesive
properties of the adhe‐
sive sealant will be im‐
paired.
Note
Four people are required to lift the

sunroof above the vehicle and to fit
it into the body.
❑ Install the roof module in the vehicle.
❑ Distance -a- to sheet-metal panel must be 5 mm.
❑ Press the roof fully into the roof opening (except for spacers).
❑ Secure roof so that it aligns with body contour,
Protected usingCopying
by copyright. tensioning
for privatestraps (fitted
or commercial through
purposes, in part opened
or in whole, doors).
is not
❑ To increase the preload of the sunroof module
with respectvis-a-vis the vehicle,
to the correctness place
of information in thise.g. plastic
document. blocks
Copyright (polystyrene)
by AUDI AG.
on panels -1- and -3-; then fit and tighten a tensioning strap - T10038- .
❑ After completing installation, check for leaks before installing headliner.
Note
If you are re-installing the "old" sun‐

roof you must also install panel -1-
in the roof module ⇒ page 116 .
12 - Adhesive bead for panel -1-

❑ Do not cut back remaining bead until just before installing panel -1-.
❑ Apply adhesive for panel -1- onto remaining sealant bead on body.
Bond on spacers for module (6x)

– Pull protective paper off spacers -2- and press spacers onto
module -1- as shown.

Audi A3 2004 ➤
Butyl seal for sheet-metal panel

– Before installing a new sheet-metal panel, attach butyl adhe‐
sive sealing cord (8 mm ∅) -2- around cut-out for vehicle aerial
(as shown) and, if applicable, also position new felt strips -1-
⇒ Parts catalogue .
Note
Make sure butyl adhesive sealing cord is leak-proof and position

ends so that there is no gap between them.
– Peel protective paper off felt strips and bond felt strips onto
body as shown.
Removing panel -1-
Note
If the windscreen is not removed, the panel cannot be removed without damaging it irreparably.
1 - Panel -1- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Before removing panel,

remove moulding using
a sharp carpet knife or
similar.
2 - Moulding on panel -1-
❑ Items supplied
❑ Use a sharp carpet knife
to remove moulding,
cutting as close as pos‐
sible to glass edge
-arrows-.
Caution
Make sure that the
moulding on the wind‐
screen -3- is not dam‐
aged.
❑
3 - Moulding on windscreen
❑ Must not be damaged
when removing panel
-1-
4 - Windscreen
5 - Adhesive bead for panel
-1-
6 - Adhesive bead for roof
module

Audi A3 2004 ➤
Pull handles for cutting operation

– Cut right through adhesive which has not yet been cut com‐
pletely using cutting cord - 357 853 999A- and two pull handles
- V.A.G 1351/1- , as shown in illustration.
Removing and installing roof strip
1 - Roof strip
❑ To remove, carefully un‐
clip roof strip clip for clip,
starting at rear.
❑ To install, insert roof
strip at front under panel
-1- of sunroof module. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ When installing, gradu‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ally press roof strip into
roof, starting at front.
2 - Clip
❑ 10x on each side, bon‐
ded on with double-si‐
ded adhesive tape -3-.
❑ Bonding surface of clips
must be free of dust and
grease.
❑ To install, place clips on
side of side frame as
shown and then press
onto body.
3 - Double-sided adhesive
tape
❑ Bonding surface must
be free of dust and
grease; clean with
cleaning solution
D 009 401 04.
❑ After installing, clip must
make contact with side
frame as shown in detail
view of illustration.
4 - Panel -3- of sunroof module
5 - Panel -1- of sunroof module

Audi A3 2004 ➤
3.2 Minimum drying times
WARNING
♦ For safety reasons, when installing the sunroof module,

use only non-conductive 2-component adhesive with the
designations listed below.
♦ You must NOT drive the vehicle until the minimum drying
time has elapsed, as the vehicle is otherwise not safe to
drive.
Vehicle with: Adhesive sealant Minimum drying

time (in hours)
Sliding sunroof DA 004 600 A2 8
module
3.3 Assembly parts (exterior)
1 - Panel -1-
❑ Bonded to roof module
❑ Cannot be removed un‐
damaged without re‐
moving the windscreen.
2 - Panel -2-
3 - Panel -3-
4 - Sunroof sun blind (rear)
5 - Sunroof sun blind (front)
6 - Roof module
❑ Overview
7 - Sunroof motor
❑ Removing and instal‐
ling ⇒ page 132
8 - Bolts with washers
❑ 3.5 Nm
9 - Wind deflector
❑ Removing
⇒ “3.4 Removing and in‐
stalling wind deflector”,
page 113

Audi A3 2004 ➤
3.4 Removing and installing wind deflector

Exploded view
1 - Wind deflector
❑ To remove, use a
screwdriver or similar to
release front catches
(3x) -arrows- and pull
wind deflector upwards
out of retainer.
❑ Use a punch to drive out
pins on tilt arm
-arrow A- and on wind
deflector -arrow B-,
working inwards from
outside.
Removing wind deflector

– Fully open the sunroof.
Note
Wind deflector is clipped into retainer at front -3x-.

Audi A3 2004 ➤
– Press catches -arrow- apart gradually with a screwdriver, and

pull wind deflector out of retainer.
– Use a punch to press rear pin of wind deflector out, working

inwards from outside.
– Press top pin -arrowof tilt lever out using a punch, working
inwards from outside.
3.5 Removing and installing sunroof panel

Panels which are firmly bonded
♦ Electric cutter - V.A.G 1561A-
♦ Universal blade - V.A.G 1561/11-

Audi A3 2004 ➤
♦ Blade (58 mm) - V.A.G 1561/2-
♦ Blade (L-shaped, 25.4 mm) - V.A.G 1561/22-
♦ 2 x double cartridge gun - VAS 5237-
♦ Wet and dry cleaner - VAS 5128-

Material required for installing:
♦ 2-component window adhe‐ DA 004 600 A2 1), 2)
sive
♦ Glass primer/paint primer D 009 200 02


Audi A3 2004 ➤
Note
♦ Panels -1- and -3- are bonded firmly to the roof module and
can only be cut out.
♦ Panel -1- cannot be removed undamaged without removing
the windscreen.
Removing and installing bonded panels
WARNING
Keep bonding surface clean and free from grease. Do not cut
back bonding surface until shortly before installation. Do not
apply primer to bonding surface and do not use cleaning sol‐
ution.
Make sure there is a little overlap where the adhesive beads
merge (start and end of beads), otherwise there mightProtected
be leaksby copyright. Copying for private or commercial purposes, in part or in whole, is not
in these areas. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The bonded panel must be installed in the vehicle within 10

minutes of starting work on the job, as the adhesion of the ad‐
hesive sealant will otherwise be impaired.
Note the minimum drying times for the bonded panels
⇒ page 118 .

Audi A3 2004 ➤
1 - Adhesive bead for panel

-1-
❑ Do not cut back until just
before installing the new
panel.
❑ Apply new adhesive to
remaining bead on body
side.
2 - Panel -1-
Note
♦ It is not possible to remove panel

-1- without damaging it irrepara‐
bly.
♦ Use pull handles - V.A.G 1351/1-
(2x) and cutting cord 357 853
999 A to remove panel 1.
❑ Use a sharp carpet knife
to detach moulding from
front and sides of panel
-1-.
❑ Retract panel -2- fully to
the rear.
❑ Position cutting cord be‐
tween glass panel -1-
and sunroof module.
❑ Attach adhesive tape to
cutting area at top of
roof frame in order to
protect paintwork.
❑ Secure ends of cord in
pull handlesProtected
and cut by copyright. Copying for private or commercial purposes, in part or in whole, is not
through adhesive,
permitted start‐
ing from sideswith
of respect
vehi‐to the correctness of information in this document. Copyright by AUDI AG.
cle.
❑ When installing, panel -2- must be installed and closed.
❑ Clean bonding surface of new panel and apply primer.
❑ Apply adhesive to remaining adhesive bead.
❑ Insert panel in roof opening.
❑ Centrally align panel with body contour and then press into roof opening as far as the stop.
❑ Hold panel in position in roof opening using adhesive tape.
3 - Panel -2-
4 - Panel -3-
❑ Panel -2- removed.
❑ Roof strip removed ⇒ page 111
Caution
To avoid damage to
paint, mask area around
the panel with fabric-
backed adhesive tape.
❑ Use electric cutter - V.A.G 1561A- and blade (L-shaped, 25.4 mm) - V.A.G 1561/22- to cut through
adhesive bead along the side frame.

Audi A3 2004 ➤
❑ Cut through adhesive bead at rear edge of panel -2-.

❑ Use electric cutter - V.A.G 1561A- and blade (L-shaped, 58 mm) - V.A.G 1561/2- to cut through adhesive
bead at front edge of panel -3-.
❑ Use a suction lifter to lift panel out of roof opening.
❑ When installing, panel -2- must be installed and closed.
❑ Clean bonding surface of new panel and apply primer.
❑ Apply adhesive to remaining adhesive bead.
❑ Insert panel in roof opening.
❑ Centrally align panel with body contour and then press into roof opening as far as the stop.
❑ Hold panel in position in roof opening using adhesive tape.
5 - Adhesive bead for panel -3-
❑ Do not cut back until just before installing the new panel.
❑ Apply adhesive to remaining bead on body side.
Minimum drying times for bonded sunroof panels

Vehicle with: Adhesive sealant Minimum drying time (in
hours)
Sliding sunroof DA 004 600 A2 3
module
Removing and installing non-bonded panel
– To remove, fully open the sunroof.
Detach panel -1- on body side from sunroof module by pulling it

to side, towards centre of vehicle.
– Tilt sunroof open and detach panel -2- from sunroof panel
-1-, pulling it to the side.

Audi A3 2004 ➤
– When installing, insert trim -1- in side of retaining strip -2- at

panel.
– Unscrew bolts -arrows- from both sides of slotted guide -1-.

– Lift panel out of opening.
– Tighten bolts to 3.5°Nm when installing.
Adjusting glass sunroof panel
– To avoid wind noise, adjust the height of the sunroof panel at

the front and rear as shown in illustration.
– Check the height adjustment at the points where the rounded
corners merge with the straight parts of the roof cut-out at the
front and back.
– The sunroof panel should not be higher than the roof at any
point at the front or lower than the roof at any point at the rear.
– For heightProtected
adjustment, always close sunroof from open (non-
tilted) position.
Adjusting
– Slacken off bolts -1-, -2- and -3- several turns.

– Adjust panel.
3.6 Removing and installing cable guide

Audi A3 2004 ➤
1 - Bolt
❑ 3.5 Nm
2 - Sunroof sun blind
Note
Cross struts on front and rear of sun‐

roof sun blind can be renewed sep‐
arately ⇒ page 122 .
❑ Guide rail (rear) re‐
moved.
❑ To remove component,
unscrew bolts -1-, pull
component out of guide
rail (front) towards rear
and detach downwards.
3 - Cable guide
Removing:
❑ Headliner removed ⇒
Rep. gr. 70 .
❑ Remove sunroof motor. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Remove retaining strip with respect to the correctness of information in this document. Copyright by AUDI AG.
for wind deflector.

❑ Remove sunroof panel.
– Remove cross member
for sliding/tilting sunroof
⇒ page 131
– Remove guide rails

(rear).
– Sunroof sun blind re‐

moved
-7- from below, unscrew bolt -9- ⇒ page 121 from above and detach entire cable guide downwards.
4 - Sunroof motor
5 - Bolt
❑ 3.5 Nm
6 - Bolt
❑ 3.5 Nm
7 - Bolt
❑ 3.5 Nm
8 - Retaining strip for wind deflector
9 - Bolt
❑ 3.5 Nm
10 - Roof module
11 - Guide rail (rear)
❑ To remove, unscrew bolts -12-.

Audi A3 2004 ➤
12 - Bolt
❑ 3.5 Nm
Removing retaining strip for wind deflector

– To remove component, unscrew centre bolts -arrows- (2x) and
outer bolts (left and right) -arrow- and detach retaining strip.
Removing bolt from cable guide
– Retaining strip for wind deflector removed.

– To remove guide, unscrew bolts from above.

Audi A3 2004 ➤
3.7 Exploded view - cross strut and sunroof sun blind (front)
1 - Slide
❑ Slide onto actuator
2 - Actuator
❑ Insert into cross strut for
sunroof sun blind from
side
3 - Cross strut for sunroof sun
blind
⇒ page 122
4 - Retaining hook
❑ 2 Nm
6 - Sunroof sun blind
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 124 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing and installing cross strut for sunroof sun blind
Note
Sunroof sun blind remains installed when removing cross strut.
– Open sunroof and unclip trim panels -1- at sides.
Caution
Make sure you do not damage visible paintwork when releas‐

ing actuator; protect this area with adhesive tape.

Audi A3 2004 ➤
– Use a screwdriver or similar to release actuator -2- on both

sides from cross strut for sunroof sun blind -1- in direction of
-arrow-.
– Release cross strut for sunroof sun blind -1- from actuator
-2- by twisting it in direction of -arrow-.
Detach cross strut for sunroof sun blind -1- from actuator -2- in
direction of -arrow-.

Audi A3 2004 ➤
– Cut off corner of cross strut for sunroof sun blind -1-, at point
shown.
– Slide fabric for sunroof sun blind with piping -2- to the side out
of guide on cross strut -3-.
Caution
The sunroof sun blind is pre-tensioned; do NOT let go of it at

this point to prevent it from unwinding.
– Cut off corner of new cross strut on same side.

– Insert fabric of sunroof sun blind back into cross strut from
side.
– Perform remaining installation in reverse order of removal.
Renewing actuator
Note
When renewing slide, only twist sunroof sun blind towards out‐
side; piping remains in actuator of cross strut.
– After twisting out cross strut for sunroof sun blind (front), slide
actuator -1- out of guides towards rear and side.
– Slide actuators at rear of sunroof sun blind towards front.
Note
On vehicles with new actuators and an old cross strut (without

recess), the retaining tabs -arrow- must be cut off completely so
the surface is even before the cross strut can be twisted in again.
3.8 Removing and installing sunroof sun blind (rear)

Audi A3 2004 ➤
1 - Slide
❑ Fit onto actuator
2 - Actuator
❑ Insert into cross strut for
sunroof sun blind from
side
3 - Sunroof sun blind with re‐
tractor
❑ Cross member for sun‐
roof removed
⇒ page 131
Caution
The sunroof sun blind is
pre-tensioned with a
spring and must be se‐
cured before removal to
ensure it does not un‐
wind ⇒ page 126 .
❑ ⇒ page 126 Before re‐

moving sun blind you
must first detach clip
from shaft.
❑ To remove, push sun‐
roof sun blind to side in
Note
The sunroof sun blind can only be

pushed in on the side on which the
retaining clip is located (clip has to
be removed first) ⇒ page 127 .
❑ Secure shaft to prevent
sunroof sun blind from unwinding and lift sun blind out on one side.
❑ Take sunroof sun blind with slides out of guides (first detach one side, then the other).
Note
On front sunroof sun blind, sun blind

must be inserted opposite to direc‐
tion of -arrow-.
4 - Cross strut for sunroof sun blind

5 - Retaining hook
6 - Bolts with washers Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 2 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A3 2004 ➤
Locating element for sunroof sun blind
Caution
The sunroof sun blind is pre-tensioned with a spring and must

be secured before removal to ensure it does not unwind
⇒ page 126 .
– After removing retaining clip, align holes in shaft and sleeve

by moving them sideways.
– Lock shaft and sleeve -3- in place with a thin wire -4- to secure
sunroof sun blind so that it does not unwind.
– Now you can remove sunroof sun blind from roof module.
– Should slides -1- remain in guides, they must be removed and
re-inserted before installing sunroof sun blind -2-.
Removing sunroof sun blind (front)
– Headliner lowered
– Cross member for sliding/tilting sunroof removed
– Press clip -1- off sun blind shaft -2- in direction of arrow by
inserting pin of locking spring through hole.
Caution
Make sure you do not damage visible paintwork when releas‐

ing actuator; protect this area with adhesive tape.
– Use a screwdriver or similar to release actuator -2- on both

sides from cross strut for sunroof sun blind -1- in direction of
-arrow-.

Audi A3 2004 ➤
– Release cross strut for sunroof sun blind -1- from actuator
-2- by twisting it in direction of -arrow-.
Detach cross strut for sunroof sun blind -1- from actuator -2- in
direction of -arrow-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull retaining clip -1- off shaft in opposite direction of arrow.
– Push sun blind towards the side -arrow A- and align the two
holes -arrow B- on shaft and sleeve.

Audi A3 2004 ➤
– Secure sun blind to prevent it from turning using a wire pin as

shown and then take out the sun blind.
Installing sunroof sun blind (front)
– Insert flat end of sun blind shaft -arrow- sideways into roof.
– Also insert in mounting on opposite side.
– After fitting sun blind, slide retaining clip back onto shaft using
pliers or similar.

Audi A3 2004 ➤
– The illustration shows the retaining clip in its correct installa‐

tion position.
Note
It is now no longer possible to move the sun blind -2- sideways.
– Position cross strut for sunroof sun blind on actuator as shown

-arrow-.
– Twist cross strut for sun blind into actuator in direction of -

arrow-.
– When twisting into position -arrowProtected

A-, cross strut for sun blind
-1- must engage fully in actuator -2- and unless
permitted lock authorised
into place by AUDI AG. AUDI AG does not guarantee or accept any liability
-arrow B-. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A3 2004 ➤
Removing actuator
– After removing cross strut for sun blind, push actuator towards
rear and side out of guide.
Note
Illustration shows actuator from vehicle interior.
Removing sunroof sun blind (rear)

– Headliner lowered
– Cross member for sliding/tilting sunroof removed
– Press clip -1- off shaft in direction of -arrow- using pin of locking
spring.
– Pivot cross strut for sun blind out of guides on side of sunroof
as shown in illustration. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Push sun blind towards the side -arrow A- and align the two
holes -arrow B- on shaft and sleeve.

Audi A3 2004 ➤
– Secure sun blind to prevent it from turning using a wire pin as

shown and then take out the sun blind.
Installing sunroof sun blind (rear)

– Install in reverse order of removal.
– After
permitted fitting
unless sunroof
authorised by AUDIsun blind,
AG. AUDI slide
AG does notretaining clip back
guarantee or accept onto
any liability
with shaft using
respect to pliers.of information in this document. Copyright by AUDI AG.
the correctness
– The illustration shows the retaining clip in its correct installa‐

tion position.
Note
It is now no longer possible to move the sun blind -2- sideways.
Cross member for sliding/tilting sunroof

Audi A3 2004 ➤
1 - Cross member for sliding/

tilting sunroof
❑ Moulded headliner is
only lowered, not re‐
moved
– To do so, remove A-pil‐
lar trim panels, B-pillar
trim panels. sun visors,
interior light, all grab
handles and roof end
trim ⇒ Rep. gr. 70 .
hexagon bolts -2-.
❑ Connecting pieces -3-
(left-side) and -5- (right-
side) remain in vehicle.
2 - Hexagon bolts
❑ 7 Nm
3 - Connecting piece (left-side)
4 - Hexagon bolt
❑ 3.5 Nm
5 - Connecting piece (right-
side)
6 - Moulded headliner
❑ Only lower, do not re‐
move ⇒ Rep. gr. 70
7 - Sunroof sun blind (rear)
8 - Sunroof sun blind (front)
3.9 Removing and installing sliding sunroof
motor
Note
The sliding sunroof must be completely closed before the motor

is removed.
– Remove interior light/reading light ⇒ Rep. gr. 96 .


Audi A3 2004 ➤

– Unplug electrical connector -1- at motor.
– Remove sunroof motor -2- through opening in headliner.
Installing
– Install motor in »roof closed« position.
Tightening torque
Component Nm
Sunroof motor to body 3.5

Audi A3 2004 ➤
63 – Bumpers
1 Bumper (front)
⇒ “1.1 Removing and installing bumper (front)”, page 134
⇒ “1.2 Attachment points for bumper cover”, page 138
⇒ “1.3 Removing and installing trim grille”, page 139
⇒ “1.4 Installing brackets for parking aid”, page 140
1.1 Removing and installing bumper (front)
Note
Bumper covers with parking aid senders which have not been
supplied with brackets must be painted before the holes are dril‐
led and the appropriate brackets are fitted ⇒ page 140 .
Exploded view (vehicles with 3 doors)
1 - Bolt
❑ 8.5 Nm
❑ When installing, ob‐
serve tightening se‐
quence: start on the in‐
side and work outwards.
2 - Bumper
bolts -3- and detach
bumper forwards, pull‐
ing it out of impact
dampers.
❑ 23 Nm
4 - Hexagon bolt
❑ 4 Nm
❑ Press wheel housing lin‐
er to the side in area of
bolt.
5 - Fastener
❑ Insert in wing panel
6 - Guide
134 Rep. gr.63 - Bumpers

Audi A3 2004 ➤
panel bolts -7-.

❑ Installing ⇒ page 138 .
7 - Panel bolt
❑ 1.5 Nm
8 - Impact damper
9 - Bumper cover
❑ To remove, unscrew bolts -1-.
❑ Slacken off hexagon bolt
with -4-to under
respect wheel
the correctness housingin liner.
of information this document. Copyright by AUDI AG.
❑ Unscrew bolts from wheel housing liner in this area and push wheel housing liner to one side.
❑ Unscrew Torx bolts -T25- on wheel housing liner (3x each side) on left and right.
❑ Unscrew panel bolts -10- on underside.
❑ Unscrew bolts securing noise insulation.
❑ First unclip bumper cover at top from guide -6- and wing panel, then lever over wheel housing liner and
detach forwards from lock carrier.
10 - Spoiler
❑ Supplied with bumper cover; not available separately.
11 - Panel bolt
❑ 1.5 Nm
Exploded view (vehicles with 5 doors)
1. Bumper (front) 135

Audi A3 2004 ➤
1 - Radiator grille
2 - Bolt
❑ 8.5 Nm
❑ When installing, ob‐
serve tightening se‐
quence: start on the in‐
side and work outwards.
3 - Air intake grille
4 - Bumper cover
Note
On covers with transportation cross‐

piece, crosspiece must be removed
before painting ⇒ page 137 .
bolts -2-.
❑ Unscrew bolts from
wheel housing liner at
front and push wheel
housing liner to one
side.
❑ Unscrew bolt -14- be‐
neath wheel housing lin‐
er and bolts -15- from Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
underside. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ First unclip bumper cov‐
er at top from guide
-12- on wing panel, then
lever over wheel hous‐
ing liner and detach for‐
wards from lock carrier.
5 - Bumper
❑ To remove, unscrew bolts -7- and detach bumper forwards, pulling it out of impact dampers.
6 - Washer
7 - Bolt
❑ 23 Nm
8 - Impact damper
9 - Nut
❑ 23 Nm
10 - Fog light
❑ Removing and installing ⇒ Rep. gr. 94
11 - Fastener
❑ Insert in wing panel
12 - Guide
❑ To remove, unscrew panel bolts -13-.
❑ Installing ⇒ page 138 .
13 - Bolt
❑ 1.5 Nm

Audi A3 2004 ➤
14 - Bolt
❑ 4 Nm
❑ Press wheel housing liner to the side in area of bolt.
15 - Bolt
❑ 1.5 Nm
Removing transportation crosspiece on bumper cover

– Transportation crosspiece -2- must be removed from cover
-1- on left (-arrow-) and right before painting.
Remove impact damper (left-side)

– Bumper cover and bumper removed.
– Unscrew hexagon bolts -2- (securing lock carrier to longitudi‐
nal member).
– Unscrew Torx bolts -arrows- and remove impact damper -1-
from lock carrier.

Audi A3 2004 ➤
Remove impact damper (right-side)

– Bumper cover and bumper removed.
– Unscrew hexagon bolts -2- (securing lock carrier to longitudi‐
nal member).
– Unscrew Torx bolts -arrows- and remove impact damper -1-
from lock carrier.
Guide for bumper cover

– Press fastener into wing from below.
– When installing, fasten guide -2- with bolts, working from front
to rear.
– Tighten bolts -3- to 1.5 Nm.
1.2 Attachment points for bumper cover

Audi A3 2004 ➤
1 - Bumper cover
2 - Torx bolts
❑ Bolt connection for lock
carrier (top).
❑ 8.5 Nm
3 - Wing panel
4 - Hexagon bolt
❑ Bolt connection wing
panel.
❑ 4 Nm
❑ To remove, press wheel
housing liner to the side
in area of bolt.
5 - Panel bolt
❑ Bolt connection on lock
carrier (bottom).
❑ 1.5 Nm
Note
Bumper cover is also secured to

noise insulation with 3 additional
panel bolts.
6 - Panel bolt
❑ Bolt connection wheel
housing liner
❑ 1.5 Nm
1.3 Removing and installing trim grille

Vehicles with 3 doors
– Release retainers -arrows- and pull trim grille forwards out of
cover.
– When installing, make sure that retainers lock correctly into
cover.

Audi A3 2004 ➤
1 - Audi emblem (front)

– To remove, unclip from
reverse side.
2 - Frame
❑ Clipped into radiator
grille
– To remove, unclip re‐
taining hooks one-by-
one from reverse side.
3 - Radiator grille
❑ To remove, release re‐
taining hooks and pull
forwards out of bumper
cover.
5 - Bumper cover
Removing radiator grille

– Release retaining hooks -arrows- fully on bumper cover.
– Pull radiator grille out of bumper cover towards rear.
1.4 Installing brackets for parking aid
Note
If a vehicle has been delivered without the brackets for the parking
aid fitted on the bumpers, after the paintwork is done the holes
must first be punched and the brackets must be bonded on.

Audi A3 2004 ➤
1.4.1 Tools
♦ Attachment device for PDC holder - VAS 6614-
♦ Hand cartridge gun - VAS 5155-
1.4.2 Materials
♦ 2-component plastic adhe‐ 4) 1

sive - D 180 KU2 A1-
♦ Primer for plastic compo‐ 4) 1

nents - D 822 150 A1-
♦ Cleaning solution - D 009 4) 1

401 04-
♦ Primer applicator
4) Follow the manufacturer's instructions supplied with the product.
5) Note minimum drying time ⇒ page 145 .
1.4.3 Installing brackets
Note
The brackets are only installed after the bumper cover has been
painted.

Audi A3 2004 ➤
The markings for the bracket -1- are located on the inside of the
bumper cover.
– If they are missing, determine centre point -2-.
– Pre-drill holes using 10.2 mm drill bit -3- supplied with tool kit.
Making holes with punch

Audi A3 2004 ➤
– Unscrew punch bit -1- of attachment device for PDC holder -

VAS 6614/1- from bolt -4-.
– Apply punch with screw, washer and thrust bearing -3- from
inside of bumper cover -2-.
– Screw on punch bit -1- of attachment device for PDC holder -
VAS 6614/1- from outside until it is almost touching bumper
cover -2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Then press punch bit -1- against bumper cover -2-.

– Screw bolt -4- into punch via hexagon flats.
Note
When screwing in the bolt -4-, the punch bit -1- must not be allowed to turn while in contact with the painted
surface of the bumper cover.
– When bolt -4- is turned, punch bit -1- is drawn through material
of bumper cover -2- in direction of -arrow-.
– Remove punch and apply again to punch out remaining holes.

Audi A3 2004 ➤
Inserting brackets in bumper cover
Note
The brackets must be attached in the same position in the new bumper cover as they were in the old one.
– Sand inside of bumper cover and bracket at bonding surfaces,

and clean thoroughly.
– Clean bumper cover and brackets thoroughly with plastic
cleaner - D 195 850 A1- and allow to flash off for 5 minutes.
– Apply a thin coating of primer for plastic components - D 822
150 A1- to bumper cover and bracket, and allow to flash off for
10 minutes.
– Slide bracket -6- onto centring mandrel -3- and push mandrel
through bumper cover.
– Slide on counterhold tool -2- from outside and tighten knurled
nut slightly.
– Align bracket -6- in correct position and according to markings
on bumper cover.

Audi A3 2004 ➤
– Slide on clamp -4- and screw in knurled nut -5- but do not
tighten yet.
– Prepare all brackets up to this step prior to bonding.
Note
♦ The first few centimetres of adhesive from the mixing nozzle may not be properly mixed and must therefore
be discarded.
♦ The adhesive must not spread from the bracket as far as the hole for the sensor.
– Bend tabs open slightly and apply 2-component plastic adhe‐

sive - D 180 KU2 A1- to surfaces marked by arrows between
bracket and bumper cover.
– Tighten knurled nut -3- at centring pin -1-.
– This results in clamp -2- pushing tabs on side of bracket -4-
flat onto bumper cover -5-.
– Perform this step for all brackets.
– After minimum drying time for 2-component plastic adhesive -
D 180 KU2 A1- , remove all centring mandrels.
1.4.4 Minimum drying times

Caution
• A minimum drying time of 30 minutes must be observed

before performing further work on the bumper cover or
brackets.
• The bumper cover must be left at the work station during
this period and must not be moved.

Audi A3 2004 ➤
2 Bumper (front) - RS 3
⇒ “2.1 Exploded view - bumper cover”, page 146
⇒ “2.2 Removing and installing bumper cover (front)”, page 148
⇒ “2.3 Removing and installing closure plate for bumper cover
(front)”, page 148
⇒ “2.4 Removing and installing spoiler (bottom section)”,
page 149
⇒ “2.5 Removing and installing bumper cover mounting (front)”,
page 149
⇒ “2.6 Removing and installing impact absorber”, page 150
⇒ “2.7 Removing and installing cover for headlight washer jet”,
page 150
⇒ “2.8 Removing and installing air intake grille and trim strip”,
page 150
⇒ “2.9 Exploded view - impact bar”, page 151
⇒ “2.10 Removing and installing impact bar”, page 153
⇒ “2.11 Removing and installing connecting piece”, page 153
⇒ “2.12 Removing and installing mounting for impact bar”,
page 154
2.1 Exploded view - bumper cover


Audi A3 2004 ➤
1 - Bolt
❑ 7x
❑ 1.8 Nm
2 - Closure plate for bumper
cover
⇒ page 148
3 - Bolt
❑ 3x
❑ 1.8 Nm
4 - Spoiler (bottom section)
⇒ page 149
5 - Bolt
❑ 4x
❑ 1.8 Nm
6 - Cover
❑ For towing eye
7 - Impact absorber
⇒ page 150
8 - Cover for washer jet
❑ For headlight washer
system
⇒ page 150
9 - Bumper cover mounting
(front)
⇒ page 149
10 - Bolt
❑ 1.7 Nm
11 - Bolt
❑ 4 Nm
12 - Bolt
❑ 1.7 Nm
13 - Bumper cover
14 - Trim strip
❑ Remove bumper cover ⇒ page 148 .
❑ The tabs on the trim strip are ultrasonically welded to the bumper cover and must be milled off during
removal such that surface is even.
– Removing and installing ⇒ pagepermitted
150 unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Remove bumper cover ⇒ page 148 .
❑ The tabs on the air intake grille are ultrasonically welded to the bumper cover and must be milled off
during removal such that surface is even.
– Removing and installing ⇒ page 150
2. Bumper (front) - RS 3 147

Audi A3 2004 ➤
2.2 Removing and installing bumper cover

(front)
Removing
⇒ page 245 .
– Remove front section of wheel housing liner (front)
⇒ page 245 .

– Detach side section -3- from side panel (front) -arrow- and de‐
tach bumper cover towards the front with the help of a second
mechanic.
Installing
• Tightening torques ⇒ page 146
– Install front section of wheel housing liner (front)
⇒ page 245 .
⇒ page 245 .
2.3 Removing and installing closure plate

for bumper cover (front)
Removing
⇒ page 245 .
– Remove front section of wheel housing liner (front)
⇒ page 245 .
– Remove bolts -1, 2, 3 and 5-.
– Detach closure plate -4- for bumper cover (front) towards rear
(as seen in direction of travel).
Installing
– Install front section of wheel housing liner (front)
⇒ page 245 .
⇒ page 245 .

Audi A3 2004 ➤
2.4 Removing and installing spoiler (bottom

section)
Removing
– Remove closure plate for bumper cover (front) ⇒ page 148 .
– Starting at outer edge, pull bottom section of spoiler -1- off
bumper cover (front) towards front -arrows-.
Installing
– Tabs -3- must engage in guides on lock carrier -2- -arrow-
when bottom section of spoiler -1- is inserted.
– Install closure plate for bumper cover (front) ⇒ page 148 .

mounting (front)
Removing
– Remove bolt -1-.
– Remove bumper cover mounting (front) -2-.
Installing
– Install bumper cover (front) ⇒ page 148 .

Audi A3 2004 ➤
2.6 Removing and installing impact absorb‐

er
Removing
– Carefully press retaining tabs in direction of -arrows- and dis‐
engage impact absorber -2- from bumper cover (front) -1-.
– Detach impact absorber.
Installing
2.7 Removing and installing cover for head‐

light washer jet
Removing
– Carefully press retaining pins -3 and 4- to the side and at the
same time take cover -1- for washer jet out of bumper cover
(front) -2-.
Installing
2.8 Removing and installing air intake grille

and trim strip
♦ Laser weld seam grinder - VAS 6319-
♦ Temperature gauge - VAS 6519-
Note
♦ The air intake grille and trim strip are ultrasonically welded to
the bumper cover.
♦ After removal, they must be renewed and bonded using the
listed materials from the plastic repair set - D 007 700- .
Removing air intake grille


Audi A3 2004 ➤
– Mill ultrasonically welded tabs off air intake grille such that
surface is even, e.g. using laser weld seam grinder - VAS
6319- .
– Detach air intake grille from bumper cover.
Removing trim strip
– Mill ultrasonically welded tabs off trim strip such that surface
is even, e.g. using laser weld seam grinder - VAS 6319- .
– Detach trim strip from bumper cover.
Installing air intake grille and trim strip
– Clean bonding surfaces (tabs and bumper cover) with plastic
– Apply primer for plastic components - D 822 150 A1- to bond‐
ing surfaces and allow to flash off for 5 to 10 minutes.
– Insert air intake grille / trim strip in bumper cover so it is flush,
and secure with adhesive tape.
– Bond tabs and bumper cover together with 2-component plas‐
tic adhesive - D 180 KU2 A1- .
Caution
Adhesive must not be visible from outside through air intake

grille.
– Minimum drying time at room temperature: 1.5 hours
Note
If a space heater is used and the temperature is increased to

60-70°C, the minimum drying time can be reduced to 15 minutes.
2.9 Exploded view - impact bar

Audi A3 2004 ➤
1 - Nut
❑ 2x
❑ 16 Nm
2 - Impact bar
❑ Different versions ⇒
Electronic parts cata‐
logue
⇒ page 153
3 - Bolt
❑ 2x permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Lock carrier
5 - Bolt
❑ 2x
❑ 5 Nm
6 - Mounting for impact bar
⇒ page 154
7 - Bolt
❑ 4x
❑ 50 Nm
8 - Connecting piece
❑ For supporting lock car‐
rier (bottom)
⇒ page 153
9 - Bolt
❑ 2x
❑ 20 Nm
10 - Bolt
❑ 6 Nm

Audi A3 2004 ➤
2.10 Removing and installing impact bar

Removing
– Remove headlight housing ⇒ Electrical system; Rep. gr. 94 .
– Move clear fluid line -2- at impact bar.
– Unscrew nuts -5- and pull out bolts -3- upwards.
– Take impact bar -4- out of mountings.
Note
If impact bar cannot be removed from mountings easily, it must

be levered out.
Installing
– Install headlight housing ⇒ Electrical
permitted unless system;
authorised by AUDI Rep.
AG. AUDI gr. not
AG does 94guarantee
. or accept any liability
2.11 Removing and installing connecting

piece
Removing
– Left side: detach air duct -1-.

Audi A3 2004 ➤
– Remove bolts -1 ... 4-.

– Swivel connecting piece -5- towards rear -arrow- and pull out
downwards.
Installing
– Install air duct ⇒ Rep. gr. 21 .
2.12 Removing and installing mounting for
impact bar
Removing
– Remove lock carrier ⇒ page 3 .
– Detach mounting -1- for impact bar from lock carrier -2-.
Installing
– Install lock carrier ⇒ page 3 .

Audi A3 2004 ➤
3 Bumper (rear)
⇒ “3.1 Exploded view - bumper cover (rear)”, page 155
⇒ “3.2 Removing and installing bumper cover (rear)”, page 157
⇒ “3.3 Removing and installing guides (side/rear)”, page 159
⇒ “3.4 Removing and installing bumper cover trim”, page 160
⇒ “3.5 Removing and installing bumper cover (bottom section)”,
page 160
⇒ “3.6 Removing and installing bumper cover mounting”,
page 161
⇒ “3.7 Removing and installing impact bar (vehicles without tow‐
ing bracket)”, page 161
⇒ “3.8 Removing and installing impact bar (vehicles with towing
bracket)”, page 161
⇒ “3.9 Installing brackets for parking aid”, page 162
3.1 Exploded view - bumper cover (rear)

Bumper cover (rear), parking aid senders
Note
Bumper covers with parking aid senders which have not been supplied with brackets must be painted before
the holes are drilled and the appropriate brackets are fitted ⇒ page 162 .
3. Bumper (rear) 155

Audi A3 2004 ➤
1 - Bolt
❑ 1.8 Nm
2 - Bumper cover (bottom sec‐
tion)
⇒ page 160
3 - Bolt
❑ 2.1 Nm
4 - Rear left parking aid sender
- G203-
⇒ Rep. gr. 94
5 - Rear centre left parking aid
sender - G204-
⇒ Rep. gr. 94
6 - Bumper cover trim
⇒ page 160
7 - Rear centre right parking
aid sender - G205-
⇒ Rep. gr. 94
8 - Rear right parking aid send‐
er - G206-
⇒ Rep. gr. 94
9 - Nut
❑ 5 Nm
10 - Bumper cover
⇒ page 157
11 - Cover
❑ For towing hook
12 - Cover
❑ For towing bracket
13 - Bolt
❑ 1.8 Nm
Impact bars (rear), guide (side), guide (rear)


Audi A3 2004 ➤
1 - Bolt
❑ 75 Nm
2 - Impact bar
❑ For vehicles with towing
bracket
⇒ page 161
3 - Bumper cover mounting
⇒ page 161
4 - Bolt
❑ 23 Nm
5 - Radio controlled clock re‐
ceiver - J489-
⇒ Rep. gr. 90
6 - Bolt
❑ 1.5 Nm
7 - Bolt
❑ 1.7 Nm
8 - Nut
❑ 2.5 Nm
9 - Guide (side)
⇒ page 159
10 - Bolt
❑ 2.3 Nm
11 - Guide (rear)
⇒ page 159
12 -Protected
Bolt by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑permitted
2.3 Nmunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
13 - Bolt
❑ 23 Nm
14 - Impact bar
❑ For vehicles without towing bracket
15 - Nut
❑ 2.0 Nm
16 - Bolt
❑ 75 Nm

(rear)

Audi A3 2004 ➤
♦ Socket - T40078-
Removing
– Remove outer tail lights ⇒ Rep. gr. 94 .
– Remove rear cross panel trim ⇒ Rep. gr. 70 .
– Unfasten luggage compartment side trim in area of nut -1- ⇒
Rep. gr. 70 .
– Unscrew nuts -1- (left and right) with socket - T40078- .
– Remove bolts -2-.
– Remove bolts -6- and -7- at floor trim cover (rear).

– Remove bolts -4- and -5- from guide.
– Unscrew bolts -1, 2, 3- from side sections of bumper cover.
– Disengage side sections at side panel outwards -arrows-.
– If fitted, unplug electrical connector for parking aid sender ⇒
Rep. gr. 94 .
– Detach bumper cover.
Installing
• Tightening torques ⇒ page 155 and ⇒ page 156 .
– Install luggage compartment side trim ⇒ Rep. gr. 70 .
– Install rear cross panel trim ⇒ Rep. gr. 70 .
– Install outer tail lights ⇒ Rep. gr. 94 .

Audi A3 2004 ➤
3.3 Removing and installing guides (side/

rear)
Removing
– Remove bumper cover (rear) ⇒ page 157 .
– If fitted, unplug electrical connector -2- at radio controlled clock
receiver - J489- .
– Remove guide (rear) -1-.
– Remove wheel housing liner (rear) ⇒ page 243 .

– Unscrew bolts -arrows- and nut -1-.
– Detach guide (side) -2-.
Installing
– Apply guide (side) -A- to body.
– Tighten bolts and nut in sequence -1 ... 5-.

Audi A3 2004 ➤
– Insert guide (rear) -A- at guide (side) and tighten bolts in the
sequence -1 ... 3-.

trim
Removing
– Release fasteners -1- overunless
permitted entire length
authorised by and pullAUDI
AUDI AG. bumper
AG doescover
not guarantee or accept any liability
trim -2- out of bumper
withcover
respect -3-
to the-arrow-.
Installing
– Press bumper cover trim into bumper cover until it engages
audibly.
– Install bumper cover (rear) ⇒ page 157 .

(bottom section)
Removing
– If fitted, pull off cover -4- for towing bracket.
– Release fasteners -arrows- and pull bottom section -3- of
bumper cover off bumper cover -2-.
Installing
– Bottom section of bumper cover must be clipped in and must
engage audibly in bumper cover.

Audi A3 2004 ➤

mounting
Removing
– Remove bumper cover mounting -1-.
Installing
3.7 Removing and installing impact bar (ve‐

hicles without towing bracket)
Removing
– Detach impact bar -1-.
Installing
3.8 Removing and installing impact bar (ve‐

hicles with towing bracket) Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removing

– Remove socket -2- for towing bracket ⇒ Electrical system;
General information; Rep. gr. 96 .
Installing
– Install socket for towing bracket ⇒ Electrical system; General
information; Rep. gr. 96 .

Audi A3 2004 ➤
3.9 Installing brackets for parking aid
Note
If a vehicle has been delivered without the brackets for the parking
aid fitted on the bumpers, after the paintwork is done the holes
must first be punched and the brackets must be bonded on.
3.9.1 Tools
♦ Attachment device for PDC holder
permitted unless -authorised
VAS 6614- by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Hand cartridge gun - VAS 5155-
3.9.2 Materials
♦ 2-component plastic adhe‐ 6) 1
sive - D 180 KU2 A1-
♦ Primer for plastic compo‐ 6) 1

nents - D 822 150 A1-
♦ Cleaning solution - D 009 6) 1

401 04-
♦ Primer applicator
6) Follow the manufacturer's instructions supplied with the product.
7) Note minimum drying time ⇒ page 166 .

Audi A3 2004 ➤
3.9.3 Installing brackets
Note
The brackets are installed after the bumper cover has been pain‐
ted.
The 4 markings for the bracket -1- are located on the inside of the
bumper cover.
– If they are missing, determine centre point -2-.
– Pre-drill holes working from inside to outside using drill bit
-3- supplied with tool kit.
Making holes with punch

Audi A3 2004 ➤
– Apply punch with top screw -4-, washer and thrust bearing
-3- from inside of bumper cover -2-.
– Screw on punch bit -1- from outside until it is almost touching
bumper cover -2-.
– Then press punch bit -1- against bumper cover -2-.
– Screw bolt with top screw -4- into punch.
Note
When screwing in the bolt -4-, the punch bit -1- must not be allowed to turn while in contact with the painted
surface of the bumper cover.
– When bolt -4- is turned, punch bit -1- is drawn through material
of bumper cover -2- in direction of -arrow-.
– Remove punch and apply again to punch out remaining holes.

Audi A3 2004 ➤
Inserting brackets in bumper cover
Note
The brackets must be attached in the same position in the new bumper cover as they were in the old one.
– Sand inside of bumper cover and bracket at bonding surfaces,

and clean thoroughly.
– Clean bumper cover and brackets thoroughly with plastic
– Apply a thin coating of primer for plastic components - D 822
150 A1- to bumper cover and bracket, and allow to flash off for
10 minutes.
– Slide bracket -6- onto centring mandrel -3- and push mandrel
through bumper cover.
– Slide on counterhold tool -2- from outside and tighten knurled
nut slightly.
– Align bracket -6- in correct position and according to markings
on bumper cover.

Audi A3 2004 ➤
– Slide on clamp -4- and screw in knurled nut -5- but do not
tighten yet.
– Prepare all brackets up to this step prior to bonding.
Note
♦ The first few centimetres of adhesive from the mixing nozzle may not be properly mixed and must therefore
be discarded.
♦ The adhesive must not be allowed to run past the bonding surfaces into the grooves on the bracket.
– Apply 2-component plastic adhesive - D 180 KU2 A1- to areas

marked by arrows between bracket and bumper cover.
– Tighten knurled nut -3- at centring pin -1-.
– This results in clamp -2- pushing tabs on side of bracket -4-
flat onto bumper cover -5-.
– Perform this step for all brackets.
– After minimum drying time for 2-component plastic adhesive -
D 180 KU2 A1- , remove all centring mandrels.
3.9.4 Minimum drying time
Caution
• A minimum drying time of 30 minutes must be observed

before performing further work on the bumper cover or
brackets.
• The bumper cover must be left at the work station during
this period and must not be moved.

Audi A3 2004 ➤
4 Bumper (rear) - RS 3
⇒ “4.1 Exploded view - bumper cover (rear)”, page 167
⇒ “4.2 Removing and installing bumper cover (rear)”, page 169
⇒ “4.3 Removing and installing bumper cover trim”, page 171
⇒ “4.4 Removing and installing guide (rear) for bumper cover”,
page 171
⇒ “4.5 Removing and installing guide (side) for bumper cover”,
page 172
⇒ “4.6 Removing and installing bumper cover mounting”,
page 172
⇒ “4.7 Removing and installing bumper cover (bottom section)”,
page 172
⇒ “4.8 Removing and installing impact bar”, page 173
4.1 Exploded view - bumper cover (rear)

Bumper cover (rear), bumper cover (bottom section)
1 - Bumper cover (bottom sec‐

tion)
⇒ page 172
2 - Clip
3 - Bolt
❑ 1.8 Nm
4 - Bolt
❑ 2.1 Nm
5 - Bumper cover (rear)
⇒ page 169
6 - Bolt
❑ 2.3 Nm
7 - Rear parking aid sender
⇒ Electrical system;
Rep. gr. 94 with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Bolt
❑ 2.3 Nm
9 - Bumper cover trim
⇒ page 171
10 - Nut
❑ 5 Nm
11 - Bolt
❑ 2x
❑ 1.8 Nm
12 - Cover
❑ For towing eye
4. Bumper (rear) - RS 3 167

Audi A3 2004 ➤
Impact bars (rear), guide (side), guide (rear)
1 - Bolt
❑ 2x
❑ 23 Nm
2 - Impact bar
⇒ page 173
3 - Radio controlled clock re‐
ceiver - J489-
Rep. gr. 90
4 - Bolt
❑ 3x
❑ Tightening sequence
⇒ page 168
5 - Guide (side)
❑ For bumper cover
⇒ page 172
6 - Bolt
❑ 4x
❑ Tightening sequence
⇒ page 169
7 - Nut
❑ 2.5 Nm
8 - Guide (rear)
❑ For bumper cover
⇒ page 171
9 - Bolt
❑ 2x
❑ Tightening torque ⇒ Electrical system; Rep. gr. 90
10 - Nut
❑ 2.0 Nm
11 - Bumper
permittedcover mounting
Guide (rear) for bumper cover - tightening torque and sequence

– Tighten bolts to 1.5 Nm in the sequence -1, 2, 3-.

Audi A3 2004 ➤
Guide (side) for bumper cover - tightening torque and sequence

– Tighten bolts to 1.7 Nm in sequence -1 … 4-.

(rear)
♦ Socket - T40078-
Removing
– Prise off cap -2- from opening -arrow- using a small screw‐
driver.
– Unscrew nut -1- using socket - T40078- .
– Remove outer tail lights ⇒ Electrical system; Rep. gr. 94 .

Audi A3 2004 ➤
– Unscrew bolts -arrows- and press wheel housing liner -2- to

the side.

– Disengage side sections at side panel outwards -arrows-.
– Detach bumper cover -2-.
– If fitted, unplug electrical connectors at parking aid senders
and move clear wiring harness ⇒ Electrical system; Rep. gr.
94 .Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Detach
withbumper cover andofset it down ondocument.
a soft Copyright
surface.
respect to the correctness information in this by AUDI AG.
Installing
• Tightening torques ⇒ page 167 and ⇒ page 168 .
– Install wheel housing liner ⇒ page 244 .
– Install outer tail lights ⇒ Electrical system; Rep. gr. 94 .

Audi A3 2004 ➤

trim
Removing
– Release fasteners -1- over entire length and pull bumper cover
trim -2- out of bumper cover -3- -arrow-.
Installing
– Press bumper cover trim into bumper cover until it engages
audibly.
4.4 Removing and installing guide (rear) for

bumper cover
Removing
– If fitted, unplug electrical connector -2- at radio controlled clock
receiver - J489- .
– Remove guide (rear) -1-.
Installing

Audi A3 2004 ➤
4.5 Removing and installing guide (side) for

bumper cover
Removing
– Remove guide (rear) ⇒ page 171 .
– Unscrew bolts -arrows- and nut -1-.
– Detach guide (side) -2-.
Installing
– Install guide (rear) ⇒ page 171 .

mounting
Removing
– Remove bumper cover mounting -1-.
Installing

(bottom section)
Removing
– Pull off securing clip -2- -arrow A- and remove bolt -1-.
– Carefully release securing tabs in direction of -arrows B-, and
at the same time pull retaining clip out of bumper cover -3- by
pulling on bottom section of bumper cover -4-.
Installing
– Clip bumper cover (bottom section) into bumper cover until it
engages audibly.

Audi A3 2004 ➤
4.8 Removing and installing impact bar

Removing
Installing

Audi A3 2004 ➤
64 – Glazing
1 Flush-bonded windows
Removing and installing flush-bonded windows - general com‐
ments
⇒ “1.1 Removing and installing flush-bonded windows - general
comments”, page 174
⇒ “1.2 Repairing windscreen using special tool VAS 6092 ”, page
176 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ “1.3 Materials”, page 176 with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “1.4 Minimum drying times”, page 177
1.1 Removing and installing flush-bonded

windows - general comments
♦
♦ Removal kit for flush bonded windows - V.A.G 1474 B-
174 Rep. gr.64 - Glazing

Audi A3 2004 ➤
♦ Suction lifter - V.A.G 1344-

♦ Cutting tool - V.A.G 1351-
♦ Windscreen removal kit - V.A.G 1755-
♦ Hand-cartridge gun - V.A.G 1628-
♦ Cartridge heater - V.A.G 1939A-
♦ Electric cutter - V.A.G 1561 A-
♦
1. Flush-bonded windows 175

Audi A3 2004 ➤
♦ Blade - V.A.G 1561/2-

♦ Blade - V.A.G 1561/3-
♦ Scraper - V.A.G 1561/8-
♦ Blade - V.A.G 1561/10-
♦ Double cartridge gun - VAS 5237-
♦ Reel device - V.A.G 1654 A-
1.2 Repairing windscreen using special tool

-VAS 6092-
Note
♦ Windscreens damaged by stone chipping can be repaired us‐

ing windscreen repair kit - VAS 6092- .
♦ The damaged areas must not exceed a certain size, and must
not be within the main field of vision.
♦ For detailed information, refer to the instructions supplied with
each kit.
1.3 Materials
♦ 2-component window
permitted unless authorised adhe‐
by AUDI AG. AUDI AG DA does004 , 2) any liability
600 A2or8)accept
not guarantee
sive
♦ 1-component window adhe‐ DH 009 100 03 9) , 4)

sive
♦ Glass primer/paint primer D 009 200 02
♦ Cutting cord 357 853 999
♦ Cutting wire 357 845 955
8) To process this material use double cartridge gun - VAS 5237- ; observe min‐
imum drying time ⇒ page 177 .
9) Small 110 ml cartridge for sealing and/or for use when the 400 ml double
cartridge is not sufficient; heat using cartridge heater - V.A.G 1939- according to
manufacturer's instructions.

Audi A3 2004 ➤
1.4 Minimum drying times
WARNING
♦ For safety reasons, when installing windscreen or rear

window, use only non-conductive 2-component adhesive
with the designations listed below.
♦ You must NOT drive the vehicle until the minimum drying
time has elapsed, as the vehicle is otherwise not safe to
drive.
Window Vehicle Adhesive sealant Drying time

in hours
Windscreen With
Protected by copyright. Copying forDA 004
private 600 A2purposes, in 3
or commercial part or in whole, is not
airbagby AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
Rear window DA 004 600 A2 3
Side windows DH 009 100 03 3
Cleaning off adhesive sealant
We recommend using adhesive remover D 002 000 10 for clean‐
ing. Always follow the safety instructions.
WARNING
When cleaning from inside the vehicle passenger compart‐

ment, make sure you do not exert outward pressure on the
window you have just fitted.
Painted surfaces:
– First clean painted surface with a dry cloth. Then clean off any
residual dirt using adhesive remover D 002 000 10.
Plastic trim:
– Allow adhesive sealant to dry (approx. 1 hour) and then pull
off.
1. Flush-bonded windows 177

Audi A3 2004 ➤
2 Windscreen
Exploded view - windscreen
⇒ “2.1 Exploded view - windscreen”, page 178
⇒ “2.2 Removing windscreen”, page 179
⇒ “2.3 Preparations before installing a new windscreen”,
page 182
⇒ “2.4 Installing windscreen”, page 184
⇒ “2.5 Removing and installing rain sensor”, page 186
⇒ “2.6 Installing fastening strip for water deflector strip”,
page 188
2.1 Exploded view - windscreen
1 - Windscreen
❑ Installing ⇒ page 184
2 - Glass adhesive
❑ Note different distances
from edge of wind‐
screen.
❑ Note minimum drying
times ⇒ page 177 .
3 - Trim cover
❑ Is cut through with cut‐
ting cord when wind‐
screen is removed.
rately ⇒ page 179 .
❑ Allow glass adhesive to
harden before pressing
component into retain‐
ing strip.
❑ Before assembly, first
remove protective strip
from new windscreen
⇒ page 179 .
5 - Windscreen surround Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Supplied with wind‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
screen
6 - Water deflector strip
❑ Do not press into sur‐
round until glass adhe‐
sive has hardened.
7 - Fastening strip
❑ Assembly ⇒ page 188

Audi A3 2004 ➤
Renewing trim cover
WARNING
When removing remnants of trim cover using glass scraper,

make sure you do not damage black ceramic band.
– Remove remnants of trim cover using a glass scraper.

– Clean bonding area with D 009 401 04.
– Use a soft pencil to make marks at even distance -a- = 10 mm
-1 mm on the ceramic screen coating.
– Apply primer to bonding Protected

area up to these marks using D 009
200 02 and let the primer set for attoleast 10 minutes.

with respect the correctness of information in this document. Copyright by AUDI AG.
– Pull off protective paper from double-sided adhesive tape

-2-.
– Position new trim cover on window at even distance -a- = 10
mm -1 mm (inner edge of primer marking) to edge of window
-1-.
– Press trim cover firmly onto windscreen using a roller.
Removing protective strip

– In the case of a new windscreen, you must, before installing
plenum chamber cover -4-, remove protective beading -2-
from retaining strip -3- on windscreen -1-.
2.2 Removing windscreen

– Remove wiper arms. ⇒ Electrical system; Rep. Gr. 92
– Remove cowl panel trim.
– Pull water deflector on left and right out of fastening strips,
starting at top.
– Remove sun visors on left, in centre and on right ⇒ Rep. gr.
70 ; Trim panels .
– Remove interior mirror. ⇒ Rep. gr. 70 ; Trim panels
– Detach trim on A-pillars (top). ⇒ Rep. gr. 70 ; Trim panels
– Using an awl, pierce adhesive bead from inside at bottom left
corner of windscreen.
2. Windscreen 179
Audi A3 2004 ➤
– Insert cutting cord into awl and pull through into vehicle inte‐
rior.
– Position cutting cord under glass all around windscreen.
– In upper area of windscreen, position cutting cord -2- between

window glass -1- and trim cover -3-.
– When you cut out the windscreen the trim cover will also be
cut through.
Note
If you re-install a windscreen which has been removed, you can

glue a new trim cover to the edge of the glass.
– Fasten end of cutting cord to bolt for securing wiper arms.

– Insert protective cover -V.A.G 1474/13- between windscreen
and dash panel.

Audi A3 2004 ➤
– Secure start of cutting cord in reel device and cut out first sec‐
tion of glass (approx. up to centre of windscreen).
– Move reel device to next position as shown in illustration and

continue to cut out glass.
– Move reel device to next position as shown in illustration and

fit guide roller.
– Route cutting cord as illustrated.
– Cut out glass up to the point where the cutting cord no longer
runs in the guide roller.
– Remove guide roller and continue to cut out glass.
2. Windscreen 181
Audi A3 2004 ➤
– Move reel device to next position as shown and attach guide

roller in top corner of windscreen.
– Route cutting cord as illustrated.
– Insert protective foil -V.A.G 1474/11- between windscreen and
moulded headliner.
– Cut out glass up to the point where the cutting cord no longer
runs in the guide roller.
– Remove guide roller and continue to cut out glass.
– Now repeat these steps in the top left and bottom left corners
of the windscreen.
– Completely cut out windscreen following this procedure.
– Remove glass from windscreen opening using double suction
lifters.
2.3 Preparations before installing a new

windscreen
If you are reusing an undamaged windscreen
– When reusing an undamaged windscreen, cut back remaining
adhesive sealant on the windscreen glass and body flange
until it is even using electric cutter - V.A.G 1561- and scraper
- V.A.G 1561/10- . Do not remove adhesive sealing material
completely. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– The remaining material is required with
as a base for better adhe‐
sion of the newly applied adhesive sealant.
WARNING
Keep bonding surface clean and free from grease. Do not cut
back bonding surface until shortly before installation. Do not
apply primer to bonding surface and do not use cleaning sol‐
ution.
– Renew trim cover at upper edge of windscreen ⇒ page 179 .

If installing a new windscreen:
– Clean all round bonding surface of glass using cleaning solu‐
tion D 009 401 04.
– Apply primer (D 009 200 02) as described below.
WARNING
The ceramic coating on the glass is not a primer. The glass

must always be primed before applying adhesive sealant.

Audi A3 2004 ➤
Applying primer
– Use applicator -1- to apply primer -2- evenly in one stroke.
– Start application with fully soaked felt.
– Drying time approx. 10 minutes.
– Width of primer coat -a- = approx. 20 mm.
– Apply primer centrally in relation to adhesive bead.
Dimensions for applying adhesive

– Adhesive bead -1-.
– Primer -2-.
– Windscreen -3-.
– Dimension -a- = 8 mm
– Dimension -b- = 12 mm
– Dimension -c- = 8 mm (along edge of glass).
Repaired windscreen flange.
– If the windscreen flange has been repaired or renewed, the
paintwork must be restored according to specifications in the
"Assessment of vehicle paintwork" manual and corrosion pro‐
tection must, if necessary, be applied according to the "Sur‐
face Treatments/Chemical Materials" manual.
– First clean repaired area with D 009 401 04, then apply primer
D 009 200 02.
– After completing preparations, cut tip of the nozzle to shape

as shown in illustration.
– Dimension -a- = 12mm.
– Width of adhesive bead = 8 mm.
– Direction of application -arrow-.
Note
The cross-section of the adhesive bead is determined by the noz‐

zle opening and the rate of application.
2. Windscreen 183
Audi A3 2004 ➤
– Apply adhesive sealant around circumference of windscreen

glass as shown.
– Distance between centre of adhesive bead and edge of wind‐
screen is 8 mm.
– Install windscreen glass in windscreen opening using two dou‐
ble suction lifters.
WARNING
The windscreen must be fitted within 15 minutes; otherwise the

adhesive properties of the adhesive sealant will be impaired.
– Align windscreen glass so that spacing is equal on both sides.

– Distance
Protected by between trimfor
copyright. Copying surrounding windscreen
private or commercial purposes, inand
part orroof frame
in whole, is not
must beunless
permitted 4 mm.authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Allow adhesive -1- to dry before pushing water deflector strip

into retaining clips -3- as far as it will go.
– When pressing in, ensure sealing lip of water deflector makes
contact with windscreen and does not slip behind edge of
windscreen.
– Pop rivet -2-.
– Secure windscreen glass in position in windscreen opening
with adhesive tape.
2.4 Installing windscreen

Overview

Audi A3 2004 ➤
1 - Windscreen
❑ Applying primer
⇒ page 183
❑ Applying adhesive
⇒ page 183
2 - Trim cover
❑ Supplied with wind‐
screen
rately.
3 - Glass adhesive
❑ Dimensions for adhe‐
sive bead ⇒ page 183
❑ Dimension -a- 8 mm ±
2 (along edge of glass)
❑ Note minimum drying

times ⇒ page 177
❑ Do not press into fasten‐
ing strip until glass ad‐
hesive has hardened.
5 - Windscreen surround
❑ Supplied with wind‐
screen
❑ Not available as a sepa‐
rate replacement part
6 - Protective strip
❑ Allow glass adhesive to
harden before pressing
component into retain‐
ing strip.
❑ Before assembly of new windscreen, first remove protective strip -6-.
2. Windscreen 185
Audi A3 2004 ➤
2.5 Removing and installing rain sensor

Removing rain sensor
Note
The sensor foil on the rain sensor is destroyed when removing

the rain sensor. You therefore have to renew the sensor foil before
re-installing the rain sensor.
– Exterior mirror removed ⇒ Rep. gr. 70

– Detach clip -3- from retainer plate -1- for mirror base.
– Unplug electrical connector leading to rain sensor.
– Remove rain sensor from mirror base.

– Sensor foil will remain attached to windscreen.
– If you are re-installing the same windscreen, the sensor foil
has to be completely removed from the glass.
– Clean glass surface using cleaning solution D 009 401 04.
Installing rain sensor
Note
If re-installing the same rain sensor please proceed as follows:
– Remove any remains of the sensor foil from the rain sensor.
0
– In addition, clean surface using cleaning solution
D 009 401 04.
Caution
The surface on the sensor must be completely free of foil rem‐

nants.
– Detach the silicone paper from the sensor foil.

– Transparent protective film remains on the sensor foil for the
time being in order to facilitate installation.

Audi A3 2004 ➤
– Place sensor foil on rain sensor, using protective film as an

aid.
– Press sensor foil onto rain sensor in direction of -arrow- (as

shown in illustration), making sure there are no air bubbles.
– Pull transparent protective film off sensor foil.
– Spray cleaning solution D 009 401 04 onto entire surface of

sensor foil and insert sensor in mirror base.
Caution
To ensure it functions correctly, the rain sensor must be fitted

in such a way that it makes contact with the windscreen without
trapping any air bubbles.
– PressProtected
retaining clip for
by copyright. sensor
Copying ontoor mirror
for private base.
commercial purposes, in part or in whole, is not
Renewing rain sensor
Note
To remove the sensor please proceed as already described.
– Remove any remnants of the "old" rain sensor foil from the
windscreen.
2. Windscreen 187
Audi A3 2004 ➤
– Clean contact surface of sensor on windscreen using cleaning

solution D 009 401 04.
– Detach protective film from sensor foil.

– Spray cleaning solution D 009 401 04 onto entire surface of
sensor foil and insert sensor in mirror base.
– Press sensor onto windscreen making sure you do not trap
any air bubbles and position retaining clip on mirror base.
Caution
To ensure it functions correctly, the rain sensor must be fitted

in such a way that it makes contact with the windscreen without
trapping any air bubbles.
2.6 Installing fastening strip for water deflector strip

Audi A3 2004 ➤

❑ Lever out of fastening
strip, starting at bottom.
❑ To install, press into fas‐
tening strip, working
from top to bottom.
2 - Fastening strip
❑ Windscreen removed.
❑ To remove, drill head off
pop rivet -3- and strike
out rivet stem.
3 - Pop rivet
2. Windscreen 189
Audi A3 2004 ➤
3 Removing and installing rear window

⇒ “3.1 Exploded view (vehicles with 3 doors)”, page 190
⇒ “3.3 Removing undamaged rear window”, page 191
⇒ “3.4 Removing damaged rear window”, page 193
⇒ “3.5 Preparations before installing a new rear window”,
page 194
⇒ “3.6 Installation instructions”, page 194
3.1 Exploded view (vehicles with 3 doors)

Notewith respect to the correctness of information in this document. Copyright by AUDI AG.
Cut out rear window using cutting cord 357 845 955 and special
tool -V.A.G 1654- .
1 - Rear window
❑ Removing undamaged
window ⇒ page 191
❑ Removing damaged
window ⇒ page 193
2 - Adhesive bead
from edge of window.
❑ Distance from edge of
window (sides): dimen‐
sion -c- = 33 mm
window (top): dimen‐
sion -a- = 14 mm
window (bottom): di‐
mension -b- = 15 mm
❑ Dimensions for applying
adhesive and adhesive
bead cross-section
⇒ page 194
3 - Trim cover (top/bottom)
❑ Position cutting cord all
around rear window
(from outside) and pull
both ends through into
interior of vehicle using
a piercing awl.
❑ Place cutting cord (at
top and bottom) under‐
neath trim cover.
4 - Outer trim cover
❑ Place cutting cord un‐
derneath trim cover.

Audi A3 2004 ➤
WARNING
When installing window,
wiper motor shaft must
be centrally aligned with
grommet to prevent leak‐
age.
1 - Rear window
window ⇒ page 191
window ⇒ page 193
❑ Align in centre and at
distance -a- to rear lid
(top and bottom). Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Adhesive bead with respect to the correctness of information in this document. Copyright by AUDI AG.

window (top): dimen‐
sion -a- = 18.5 mm.
window (bottom): di‐
mension = 21 mm.
window (sides): dimen‐
sion = 12 mm.
❑ Dimensions for applying
adhesive and adhesive
bead cross-section
⇒ page 194
3 - Spacer
4 - Spacer
3.3 Removing undamaged rear window

– Remove rear lid interior trim ⇒ General body repairs, interior;
Repair group 70; Trim panels .
– Remove rear window wiper ⇒ Electrical system; Repair group
92 .
3. Removing and installing rear window 191

Audi A3 2004 ➤
– Open rear lid and use handle -1- to guide trimming needle be‐
neath sealing lip; then pierce adhesive bead.
– Unscrew handle and insert cutting cord in eye of needle.
– Pull one end of cutting cord through into interior of vehicle; use
pliers and wear gloves.
– Use plastic wedge to release sealing lip from window flange
and spray with cleaning fluid D 009 401 04 (lubricant substi‐
tute).
– Place other end of cutting cord around window using insertion

tube.
– Pull other end of cutting cord -B- into interior of vehicle as

shown using trimming needle and handle.
– Thread end of cutting cord -A- into reel device -V.A.G 1654-
and secure.
– Attach end of cutting cord -B- to rear lid hinge.

Audi A3 2004 ➤
– Secure reel -V.A.G 1654- to rear window as shown.

– Press cutting cord in direction of arrow while cutting out sec‐
tions at sides.
– Cut out window at bottom.
– Move reel to next position and continue to cut out window.

– Press cutting cord in direction of arrow while cutting out section
at bottom of window.
– Cut out section at side of window.
– Press cutting cordwithinrespect
direction of arrowof while
to the correctness cutting
information out sec‐
in this document. Copyright by AUDI AG.
tions at sides.
– Cut out section at top of window.
– Press cutting cord in direction of arrow while cutting out section

at top of window.
– Completely cut out window and remove from rear lid using
double suction lifters -V.A.G 1344- .
3.4 Removing damaged rear window

– Protect body and interior against damage from glass splinters.
– Remove glass fragments down to adhesive sealant.
– Unplug connectors for heated rear window.
– Mask flange all round with fabric-backed adhesive tape.

Audi A3 2004 ➤
– Cut through adhesive sealant (with glass fragments) in win‐

dow opening with electric cutter and blade -V.A.G 1561/10-
(with stop roller).
WARNING
Always wear protective goggles and leather gloves.

rearProtected
window by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the window flangewith
has been damaged during removal, the
paintwork must be restored according to specifications in the “As‐

sessment of vehicle paintwork” manual and corrosion protection
measures must, if necessary, be taken according to the “Surface
Treatments/Chemical Materials” manual.
– Clean window all around bonding area with cleaning fluid Part
No. D 009 401 04.
– Apply primer D 009 200 02 to window in bonding area.
WARNING
The ceramic coating on the glass is not a primer. The glass

must always be primed before applying adhesive sealant.
– Apply primer -2- D 009 200 02 evenly to the window all around
bonding area using applicator -1- Part No. D 009 500 25 (felt
pad with wire).
– Note different distances from edge of window
⇒ Item 2 (page 190) .
– Drying time approx. 10 minutes.
– Width of primer coating = 22 mm.
Note
Do not "rework" primer strip until it has dried completely.
Cross-section of adhesive bead

– Adhesive bead -1-.
– Primer -2-.
– Window -3-.
– Dimension -a- = 8 mm
– Dimension -b- = 12 mm
– Dimension -c-: note different distances from edge of window
⇒ Item 2 (page 190) .
3.6 Installation instructions

– Apply adhesive all around the cleaned and primed window.
– Note differing distances from edge of window
⇒ Item 2 (page 190) .

Audi A3 2004 ➤
WARNING
Window must be fitted within 15 minutes, otherwise the adhe‐

sive properties of the adhesive sealant will be impaired.
– Use double suction lifters to fit window in opening, align in

centre and press in as far as spacing lip on trim strip.
– Secure window glass in position in window opening with ad‐
hesive tape.
– Drying time: 3 hours.
Aerial connections
– Connection -a- = rear window heating
– Connection -b- = aerial for Chorus radio
– Connection -c- = aerial for Concert/Symphony radio
– Connection -d- = aerial for TV
– Connection -d- = anti-theft alarm

Audi A3 2004 ➤
4 Removing and installing side window

⇒ “4.2 Removing undamaged side window”, page 197
⇒ “4.4 Removing undamaged side window”, page 200
⇒ “4.5 Removing damaged side window”, page 203
⇒ “4.6 Preparations before installing a new window”, page 203
⇒ “4.7 Installing side window”, page 204
1 - Pop rivet
❑ Before removing, pull
door seal off door flange
in area of pop rivets.
2 - Trim panel for B-pillar
❑ Before removing trim
panel for B-pillar, drill
out rivet heads and
strike out rivet stems.
3 - Side window
window ⇒ page 197
❑ Before removing:
❑ Remove B- and C-pillar
trims.
❑ Only loosen luggage
compartment side trim,
do not remove. ⇒ Gen‐
eral body repairs, interi‐
or; Repair group 70
window ⇒ page 203
tape
❑ Before installing side
windows, pull off protec‐
tive paper and press
firmly onto body.
5 - Pop rivet
❑ 2x to secure side win‐
dow.
6 - Adhesive bead
❑ Dimension -a- = 7.5 mm
❑ Dimension -b- = 7.5 mm
❑ Dimension -c-
Protected by = 15.5 Copying
copyright. mm for private or commercial purposes, in part or in whole, is not

Audi A3 2004 ➤
4.2 Removing undamaged side window
WARNING
Always wear safety goggles and leather gloves when removing

window.
Remove the following trim panels:

– B-pillar trim ⇒ Rep. gr. 70 .
– C-pillar trim ⇒ Rep. gr. 70 .
– Only loosen trim from side of luggage compartment, do not
remove ⇒ Rep. gr. 70 .
– Pull door seal off door flange in area of trim.
– Drill the rivet heads off the pop rivets -2- and strike out rivet
stems.
– Pull trim panel -1- for B-pillar off side window -3- towards front
-arrows-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pierce adhesive bead using trimming needle and handle from
-V.A.G 1755- .
– Unscrew handle and thread cutting cord into eye of trimming

needle.
4. Removing and installing side window 197

Audi A3 2004 ➤
– Pull one end of cutting cord -A- into vehicle interior as far as
opposite side of the window using trimming needle from -
V.A.G 1755- (use pliers and protective gloves).
– Pull cutting cord -B- with tube from -V.A.G 1755- into moulding
around side window.
– Position cutting cord all round window.

-V.A.G 1755- .
– Unscrew handle and thread end of cutting cord -B- into eye of
trimming needle.
– Pull end of cutting cord -B- into interior of vehicle using trim‐
ming needle (use pliers and protective gloves).
– Attach end of cutting cord -B-, for example, to bracket for belt
guide.
– Attach reel device - V.A.G 1654- as shown and secure cutting

cord in it.

Audi A3 2004 ➤
– Cut out first section at B-pillar and at bottom of window.
Note
Press cutting cord towards body whilst cutting.
– Attach guide roller - V.A.G 1474/1- as shown in illustration.

– Move reel device - V.A.G 1654- to next position and continue
cutting.
WARNING
Always press cutting cord at top onto side window to avoid

damaging the headliner with the cutting cord.

cutting.
– Take out side window using double suction lifter -

V.A.G 1344- .

Audi A3 2004 ➤
1 - Side window
2 - Adhesive bead
– Apply directly next to
trim surrounding win‐
dow edge.
3 - Moulding
– Not a replacement part,
is supplied together with
side window; must not
be damaged during re‐
moval
tape
5 - B-pillar trim
6 - Locating pin
– Not a replacement part,
is supplied together with
side window.
– Locating pin is
permitted cutauthorised
unless when by AUDI AG. AUDI AG does not guarantee or accept any liability
cutting out window.
– If "old" window is re-in‐

stalled, window must be
secured in window
opening using adhesive
tape.
7 - Door seal
4.4 Removing undamaged side window
WARNING

window.
Remove the following trim panels:

– B-pillar trim ⇒ Rep. gr. 70 .
– C- and D-pillar trims ⇒ Rep. gr. 70 .
– Only loosen trim from side of luggage compartment, do not
remove ⇒ Rep. gr. 70 .
– Pull door seal off door flange in area of trim.
-V.A.G 1755- .

Audi A3 2004 ➤
– Unscrew handle and thread cutting cord into eye of trimming

needle.
– Pull one end of cutting cord -A- into vehicle interior as far as
opposite side of the window using trimming needle from -
V.A.G 1755- (use pliers and protective gloves).
– Pull cutting cord -B- with tube from -V.A.G 1755- into moulding
around side window.
– Position cutting cord all round window.

-V.A.G 1755- .
– Unscrew handle and thread end of cutting cord -B- into eye of
trimming needle.
– Pull end of cutting cord -B- into interior of vehicle using trim‐
ming needle (use pliers and protective gloves).
– Attach end of cutting cord -B-, for example, to bracket for belt
guide.

Audi A3 2004 ➤
– Attach reel device - V.A.G 1654- as shown and secure cutting

cord in it.
– Cut out first section at B-pillar and at bottom of window.
Note
Press cutting cord towards body whilst cutting.

cutting.
WARNING
Always press cutting cord at top onto side window to avoid

damaging the headliner with the cutting cord.

cutting.

Audi A3 2004 ➤
– Take out side window using double suction lifter -

V.A.G 1344- .
4.5 Removing damaged side window
WARNING

window.
– Protect body and interior against damage from glass splinters.

– Remove glass fragments down to adhesive sealant.
– Mask flange all round with fabric-backed adhesive tape.
– Cut through adhesive sealant (with glass fragments) in win‐
dow opening with electric cutter and blade -V.A.G 1561/10-
(with stop roller).

window
Note
If window flange is damaged on removal, re-establish paintwork

structure as stipulated in “Vehicle Paintwork” manual and take
anti-corrosion measures if necessary in line with instructions giv‐
en in “surface treatment/chemical materials” binder.
If you are reusing an undamaged window

– When reusing an undamaged window, use a carpet knife to
cut back the remaining adhesive sealant on the window and
body flange for an even surface, but do not remove complete‐
ly.
– The remaining sealant is required as a base for better adhe‐
sion of the new adhesive sealant.
If you are re-installing the "old" window, attach double-sided ad‐
hesive tape D 004 400 to corner section/C-pillar on the trim
surrounding the window.

Audi A3 2004 ➤
WARNING
♦ Keep bonding surface clean and free from grease.

♦ Do not cut back bonding surface until shortly before in‐
stallation.
♦ Do not apply primer to bonding surface and do not use
cleaning solution.
– Apply adhesive bead to remaining adhesive material.

♦ Width of bead = 8 ± 2 mm
♦ Height of bead = 13.5 ± 1.5 mm
Note
We recommend the use of adhesive sealant D 009 100 03 (small

cartridge) for bonding on a single window or D 004 300 05 (2-
component adhesive) for more than one window.
If installing a new window:

– Clean window in bonding area using D 009 401 04 and apply
glass/paint primer D 009 200 02.
– Note 10-minute flash-off time for primer.
– Apply adhesive.
Dimensions for applying adhesive
1 - Adhesive bead
2 - Primer
3 - Window
♦ Width of bead -a- = 8 ± 2 mm
♦ Height of bead -b- = 13.5 ± 1.5 mm
♦ Dimension -c-: note different distances from edge of window
⇒ Item 6 (page 196)
4.7 Installing side

Protected window
– Use double suctionwith
lifter - V.A.G
respect 1344- to
to the correctness press side
of information in thiswindow
document. Copyright by AUDI AG.
into window opening and align window with opening.
– Rivet top and bottom of side window to B-pillar.
– Secure window in opening using adhesive tape.
– Observe drying times.

Audi A3 2004 ➤
– Push trim -1- with clips onto side window -4-.

– Fit trim using pop rivets -2-.
– Fit door seal -3- back onto body flange.

Audi A3 2004 ➤
66 – Exterior equipment
1 Strips and panels
⇒ “1.1 Removing and installing trim panel for B-pillar”,
page 206
⇒ “1.2 Renewing protective side strips”, page 208
⇒ “1.3 Trim cover on door (bottom)”, page 210
⇒ “1.4 Renewing sill panel trims”, page 213
1.1 Removing and installing trim panel for B-

pillar
1 - Pop rivet
❑ To remove, drill out rivet
heads and strike out riv‐
et stems
❑ Detach trim panel from Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
side window -3- by pull‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ing forwards.
❑ When installing, trim
panel with clips must be
pushed onto vent win‐
dow as shown.
❑ Rivet on trim panel,
working from top to bot‐
tom.
3 - Side window
4 - Door seal
❑ Press seal near trim
panel to side before drill‐
ing out rivet heads.
206 Rep. gr.66 - Exterior equipment

Audi A3 2004 ➤
1 - Threaded sleeve
2 - Bracket for trim panel
– Height is adjusted so
that it makes contact
with height buffer on
roof trim strip.
– For correct lateral posi‐

tion lateral buffer (rear)
must make contact with
closed rear door.
– After trim panel has
been installed break lat‐

eral buffer off at break‐

ing point on bracket.
3 - Bolt
♦ 2 Nm
– Push trim panel into
bracket -2- with rear
door closed.
– Close rear door and

align trim panel so that it
is parallel to door frame.
– Secure trim panel with

front bolt -6-.
– Open rear door and se‐

cure trim panel with rear
bolt -6-.
5 - Seal
6 - Bolt
♦ 2 Nm
7 - Grommet
– Grommet must be renewed when re-installing cover -8- after removal.
8 - Cover
– Press locking pin of cover into grommet -7- as shown.
1. Strips and panels 207

Audi A3 2004 ➤
1.2 Renewing protective side strips

Note
♦ Heat protective side strip using hot air blower before removing.
♦ Clean bonding surface with petrol, treat with silicone remover and rub dry.
♦ Before installing, heat protective side strip to approx. 40° C using hot air blower.
♦ Peel off protective film. Attach protective strip in position and then press on firmly using roller.
1 - Protective strip on front door

❑ Self-adhesive, fit into
holes in door and press
Protectedon.
2 -with
Protective strip
respect to the on side
correctness pan‐ in this document. Copyright by AUDI AG.
of information
el
holes on side panel and
press on.
tape
❑ Peel off protective film
before mounting.

Audi A3 2004 ➤
Note
♦ Heat protective side strip using hot air blower before removing.
♦ Clean bonding surface with petrol, treat with silicone remover and rub dry.
♦ Before installing, heat protective side strip to approx. 40° C using hot air blower.
♦ Peel off protective film. Attach protective strip in position and then press on firmly using roller.
1 - Protective strip on front door

holes in door and press
on.
2 - Protective strip on rear door
holes in rear door and
press on.
tape
❑ authorised
Peel offbyprotective film
permitted unless AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to before mounting.

Audi A3 2004 ➤
1.3 Trim cover on door (bottom)

Door (front) and side panel
❑ 1 Nm
2 - Trim cover on door
❑ To remove, open door
and unscrew cross-
head screw -1-byon inside
permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
with of door.
❑ Pull trim cover out of
locking element towards
rear and remove from
door.
Note
♦ Heat protective side strip using

hot air blower before removing.
♦ Clean bonding surface with pet‐
rol, treat with silicone remover
and rub dry.
♦ Before installing, heat protective
side strip to approx. 40° C using
hot air blower.
♦ Peel off protective film. Attach
protective strip in position and
then press on firmly using roller.
3 - Trim cover for side panel

❑ To detach from side
panel pull outwards out
of retaining hooks.
❑ Observe notes listed
above when installing or
removing.
tape
❑ Self-adhesive, detach protective film before mounting
Front door (vehicles with 5 doors)

Audi A3 2004 ➤
❑ 2 Nm
2 - Trim cover for front door
and unscrew cross-
head screw -1- at on in‐
side (front bottom) of
door.
door -3-.
3 - Front door
4 - Sill panel trim
5 - Fastener
❑ Is supplied together with
trim cover
Door (rear) and side panel

Audi A3 2004 ➤
❑ 2 Nm
2 - Trim cover for rear door
and unscrew cross-
head screw -1- at on in‐
side (front bottom) of
door.
door -3-.
3 - Side panel trim
Note
♦ Heat protective side strip using

hot air blower before removing.
♦ Clean bonding surface with pet‐
rol, treat with silicone remover
and rub dry.
♦ Before installing, heat protective
side strip to approx. 40° C using
hot air blower.
♦ Peel off protective film. Attach
protective strip in position and
then press on firmly using roller.
❑ To detach from side
panel pull outwards out
of retaining hooks.
❑ Observe notes listed
above when installing or
removing.
tape
❑ Self-adhesive, detach protective film before mounting
5 - Fastener
❑ Is supplied together with trim cover
6 - Sill panel trim

Audi A3 2004 ➤
Wing panel trim strip

– Before removing, loosen wheel housing liner -4- in area of
cover and push to one side.
– Unscrew Torx bolt -2-.
– Push together retaining hooks -arrows- and pull trim cover
-3- sideways from wing panel.
– Torx bolt: 2.5 Nm
1.4 Renewing sill panel trims
Note
♦ Heat sill panel trim using hot air blower before removing.
♦ Clean bonding surface with petrol, treat with silicone remover
and rub dry.
♦ Before installing, heat sill panel to approx. 40° C using hot air
blower.
♦ Peel off protective film and press sill panel on firmly.

Audi A3 2004 ➤
1 - Sill panel trim (front)

2 - Sill panel trim (rear)
3 - Trim cover (front) for side
member
tape
❑ Peel protective film off
double-sided adhesive
tape -4- before mount‐
ing.
5 - Trim cover (rear front) for
side member

Audi A3 2004 ➤
2 Strips and panels - RS 3

⇒ “2.1 Exploded view - outer sill panel trim, side member trim”,
page 215
⇒ “2.2 Removing and installing sill panel trim (front and rear)”,
page 216
⇒ “2.3 Removing and installing side member trim for wing panel”,
page 217
⇒ “2.4 Removing and installing side member trim”, page 218
2.1 Exploded view - outer sill panel trim, side member trim
1 - Fastener
❑ Black
❑ 2x
2 - Side member trim
❑ For wing
⇒ page 217
3 - Fastener
❑ Orange
❑ 4x
4 - Sill panel trim (front)
logue
⇒ page 216
5 - Sill panel trim (rear)
logue Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ page 216
6 - Retainer (rear)
❑ 2x
7 - Side member trim
❑ For body
⇒ page 218
8 - Fastener
❑ Black
❑ 2x
9 - Nut
❑ 8x
❑ 2.1 Nm
2. Strips and panels - RS 3 215

Audi A3 2004 ➤
2.2 Removing and installing sill panel trim

(front and rear)
♦ Removal wedge - 3409-
♦ Hot air blower - V.A.G 1416-
♦ Cleaning solution - D 009 401 04-
Note
The removal and installation procedures are described for the

front sill panel trim. The procedures are identical at the rear.
Removing
– Carefully heat sill panel trim -2- with hot air blower - V.A.G
1416- .
– Use removal wedge - 3409- to carefully prise sill panel trim off
side member -1- -arrow-.

Audi A3 2004 ➤
Installing
– Clean bonding surface on body with cleaning solution - D 009
401 04- .
– Peel protective film off adhesive strip -3-.
– Fit sill panel trim -2- on side member -1-, making sure that
locating lugs are pressed into mountings -arrows-.
– Press sill panel trim onto side member over entire length.
• Leave vehicle standing at room temperature for at least 2
hours.
2.3 Removing and installing side member

trim for wing panel
♦ Hot air blower - V.A.G 1416-
♦ Cleaning solution - D 009 401 04-

Audi A3 2004 ➤
Removing
– Detach side member trim in area of A-pillar ⇒ page 218 .
⇒ page 245 .
– Remove expanding screws -1- and pull out fastener -2-.
– Carefully heat side member trim -3- with hot air blower - V.A.G
1416- .
– Release fasteners -arrows- and carefully prise side member
trim off wing panel -4- using removal wedge - 3409- .
Installing
– Clean bonding surface on wing with cleaning solution - D 009
401 04- .
– Peel protective film off adhesive strip -3-.
– Fit side member trim -1- on wing panel (front), making sure
that locating lugs -arrows- are pressed into mounting.
– Press side member trim onto wing panel (front) -2-.
⇒ page 245 .
2.4 Removing and installing side member

trim

Audi A3 2004 ➤
Removing
– Remove sill panel trim (front and rear) ⇒ page 216 .
– Remove expanding screws -3- and pull fastener -2- out of side
member trim -1-.
– Remove nuts -1-.

– Carefully prise off side member trim -2- in area of C-pillar -3-
-arrow- using removal wedge - 3409- .
– Detach side member trim and set it down on a soft surface.
Installing
– Apply side member trim on C-pillar and press it on until it en‐
gages audibly in mountings.
– Install sill panel trim (front and rear) ⇒ page 216 .

Audi A3 2004 ➤
3 Removing and installing roof rail
1 - Roof rail
– To remove and install
roof rail, moulded head‐
liner must be lowered.
– Adjuster elements must

be inserted in roof and
be in the correct instal‐
lation position.
– Position rail on roof, fit

studs in adjuster ele‐
ments and tighten hexa‐
gon nuts to 10 Nm.
2 - Adjuster element
Caution
When inserting into roof
make sure adjuster ele‐
ments do not fall into
body shell.
❑ Insert adjuster element

in hole provided and
push it forwards into its
installation position.
❑ Position adjuster ele‐
ment so that it makes
contact, pre-tensioning
it slightly (0.2 Nm).
3 - Hexagon nut permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ 10 Nm

Audi A3 2004 ➤
4 Exterior mirrors
⇒ “4.1 Exploded view - exterior mirror - vehicles up to 05.2009”,
page 221
⇒ “4.2 Installing mirror glass”, page 223
⇒ “4.3 Removing and installing mirror adjustment motor”,
page 223
⇒ “4.4 Removing and installing mirror housing”, page 223
⇒ “4.5 Exploded view - exterior mirror (vehicles from 06.2009 on‐
wards)”, page 225
⇒ “4.6 Removing and installing mirror glass”, page 225
⇒ “4.7 Removing and installing housing for exterior mirror”, page
227
⇒ “4.8 Removing and installing cover for mounting for mirror ad‐
justment unit”, page 228
⇒ “4.9 Removing and installing mounting for mirror adjustment
unit”, page 228
⇒ “4.10 Removing and installing mirror adjustment unit”,
page 229 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Removal lever 80 - 200
4.1 Exploded view - exterior mirror - vehicles up to 05.2009
4. Exterior mirrors 221

Audi A3 2004 ➤
1 - Mirror housing
❑ Can be removed from
door without disman‐
tling entire exterior mir‐
ror ⇒ page 223
2 - Control motor
3 - Mirror adjustment unit
❑ Window frame must be
removed before renew‐
ing mirror adjustment
unit ⇒ page 39 .
❑ Before removing, de‐
tach exterior mirror from
door
❑ To remove, prise off mir‐
ror glass, unplug con‐
nectors for mirror heat‐
ing, unscrew cross-
head screws -6- and
take mirror adjustment
unit out of mirror hous‐
ing -1-.
4 - Mirror glass
❑ Use special tool 80-200
(removal lever) to unclip
mirror glass.
❑ Use fabric-backed ad‐
hesive tape to protect
mirror housing against
damage at top and bot‐
tom.
❑ Press off mirror glass at
bottom first and then at
top.
❑ To install, insert mirror
glass into guide stud and friction finger into friction spring, then press on.
❑ Always use protective gloves, and only exert pressure at centre of glass.
5 - Connector for mirror heating
6 - Electrical connector
❑ Only on vehicles with automatic anti-dazzle exterior mirror
❑ Clip into retaining clips -arrows- on inside of mirror.
7 - Electrical connector
❑ Clipped into bottom of window frame.
❑ 12 Nm
9 - Front door
10 - Sealing
Protected piece
❑ When
with respect installing,
to the correctnessmake surein sealing
of information piece
this document. is seated
Copyright correctly.
by AUDI AG.
11 - Mirror base
❑ Is supplied together with mirror adjustment unit.
❑ Window frame must be removed before removing mirror base.

Audi A3 2004 ➤
4.2 Installing mirror glass

– Fit mirror glass -3- with retainers onto base plate -2- (in direc‐
tion of arrow).
– Friction finger must be inserted into friction spring -arrowof
housing -1-.
– Always use protective gloves, and only exert pressure at cen‐
tre of glass.
4.3 Removing and installing mirror adjust‐

ment motor
– Mirror glass removed
– Unscrew bolts -arrows- from mirror adjustment unit.
– Remove motor -2- from mirror adjustment unit and unplug
electrical connector.
4.4 Removing and installing mirror housing

Audi A3 2004 ➤
1 - Mirror housing
❑ Removing:
❑ Remove bolts -4- from
trim cover -3- and de‐
tach it downwards.
❑ Release housing from
retainers of mirror ad‐
justment unit and lift
housing off.
❑ Installing
❑ Position mirror housing
on mirror adjustment
unit -2- from above.
❑ Retainers -arrows- must
engage in mirror adjust‐
ment unit at top and bot‐
tom ⇒ page 224 .
2 - Mirror adjustment unit
3 - Cover (bottom)
❑ 1 Nm
Mirror locking element (bottom)

– When installing, retainer (arrow -A-) of mirror adjustment unit
-2- must be inserted in retaining hooks of mirror housing -1- in

Audi A3 2004 ➤
4.5 Exploded view - exterior mirror (vehicles from 06.2009 onwards)
1 - Bolt
❑ 2x
❑ 1 Nm
2 - Cover
❑ For mounting for mirror
adjustment unit
⇒ page 228
3 - Turn signal repeater
Rep. gr. 94
4 - Housing for exterior mirror
⇒ page 227
5 - Lane change assist warning
lamp in exterior mirror
Rep. gr. 96
6 - Mounting for mirror adjust‐
ment unit
❑ Window frame must be
removed before renew‐
ing mirror adjustment
unit ⇒ page 39 .
⇒ page 228
7 - Sealing piece
8 - Bolt
❑ 10 Nm
9 - Mirror adjustment unit Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing and installing ⇒ page 229 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 - Bolt
❑ 1 Nm
11 - Mirror glass
4.6 Removing and installing mirror glass


Audi A3 2004 ➤
♦ Removal lever - 80 - 200-
♦ Protective gloves
Removing
WARNING
Risk of injury.
♦ Wear protective gloves.
Note
Mask the area around the mirror housing with a soft cloth to pro‐
tect the paintwork.
– Use removal lever - 80 - 200- to press mirror glass -1- off mirror
adjustment unit -arrow-.
– Unplug electrical connectors -2- and -3- for mirror glass heat‐
ing on rear of mirror glass -1-.
– If fitted, unclip electrical connector -5- from bracket.
– Unplug electrical connector -4-.
Installing
– Position mirror glass at mirror adjustment unit and press mirror
glass on.
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Only exert pressure in the centre of the mirror when pressing on

the mirror glass.

Audi A3 2004 ➤
4.7 Removing and installing housing for ex‐

terior mirror
Removing
– Remove mirror adjustment unit ⇒ page 229 .
Note
Mask the area around the mirror housing with a soft cloth to pro‐
tect the paintwork.

– Release retaining clip -2- and detach exterior mirror housing
-3- from cover -1- -arrows-.
– On vehicles with lane change assist function, pull exterior mir‐

ror housing -1- off only to the extent that electrical connector
becomes visible.
– Unplug electrical connector -2- for lane change assist warning
lamp on front of mounting -3- for mirror adjustment unit.
– Lift off exterior mirror housing -2- and unplug electrical con‐
nector -3-.
– Swivel housing -5- for turn signal bulb out of exterior mirror
housing -arrow-.
Installing
– Install exterior mirror turn signal bulb ⇒ Rep. gr. 94 .

Audi A3 2004 ➤
4.8 Removing and installing cover for

mounting for mirror adjustment unit
Removing
– Remove exterior mirror housing ⇒ page 227 .
– Disengage retaining tabs and retaining hooks -arrows A-.
– Press down cover -1- to the extent that retaining tabs do not
become engaged automatically and then disengage retaining
hook -4- -arrow B-.
– Detach cover from mounting for mirror adjustment unit.
Installing
– Install exterior mirror housing ⇒ page 227 .
4.9 Removing and installing mounting for

mirror adjustment unit
Removing
– Remove door trim ⇒ Rep. gr. 70 .
– Remove trim and bracket for treble loudspeaker ⇒ Rep. gr.
70 .
Remove window frame ⇒ page 39 .

Audi A3 2004 ➤
– Pull catch -3- towards rear -arrow A-, push release mechanism
-4- downwards and unplug electrical connector.
– Lever grommet -2- out of exterior mirror seal.
– Detach retaining lugs from door shell in area of exterior mirror.
– Lift exterior mirror seal -1- off door shell and at the same time
unscrew bolts -arrows-.
– Detach mounting for mirror adjustment unit and at the same
time guide wiring harness out through door opening.
Installing
– Install bracket and trim for treble loudspeaker ⇒ Rep. gr. 70 .
– Install door trim ⇒ Rep. gr. 70 .
4.10 Removing and

Protected by copyright. installing
Copying mirrorpurposes,
for private or commercial adjust‐in part or in whole, is not
ment unitto the correctness of information in this document. Copyright by AUDI AG.
with respect
Removing
– Remove mirror glass ⇒ page 225 .
– Unscrew bolt -1- for mirror adjustment unit -2-.
– Release retaining tabs -arrows- and detach mirror adjustment
unit.
– Unplug electrical connector -1- at mirror adjustment unit -2-.

Installing
– Press mirror adjustment unit onto mirror mounting until it en‐
gages audibly.

Audi A3 2004 ➤
5 Radiator grille
⇒ “5.1 Exploded view - radiator grille”, page 230
⇒ “5.2 Exploded view - radiator grille, RS 3”, page 230
⇒ “5.3 Removing and installing RS 3 emblem”, page 231
⇒ “5.4 Removing and installing radiator grille - RS 3”, page 232
⇒ “5.5 Removing and installing Audi rings”, page 232
5.1 Exploded view - radiator grille

Removing radiator grille
– Release retaining hooks -arrows- fully on bumper cover.
– Pull radiator grille forwards out of bumper cover.
5.2 Exploded view - radiator grille, RS 3

Audi A3 2004 ➤
1 - Bolt
❑ 2x
❑ 1.5 Nm
2 - Number plate holder
3 - Audi rings
⇒ page 232
4 - RS 3 emblem
❑ Equipment version
⇒ page 231
5 - Radiator grille
⇒ page 232
6 - Bolt
❑ 11x
❑ 1.5 Nm
5.3 Removing and installing RS 3 emblem
Removing
– Release retaining springs -2 and 3-.
– Swivel RS 3- emblem -4- out in direction of -arrow-, and at the
same time disengage retaining clip -1- from radiator grille -5-.
Installing
– Position RS 3 emblem on radiator grille and press on retaining
clips until they engage audibly.
5. Radiator grille 231

Audi A3 2004 ➤
5.4 Removing and installing radiator grille -

RS 3
Removing
– Remove impact absorber ⇒ page 150 .
– Release retaining tabs -3- and detach radiator grille -1- from
bumper cover -2- towards rear.
Installing
– Install impact absorber ⇒ page 150 .
5.5 Removing and installing Audi rings

Removing
– Lift securing tabs -4- in direction of -arrow- and release retain‐
ing catches -3-.
– Detach Audi rings -1- from radiator grille -2-.
Installing
– Press Audiunless
permitted rings on until
authorised theyAG.engage
by AUDI audibly.
AUDI AG does not guarantee or accept any liability
– Install radiator grille ⇒ page 232 .

Audi A3 2004 ➤
6 Spoiler
⇒ “6.1 Exploded view - spoiler for rear lid”, page 233
⇒ “6.2 Removing and installing wheel spoiler (front)”, page 234
⇒ “6.3 Removing and installing wheel spoiler (rear)”, page 235
⇒ “6.4 Exploded view - wheel spoiler, RS 3”, page 235
⇒ “6.5 Removing and installing wheel spoiler (front) - RS 3”, page
236
⇒ “6.6 Removing and installing wheel spoiler (rear) - RS 3”, page
236
6.1 Exploded view - spoiler for rear lid
1 - Spoiler
❑ Removing:
– Rear lid trim removed
– Remove bolts -4- and

-6-.
– Heat rear lid in bonded

area with hot air blower
and pull off spoiler.
❑ Installing:
– Remove any remaining
adhesive from rear lid.
– Rear lid must be free

from dust andwithgrease
respect to in
bonding area.
– Clean bonded area of

rear lid with cleaning flu‐
id - D 009 401 04- .
– Peel protective film off
adhesive strip shortly
before fitting.
– Guide wiring harness

through rear lid and fit
spoiler, making sure its
position matches the
contour of the body.
– Starting from the centre,

press spoiler firmly onto
bonding area across full
width.
– Tighten bolts to speci‐

fied torque.
– Plug in electrical connector for wiring harness and slide foam sheath over connectors.
– Install rear lid trim.
2 - Rear lid
3 - Adhesive tape
❑ Peel off protective film shortly before fitting spoiler.
6. Spoiler 233
Audi A3 2004 ➤
4 - Bolt
❑ 4 Nm
5 - Washer
6 - Bolt
❑ 2.5 Nm
6.2 Removing and installing wheel spoiler (front)
1 - Wheel spoiler (front)

❑ To remove, press out
clamp pins of fasteners
-2-.
❑ Pull out fasteners and
remove wheel spoiler.
2 - Fastener
❑ 4 on each side
3 - Wheel housing liner

Audi A3 2004 ➤
6.3 Removing and installing wheel spoiler

(rear)
– Before removing wheel spoiler -1-, unscrew bolts in wheel
housing liner -4- in this area.
– Push wheel housing liner in this area to one side.
– Unscrew bolts -2- and remove wheel spoiler.
– When installing, tighten bolts to 2.5 Nm.
– Clip -3- inserted.
6.4 Exploded view - wheel spoiler, RS 3
1 - Bolt
❑ 2x
❑ 2 Nm
2 - Front section of wheel
housing liner (front)
❑ Exploded view
⇒ page 244
3 - Bolt
❑ 3x
❑ 2.5 Nm
4 - Wheel spoiler (rear)
⇒ page 236
5 - Bolt
❑ 4x
❑ 2 Nm
6 - Wheel spoiler (front)
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6. Spoiler 235
Audi A3 2004 ➤
⇒ page 236

(front) - RS 3
Removing
– Detach wheel spoiler -1-.
Installing

(rear) - RS 3
Removing
– Loosen front section of wheel housing liner (rear) and press to
the side ⇒ page 246 .
– Detach wheel spoiler -1-.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not


– Install wheel housing liner (rear) ⇒ page 246 .

Audi A3 2004 ➤
7 Underbody trim
⇒ “7.2 Removing and installing heat shield for floor”, page 238
⇒ “7.1 Exploded view - heat shields”, page 237
⇒ “7.2 Removing and installing heat shield for floor”, page 238
⇒ “7.3 Removing and installing heat shield for propshaft”,
page 238
⇒ “7.4 Removing andProtected
installing heat shield for tunnel (centre)”,
page 239
⇒ “7.5 Removing and installing heat shield for rear silencer”, page
240
⇒ “7.6 Removing and installing cross member for underbody”,
page 240
⇒ “7.7 Removing and installing Cd underbody panelling”,
page 240
7.1 Exploded view - heat shields
1 - Nut
❑ 2x
❑ 2.1 Nm
2 - Nut
❑ 4x
❑ 2.1 Nm
3 - Heat shield
❑ For tunnel (centre)
⇒ page 239
4 - Bolt
❑ 2.1 Nm
5 - Heat shield
❑ For rear silencer
⇒ page 240
6 - Nut
❑ 2.1 Nm
7 - Cross member
❑ For underbody
⇒ page 240
8 - Nut
❑ 4x
❑ 23 Nm
9 - Heat shield
❑ For propshaft
⇒ page 238
10 - Bolt
❑ 2x
7. Underbody trim 237

Audi A3 2004 ➤
❑ Tightening torque ⇒ Rear final drive 02D, 0AV, 0BR, 0BY; Rep. gr. 39
7.2 Removing and installing heat shield for floor
1 - Heat shield
2 - Speed nut
speed nuts.
❑ To install, only press on
Tucker pin -3-.
3 - Tucker pin
7.3 Removing and installing heat shield for

propshaft
Removing
Caution
Risk of damage to flexible joint.

♦ Do not kink flexible joint more than 10°.
– Release clamps -1, 2-, slide them to rear and slowly lower
catalytic converters.

Audi A3 2004 ➤
– Bend open securing tabs and unscrew bolts -2, 3- and nuts
-1, 5-.
– Take out heat shield -4- towards rear with exhaust pipes hang‐
ing down slightly; at the same time press centre propshaft
bearing upwards.
Installing
– Install centre propshaft bearing ⇒ Rear final drive 02D, 0AV,
0BR, 0BY; Rep. gr. 39 .
– Align exhaust system so it is free of stress ⇒ Rep. gr. 26 .

tunnel (centre)
Removing
– Remove heat shield for propshaft ⇒ page 238 .
– Remove exhaust system (rear) ⇒ Rep. gr. 26 .
– Remove propshaft ⇒ Rear final drive 02D, 0AV, 0BR, 0BY;
Rep. gr. 39 .
– Remove cross member ⇒ page 240 .
– Loosen nuts -1, 2, 3, 5, 6, 7- for Cd panels.
– Bend open securing tabs and unscrew nuts -arrows-.
– Detach heat shield -4- towards rear.
Note
Exhaust system has been removed in illustration.
Installing
Install in reverse order of removal; note the
Protected by following:
copyright. Copying for private or commercial purposes, in part or in whole, is not
– Install propshaft ⇒ Rear final drivewith
02D, 0AV,
respect 0BR,
to the 0BY;
correctness Rep. in this document. Copyright by AUDI AG.
of information
gr. 39 .
– Install heat shield for propshaft ⇒ page 238 .

Audi A3 2004 ➤

rear silencer
Removing
– Remove exhaust system (rear) ⇒ Rep. gr. 26 .
– Bend open securing tabs and unscrew nut -1-.
– Detach heat shield -2- downwards.
Installing
– Install exhaust system (rear) ⇒ Rep. gr. 26 .
7.6 Removing and installing cross member

for underbody
Removing
– Detach cross member -1-.
Installing
Install in reverse order of removal. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
7.7 Removing and installing Cd underbody panelling

Audi A3 2004 ➤
1 - Cd panel (left-side)
❑ When installing under‐
body panelling for the
first time, push it onto re‐
taining pins using open
impact nut.
❑ Close impact nut by
hammering on head of
nut.
❑ Impact nuts must en‐
gage correctly.
❑ Weld studs and impact
nuts must be flush.
❑ When re-installing with
engaged impact nut,
screw on nut and tighten
to 1.5 Nm.
nut.
2 - Impact nut
❑ 8x
❑ When re-installing tight‐
en to 1.5 Nm.
3 - Cd panel (right-side)

Audi A3 2004 ➤
8 Wheel housing liners

⇒ “8.1 Removing and installing wheel housing liner (front)”, page
242
⇒ “8.2 Removing and installing wheel housing liner (rear)”,
page 243
⇒ “8.3 Exploded view - wheel housing liner, RS 3”, page 244
⇒ “8.4 Removing and installing front section of wheel housing liner
(front) - RS 3”, page 245
⇒ “8.5 Removing and installing rear section of wheel housing liner
(front) - RS 3”, page 245
⇒ “8.6 Removing and installing wheel housing liner (rear) - RS 3”,
page 246
8.1 Removing and installing wheel housing liner (front)
1 - Wing panel
2 - Panel bolts
❑ 2 Nm
3 - Panel bolt
❑ 2 Nm
4 - Rear section of wheel hous‐
ing liner (front)
❑ Unscrew Torx bolts -2-
and -3-; compress
wheel housing liner
slightly and remove.
❑ Unscrew bolts -2- at
front section and at tran‐
sition to rear section.
❑ Remove front section
downwards.
❑ Please note cut-out for
vehicles with auxiliary
heater ⇒ page 243 .
6 - Speed nut
❑ Pushed sideways onto
wheel housing liner

Audi A3 2004 ➤
Vehicles with auxiliary heating
– On vehicles with auxiliary heater you must make the cut-out

(dimensions as specified in the illustration) in the front section
of the wheel housing liner (right-side).
– Dimension -A = 70 mm-.
– Dimension -B = 50 mm-.
8.2 Removing and installing wheel housing liner (rear)
1 - Wheel housing liner (rear)

❑ Rear wheel removed
❑ Unscrew Torx bolts -2-
(6x); lightly press to‐
gether wheel housing
liner and remove.
2 - Torx bolt
❑ 2 Nm
3 - Expanding nut
4 - Wheel spoiler (rear)
5 - Speed nut
❑ Pushed on sideways.
8. Wheel housing liners 243

Audi A3 2004 ➤
8.3 Exploded view - wheel housing liner, RS 3
1 - Bolt
❑ 6x
❑ 1.8 Nm
2 - Speed nut
❑ 6x
⇒ page 245
4 - Rear section of wheel hous‐
ing liner (front)
⇒ page 245
5 - Retainer
❑ For securing wheel
housing liner to wing
6 - Bolt
❑ 8x
❑ 1.8 Nm
7 - Spreader rivet
❑ 2x
8 - Bolt
❑ 1.8 Nm
9 - Wheel housing liner (rear)
❑ withRemoving
respect to theand installing
⇒ page 246
10 - Bolt
❑ 11x
❑ 1.8 Nm

Audi A3 2004 ➤
8.4 Removing and installing front section of

wheel housing liner (front) - RS 3
Removing
– Front wheel removed ⇒ Rep. gr. 44 ; Wheels and tyres; In‐
structions for changing/fitting wheels .
– Remove bolts -1- at transition to rear section of wheel housing
liner ⇒ page 245 .
– Take out wheel housing liner -1-.
Installing
⇒ page 245 .
8.5 Removing and installing rear section of

wheel housing liner (front) - RS 3
Removing
– Remove spreader rivets -8-.
– Unscrew bolt -3- and disengage retainer -4- at wing panel.
Installing
8. Wheel housing liners 245

Audi A3 2004 ➤
8.6 Removing and installing wheel housing

liner (rear) - RS 3
Removing
– Remove bolts -1, 2, 3, 5 … 9-.
Installing

Audi A3 2004 ➤
9 Brand emblems and model badges

⇒ “9.1 Emblems and badges on rear lid (vehicles with 3 doors)”,
page 247
⇒ “9.2 Emblems and badges on rear lid (vehicles with 5 doors)”,
page 249
⇒ “9.3 Emblems and badges on rear lid (S3, RS 3)”, page 252
9.1 Emblems and badges on rear lid (vehicles with 3 doors)
The outer edges of the rear lid are used as reference edges.
Installing:
– Allow vehicle and brand emblem to adjust to room tempera‐

ture.
– Bonding surfaces must be dry and free from dust and grease.
9. Brand emblems and model badges 247

Audi A3 2004 ➤
– Clean outer panel with petrol, treat with silicone remover and
rub dry.
– Remove protective paper and press on parts of emblem -1- for
approx. 3 seconds.
– After gluing on emblem, press on firmly using roller.
Dimensions for vehicles with front-wheel drive
Dimensions for vehicles with four-wheel drive

Audi A3 2004 ➤
9.2 Emblems and badges on rear lid (vehi‐

cles with 5 doors)
Note
The outer edges of the rear lid are used as reference edges.
Installing: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi A3 2004 ➤
– Allow vehicle and brand emblem to adjust to room tempera‐

ture.
– Bonding surfaces must be dry and free from dust and grease.
– Clean outer panel with petrol, treat with silicone remover and
rub dry.
– Remove protective paper and press on parts of emblem -1- for
approx. 3 seconds.
– After gluing on emblem, press on firmly using roller.
Dimensions for vehicles with front-wheel drive

Audi A3 2004 ➤
♦ a = 30 mm
♦ b = 26 mm
♦ c = 149 mm
♦ d = 25 mm
♦ f = 151 mm
♦ g = 89 mm
Dimensions for vehicles with four-wheel drive

Audi A3 2004 ➤
♦ a = 30 mm
♦ b = 26 mm
♦ c = 149 mm
♦ d = 25 mm
♦ e = 4 mm
♦ f = 151 mm
♦ g = 89 mm
9.3 Emblems and badges on rear lid (S3,

RS 3)
• The vehicle must be at room temperature before bonding on
emblems and badges.
• All bonding surfaces must be free of dust and grease.
• Clean bonding surface on body with cleaning solution - D 009
401 04- .

Audi A3 2004 ➤
A - Model emblem
• Dimension -a- = 30 mm
• Dimension -b- = 149 mm
• Dimension -c- = 151 mm
-1- “RS 3” model emblem
-2- Reference edge in rear lid
B - Brand logo
• Dimension -d- = 26 mm
-2- Reference edge in rear lid
-3- Centre line

-4- Audi rings

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Service

Service Department. Technical Information

Technical information should

matter of course, be observed.

All rights reserved.

Copyright © 2015 Audi AG, Ingolstadt A0050306220

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1.9 Renewing inner window slot trim strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

58 - Rear doors, door components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

3.8 Removing and installing sunroof sun blind (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

3 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

7.2 Removing and installing heat shield for floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

1.1 Routing and attaching pipes/hoses and

1.2 Contact corrosion

1.3 Bonding surfaces for adhesive strips

♦ Bonding surfaces on the body must be free of dust and grease.

1.4 Self-locking bolts

2 Rep. gr.00 - Technical data

1.2 Exploded view - lock carrier with attachments

Lock carrier can be removed with

Service position: Screw guide pins -

Vehicles from 06.2008 onwards

4 Rep. gr.50 - Body - front

Lock carrier can be removed with

❑ If radiator is also re‐

moved, drain coolant

Service position: Screw guide pins -

7 - Bracket for bumper

12 - Pop rivet nut

Removing and installing headlight mounting

– Position mounting with headlight housing between lock carrier

Removing bracket (left-side) for bumper

6 Rep. gr.50 - Body - front

Removing bracket (right-side) for bumper

1.3 Removing and installing plenum chamber cover

– Before removal, lift off

– To remove cover -3-, lift

– Support the tyre iron e.

– When installing, do not

4 - Surround for cover

8 Rep. gr.50 - Body - front

2.1 Removing and installing wing

Removing and installing closure plate

10 Rep. gr.50 - Body - front

Removing wing panel cover

Seal for wheel housing liner

2.2 Exploded view - wing (RS 3)

12 Rep. gr.50 - Body - front

2.3 Removing and installing trim cover (left-

2.4 Removing and installing closure plate

2.5 Removing and installing wing

– Unscrew bolts -2, 3- and nuts -4-.

– Install bumper cover mounting (front) ⇒ page 149 .

14 Rep. gr.50 - Body - front

2.6 Removing and installing wing bracket

– Carry out corrosion protection measures