Door seal care
The exterior door seals in the Audi-100 require special care, as cracked seals not only do not seal, but also cause strong air pressure noises during the journey. The best pad care product is deer fat. It has another useful effect: in winter it prevents the seals from freezing to the body.
Removing the door
On models with door-mounted speakers, power adjustment or power windows, the door trim must be removed to disconnect the cable plugs. How to do this is described later in the text. The same must be done with the wires and hoses of the central locking system.
Unscrew two hexagon bolts from the upper and lower hinges, remove the door. The hinges remain on the body.
After installation, align the new door (see next section).
Proper door installation
To install and adjust the door, the vehicle must be level on the ground with all four wheels. If the car is raised, then the body may be slightly skewed, due to which the door will end up skewed.
Adjustment: The gap width of the front and rear edges of the doors must match. Otherwise, move the doors.
Gap Width:
- fender / front door: 4-5 mm;
- front door/rear door: 4.5-5.5mm;
- tailgate/side rear: 3.5-4.5mm.
О The contour of the body must be coordinated: check all around whether the center line at the height of the door handles runs smoothly, without steps, and whether the door is set too low or too high. Further: along the front and rear edges, the doors must be in contact with adjacent metal parts, i.e. they must not be moved inward or outward after installation.
Take care of soundproofing. This can be achieved by properly installing the doors. For this «door parts carrier» — i.e. top of door, window frame - must fit exactly into door recess Window glass sits 5.5-7.5mm deeper than the black roof edge trim strip.
Door alignment
Horizontal adjustment to set the door gap: unscrew the rear bolt at the hinge-to-body connection and then slightly unscrew the threaded bush behind it.
Slightly loosen the front bolt at the hinge-to-body connection so that the door can be moved.
Close the door and set the door gap.
Carefully open the door and tighten the front hinge bolts.
Vertical adjustment (circuit): loosen the bolts between the hinge and the body (as already done), move the door up or down.
Tighten the screws again.
Lateral adjustment, front door edge (soundproofing): Loosen the bolts between the hinge and the door frame.
Close the door and slide it in the door opening until it is fully seated.
Open the door, tighten the bolts.
Left: The arrows indicate the hex bolts that are loosened to separate the two parts of the doors. The enlarged image shows the position of the adjustment wedge in the white circle (3), which is more or less advanced to adjust between the carrier parts of the door (1) and the main body of the door (2).
Bottom: Fitting the top edge of the door frame. External seal (2) must fit snugly around the roof column and trim strip. Distance between roof trim (1) and door glass (3) should be 5.5-7.5 mm.
Side adjustment, rear door edge (soundproofing): Slightly loosen the locking bolt that contains the door lock.
Close the door and slide it until it is fully seated in the door niche.
Open the door, tighten the locking bolt.
Check from inside the car whether the door fits evenly against the rubber seals.
Installing the window frame: when the main element of the door is adjusted correctly, the position of the window frame in the door cutout should be checked. The outer door seal must not protrude beyond the roof rail. It must be perfectly positioned along the contour of the door cutout
If adjustment is needed, remove the door trim and loosen the four window frame mounting bolts.
Close the door.
Ask an assistant to push the frame into the door cutout - it's better to push a little harder - the elastic will cushion. Check again: the glass is 5.5-7.5 mm deeper than the black bar along the edge of the roof.
Additionally, please note: there is an adjusting wedge under the front lower fastening of the carrier of the door components, which must always be located here. By changing the position of this wedge, it is possible to adjust the inclination of the door in relation to the parts of the body adjacent to it in the region of the rear door pillar:
If the door at the bottom rear sticks out too far, insert the adjusting wedge deeper. Result: the door swings outward along the top edge and inward along the bottom edge.
If the setting is correct, tighten the bolts from the inside (top first). Tightening torque: 20 Nm.
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