Table of contents: Safety instructions for bodywork ↓ Safety instructions ↓ Instructions for performing work on… ↓
AUDI A6 cars have a monocoque body. The body is a universal welded structure and includes crumple zones in the front and rear with a safety cell in the center of the car. The windshield and rear glass are glued. Repair of large damage to the body, as well as replacement of glued glass, must be carried out at a service station.
The hood, trunk lid, doors, and front fenders are bolted on and easy to replace. When installing, it is necessary to strictly maintain the correct gap (seam width), otherwise, for example, the door will knock, or increased noise from the wind may occur during movement. In any case, the gap must be parallel, i.e. the distance between the body parts along the entire length of the seam/gap must be strictly the same. Deviations of up to 1 mm are allowed.
The main parts of the A6 body are protected from corrosion by a zinc coating. The external parts of the body are galvanized electrolytically, since these parts and components are easily varnished and easily change their shape. The internal and invisible parts and components are hot-dip galvanized for reasons of economy. To further increase the protection against corrosion, all cavities and parts of the body are filled with wax and the underbody is protected.
Safety instructions for bodywork
If welding work is to be carried out on the body, it must be carried out using contact spot welding. If it is not possible to secure the welding tongs, gas-electric welding is used. Since the body is mostly completely galvanized, the following instructions must be taken into account.
If welding work is to be carried out, the battery must be completely disconnected (+ and - terminals) and both battery terminals (+) and (+) must be carefully insulated. If welding work is to be carried out near the battery, it must be removed.
Attention
- When disconnecting the wires from the battery terminals, the memory units of the control units erase the data on the recorded faults, so before disconnecting the wires, you must contact a workshop to recall the faults recorded in the memory. After connecting the wires to the battery terminals, it is necessary to activate and reprogram the electric windows, as well as the position of the rear-view mirrors and seats.
- If the car has a radio receiver with a code, then before disconnecting the wires from the terminals from the battery, check that there is a code to reactivate the receiver. Otherwise, the radio receiver can only be put into operation at a specialized station.
Safety instructions
When welding galvanized steel sheets, toxic zinc oxide is released, so it is necessary to ensure good ventilation of the workplace.
Increase the welding current (A) by 10% to a maximum of 30%.
Use electrodes made of hard-drawn copper with high thermal resistance (more than + 400°C).
Clean the electrodes frequently. The contact diameter should be 4 mm.
Increase the pressure applied to the electrodes.
Increase the welding time. The welding time is correct if the welding spots do not spatter.
It is prohibited to carry out welding work on parts of a filled air conditioner, as well as soldering with soft or hard solder. This also applies to welding and soldering work on a car if there is a risk of heating of parts and components of the air conditioner.
As part of paintwork repair, the vehicle must be heated in a dry oven or its pre-chamber only to 80°C. Otherwise, electronic devices may be damaged. In addition, excess pressure is created in the air conditioner, which may cause the air conditioner to explode.
Remove the PVC base protection with a rotating wire brush or heat it with a torch to +180°C and remove the PVC layer with a spatula. Heating above this temperature produces hydrochloric acid, which is highly corrosive, and releases harmful vapors.
Instructions for performing work on internal equipment
If work is to be carried out on interior fittings, the following instructions must be followed.
It is recommended to use a special tool to remove the plastic trim. Always replace damaged clips/spring clamps when installing.
Seats and seat belts are safety-related equipment. Therefore, only the work described below should be performed. Do not undertake other work yourself. It is performed by qualified personnel at service centers.
[The original article is available on the online resource AudiManual.ru]