Checking door adjustment with template T40038/4 — AUDI

Checking door adjustment with template
T40038/4
Special tools and workshop equipment required
Template
T40038/4
Use template
T40038/4 for checking (e.g. for wind noise) and adjusting door as described below:
Use a regular bank card (1) or similar to check contact pressure of sealing lip on roof trim strip.
For correct adjustment, template (3) should make contact with top of roof trim strip (2) and roof (1) (arrow).
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.
Card must not penetrate between sealing lip (1) and roof trim strip (2).
Lateral adjustment of door (setting angle)
Template has arms of different length at arrows a and b.
These can be used to check lateral adjustment of doors.
Use side with
“max” mark to check whether window frame is positioned too far outwards.
Use side with
“min” mark to check whether window frame is positioned too far inwards.
Position template at distance a
= 200 mm and with cut-out (arrow) pointing towards the door window.
Make sure points (1) and (3) make contact.
A gap is permissible at point (2) of the template.
This position (max) represents outermost door setting within tolerance range.
If there is no gap at point (2) or if there is a gap at point (1)
, window frame is positioned too far outwards and must be adjusted.
Use side with arrow b (min mark) to check whether window frame is positioned too far inwards towards body.
Position template at distance a
= 160 mm and with cut-out (arrow) pointing away from door window as shown.
Make sure points (2) and (3) make contact with door window.
A gap is permissible at point (1) of the template.
This position (min) represents innermost door setting within tolerance range.
If there is no gap at point (1) or if template contact cannot be established at point (2)
, window frame is positioned too far towards inside and must be adjusted.
Height adjustment of window frame
If it is necessary to adjust height of window frame, fitted bolts (2) and (5) must be exchanged for standard bolts of same property class and length.
Height of window frame (1) can now be adjusted in relation to door (4).
Seals (5) and (2) are inserted into window frame.
Place template on roof as shown, or on upper edge of rain channel.
When correctly adjusted, lower edge of window frame should be inside grooved area a on template.
Check/adjust angle of window frame.
Adjusting front door
Underside of template
T40038/4 (illustration shows different template) can be used to check position of door.
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).