What to do when you dent your nice trunk…
We have all done something like this at one point or another. A few weeks ago, we attended a car meet with a few friends of the site. As the show came to a close things got a little funny. As everyone was leaving, goofing off while doing so, we managed to dent the crap out of our trunk on the B5. How? Well with another car of course. Luckily the other car only suffered minor injury and we were all able to laugh it off. However the massive dent was not going to fly, so with a bit of bitching we set about ordering a new one online. The replacement trunk came quickly, and we set about replacing the part we had messed up. The job is a simple one, with a few key moments that will cause some frustration. There are three main parts for replacing a trunk on the B5 sedan. The first is removing the liner inside the trunk. It’s not hard, but as usual Audi has filled the thing with screws. The first step involves removing the small fuzz covered screws that hold the trunk liner in place. There are a handful of them, along with two screws in the trunk handle and two that hold the warning triangle in place. Remove all of these to be able to wedge the lining off. (It has wedge clips that also hold it in place.)
Once you have removed the liner, you will see a few things. The wiring harness and air lines for the lights and trunk lock will all be accessible now. There are a total of four plugs that need to be disconnected, it will also help to disconnect the air-line to the trunk lock. (Although not required, as the new trunk will come with the line already.) Below you can see the plugs from the harness. You will then need to pull the harness out of the old trunk, as pictured below. Finally you will need to disconnect the air-line from the trunk at the lower passenger side corner. (You guessed it, pictured below) Once you have pulled out all these connections, the next part of the process can begin.
The last part involved in removing the trunk off the car is the four bolts (two on either side) that hold the trunk to the body. They are either 13 or 15mm and are torqued on tight, however they will come free easily after they are broken. The catch is the angle you have to get to them with. We were unable to get our ratchet in place and had to use a wrench. Also you will notice the rear bolts are adjustable, which will cause you frustration at the end. Just wait for it.
The installation is the opposite of removal, the only catch being the wiring harness. We found that a wire guide was needed to pull the harness back up through the trunk as the spaces between is small. Finally you will have to reconnect the air-line for the lock and bolt the trunk down. Start with the two front bolts (Closest to you) and then place the back bolts in. You will need to adjust the body lines of the new trunk to match your rear quarters, this was a huge pain in the ass. It can be done, and once you have the lines right, tighten the bolts really well. CAREFUL – Do not over tighten the bolts, you will strip them or snap them. Other than that, polish the shit out of your new trunk and don’t mess it up again. Happy wrenching.