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Bumpers - Cabriolet Audi A4 B6

Exterior Body Panels 1 illustration ~1556 words

Front bumper, assembly overview

The following list pertains to (Scheme 14).

  1. Bumper cover Removing and installing bumper, see «FRONT BUMPER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet) Adjustment relative to hood, see «ADJUSTING BUMPER COVER TO HOOD»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__adjusting-bumper-cover-to-hood) Placing number plate mounting holes, see «MAKING NUMBER PLATE MOUNTING HOLES»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__making-number-plate-mounting-holes) Removing and installing bumper, see «FRONT BUMPER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet) If a new part is installed, the number plate mounting holes must only be drilled at the marked locations and the number plate must only be attached at the respective locations.
  2. Combi bolt 6 Nm
  3. Bolt 3 Nm
  4. Support, right
  5. Center support
  6. Cross member Removing, see «CROSS MEMBER, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__cross-member-assembly-overview)
  7. Support, left
  8. Guide piece Removing, see «INSTALLING GUIDE PIECE»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__installing-guide-piece)
  9. Bolt 1.5 Nm
  10. Grommet 2 off Must be inserted into the wing prior to bumper cover installation
  11. Wheel housing liner

Making Number Plate Mounting Holes

Four punch marks are located in the bumper cover number plate area, which must be drilled through to install a number plate (dimensions 115 x 520 mm).

If the punch marks are not visible, proceed as follows

  1. Determine the vertical vehicle center line from the Audi logo to the center of the grille within the bumper.
  2. Determine the horizontal center line: Dimension a = dimension -a
  3. Determine the symmetrical number plate mounting locations as follows: Dimension -x- = 139 mm Dimension -y- = 62 mm

Adjusting Bumper Cover To Hood

  1. Set bumper cover in place, clip in side extensions -arrow- and fasten using the bolts -8-.
  2. Loosely screw in bolt -3-.
  3. Tighten the bolts -2- and -4- to 6 Nm, as well as the bolts -5-; -6- and -7- to 3 Nm.
  4. Close hood.
  5. Check the overlap or gap dimension of the bumper cover with respect to the hood.
  6. If OK, tighten all the bolts to torque.
  7. If not OK, open hood.
  8. Loosen bolts -2- or/and -4-, correct the upper bumper as required, and re-tighten the bolt to torque.
  9. Tighten bolt -3- to 6 Nm.

Installing Fender Grommet

  1. Prior to assembly of bumper -1- the grommet -3- must be pushed onto the threaded pin -2-.
  2. Fender -4-.
  3. Following installation, tighten the cap nut -5- to 6 Nm.

Cross member, assembly overview

The following list pertains to see scheme 5.

  1. Combi bolts 3 Nm
  2. Cross member Attachment to impact absorber see «CROSS MEMBER TO IMPACT ABSORBER, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__cross-member-to-impact-absorber-assembly) Bumper cover removed. Unplug connectors to the signal horn. Unscrew bolts -4- by approx. 15 turns and remove cross member toward the front.
  3. Supports
  4. Hex socket-head bolt 26 Nm
  5. Impact absorber Removal, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__impact-absorber-removing-and-installing) .
  6. Hollow rivet
  7. Signal horn To remove, drill out hollow rivet heads and drive out rivet stems.
  8. Guide piece Removing, see «INSTALLING GUIDE PIECE»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__installing-guide-piece)

Installing Guide Piece

  1. When installing guide piece -1- tighten the bolts in the following sequence.
  2. Tighten the bolts -2- to 4 Nm in the first pass
  3. Then secure the strut -4- with bolt -3-.
  4. Finally tighten bolt -1- to 6 Nm.

Removing

  1. To do so, loosen the bolts or quick release fasteners -1- and -2-. The rear noise insulation -quick release fasteners 3- remain installed.
  2. The quick-release fasteners remain in the bumper cover -1-.
  3. Loosen the wheel housing liners on the left and right at the front -arrows-.
  4. Tap the wheel housing liner back -arrow A-.
  5. Unscrew the bolt -2- and the nuts -1-.
  6. Unclip the bumper extension from the catch -arrow B-.
  7. Repeat the procedure on the other side of the vehicle.
  8. Remove bolts -1-.
  9. Tilt the decorative trim -2- slightly forward and pull it out upward from the bumper cover.
  10. Bolts -8- unscrewed.
  11. Unscrew the bolts -2-; -3- and -4- as well as the bolts -5-; -6- and -7-.
  12. Pull the side extensions -arrow- out of the side of the guide piece.
  13. Pull the bumper slightly forward.
  14. Where present, disconnect hose -1- to the headlamp washer unit and drain the washing fluid into a clean container for re-use.
  15. Disconnect the connector(s) -2- to the bumper.

Installing

Note. Prior to assembly of the bumper cover -1- check for presence of the threaded pins -2- at the bumper extensions as well as the grommets -3- in the fenders -4-.

  1. Tighten cap nut to 6 Nm.

Installation is carried out in the reverse order; noting the following

Scheme 14

Scheme 14
Scheme 14
  1. Slide the bumper onto the lock carrier and also connect the hose -1- of the headlamp washer unit as necessary and re-attach the connectors -2- as necessary
  2. Slide the bumper cover into the installation position. Ensure that the threaded pins in the bumper side extensions engage in the holes at the fender.
  3. Tap the wheel housing liner back -arrow A-.
  4. Attach the bumper extension in the catch -arrow B-.
  5. Screw in the nuts -1- (4 Nm) and the bolt -2- (1 Nm).
  6. Repeat the procedure on the other side of the vehicle.

Joint dimensions

Note. The joint dimensions can be checked using the special tool 3371.

  1. Dimension -A- = 2 mm +0.5 mm
  2. Dimension -B- = 0 mm => 0.5 mm
  3. Dimension -C- = 0 mm => 0.5 mm
  1. Set bumper cover in place, clip in side extensions -arrow- and fasten using the bolts -8-.
  2. Loosely screw in bolt -3-.
  3. Tighten bolts -2- and -4- to 6 Nm, and bolts -5-; -6- and -7- to 3 Nm.
  4. Close hood.
  5. Check the overlap or gap dimension of the bumper cover with respect to the hood.
  6. If OK, tighten all the bolts to torque.
  7. If not OK, open hood.
  8. Loosen bolts -2- or/and -4-, correct the upper bumper as required, and re-tighten the bolt to torque.
  9. Tighten bolt -3- to 6 Nm.

Cross member to impact absorber, assembly overview

Note. The impact absorber is self-adjusting, i.e. it can compensate for height tolerances between the cross member and impact absorber when hex socket head bolt is screwed in. On screwing in hex socket head bolts -1-, front cross member is thus automatically held in previously set position and secured.

The following list pertains to see scheme 18.

  1. Hex socket-head bolt 23 Nm
  2. Lower drive bush Plastic part pressed into adjusting bolt. Not a replacement part.
  3. Lower adjustment bolt Screw in all the way but do not tighten prior to assembly of the bumper Left-hand thread Not a replacement part.
  4. Lower threaded bush Secured with locating pin to stop it falling out. Not a replacement part.
  5. Locating pin Not a replacement part.
  6. Impact absorber Removing and installing, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__impact-absorber-removing-and-installing)
  7. Upper threaded bush Secured with locating pin to stop it falling out. Not a replacement part.
  8. Upper adjusting bolt Screw home before assembling bumper. Right-hand thread Not a replacement part.
  9. Cover Removing and installing, see «FRONT BUMPER»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet)
  10. Nut Is supplied together with cross member.
  11. Upper drive bush Plastic part pressed into adjusting bolt. Not a replacement part
  12. Cross member

Impact absorber, removing and installing

  1. Bumper removed.
  2. Unscrew combi bolts -2-.
  3. Unscrew nut -3- and detach impact absorber -1- from longitudinal member.
  4. On installation tighten combi bolts -2- to 50 Nm and hex nut -3- to 4 Nm.

Rear bumper, assembly overview

The following list pertains to see scheme 20.

  1. Guide piece Removing, see «GUIDE PIECE, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__guide-piece-removing-and-installing)
  2. Grommet 2 off on each side Must be inserted into the wing prior to bumper cover installation, see «CHECKING THREADED PINS»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__checking-threaded-pins) .
  3. Cross member Removal, see «BUMPER CROSS MEMBER, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-cabriolet__bumper-cross-member-assembly-overview) .
  4. Bumper cover Removing Unscrew the bolts in the rear portion of the wheel housing liner. Tap the wheel housing liner back and unscrew the bolts -5- from the guide piece. Removing luggage compartment side trim. See «LUGGAGE COMPARTMENT TRIM»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-cabriolet) . Unscrew the cap nuts -7- working from inside the luggage compartment. Unclip the cover side extensions -4- from the guide piece -1-. Pull the cover slightly rearward and disconnect the connectors to the parking aid sensors (on left under rear light) as necessary. Remove the bumper cover rearward.

Checking Threaded Pins

Note. Prior to assembly of the bumper cover -1- check for presence of the threaded pins -2- at the bumper extensions as well as the grommets -3-.

  1. Prior to assembly of bumper -1- the grommets -3- must be pushed onto the threaded pins -2-.
  2. Side panel -4-.
  3. Following installation, tighten the cap nut -5- to 6 Nm.

Guide piece, removing and installing

  1. Bumper removed.
  2. Unscrew bolts -3- and remove guide piece -1-.
  3. Clip -2-.
  4. Upon installation, tighten the screws -3- in sequence -a-, -b-, and -c-.
  5. Tightening torque 1.5 Nm.

Note. The joint dimensions can be checked using the special tool 3371.

  1. Dimension -A- = 2 mm +0.5 mm
  2. Dimension -B- = 0 mm => 0.5 mm
  3. Dimension -C- = 0 mm + 0.5 mm

Bumper cross member, assembly overview

Note. Bumper cover removed.

The following list pertains to see scheme 24.

  1. Bolt 18 Nm 4 off
  2. Grommets
  3. Support piece
  4. Bolt 1.5 Nm
  5. Cross member
  6. Nut 20 Nm 2 off
  7. Bolt 20 Nm 2 off
  8. Impact absorber Insert impact absorber into the cross member -5- and tighten bolt -7- or nut -6- to 20 Nm.

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