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Bumpers - Except Cabriolet Audi A4 B6

Exterior Body Panels 6 illustrations ~2481 words

Front bumper, assembly overview

Note. The following list pertains to (Scheme 6). Socket head bolt 26 Nm Air intake grille Quick release screw Side impact molding Always replace Side impact moldings are secured to bumper with double-sided adhesive tape. It is not possible to remove without destroying. To remove, pull side impact molding away from bumper. Remove any residual adhesive on bumper. Installation on same bumper Bumper must be free of dust and grease in adhesion area Clean bumper using mineral spirits or cleaning solution D 009 401 04. NOTE: Centering holes for centering pins for the exact installation of side impact moldings are already present in bumper Position centering pins with double-sided adhesive tape onto markings of side impact molding. See ADHERING CENTERING PINS ON SIDE IMPACT MOLDING. Remove protective foil from double-sided adhesive tape for side impact molding. Press side impact molding with attached centering pins firmly onto bumper over the entire surface. Installation on new bumper NOTE: Centering holes for side impact molding must be drilled on the new bumper before painting. Position centering holes for side impact moldings on bumper, see SIDE IMPACT MOLDINGS, CENTERING HOLES. Apply side impact moldings to bumper as described above. Bumper With crossmember attached Bumper, removing and installing, see FRONT BUMPER, REMOVING AND INSTALLING. Crossmember, removing and installing, see CROSSMEMBER, REMOVING FROM BUMPER COVER AND INSTALLING Separate two-piece bumper cover, see CROSSMEMBER, REMOVING FROM BUMPER COVER AND INSTALLING Positioning license plate mounting holes, see POSITIONING LICENSE PLATE MOUNTING HOLES Guide piece Removing and installing, see GUIDE PIECE, REMOVING AND INSTALLING Expanding clip 6x Must be inserted into fender before installing bumper cover Grommet 2x Must be inserted into fender before installing bumper cover Impact absorber Self-aligns to correct height in crossmember, see BUMPER TO IMPACT ABSORBER, ASSEMBLY OVERVIEW Fender Special nut 4 Nm Wheelhousing liner Bolt 1 Nm 2x

Side impact moldings, centering holes

  1. Front bumper Position hole to vehicle outside -arrow B- according to marking on bumper. NOTE: If there is no marking in this position, the long hole (as depicted in illustration) must be manufactured at upper/outer edge, according to the lines on bumper, see «POSITIONING CENTERING HOLES»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet__positioning-centering-holes) . Position hole to vehicle center -arrow A- according to marking on bumper.

Positioning centering holes

  1. Position of long holes is indicated by markings on bumper.
  2. Long hole must be aligned to dimensions -a- = +/- 8.5mm and -b- = 15.5 mm as shown
  3. If there is no marking in this area, the long hole must be aligned according to the indicated lines on bumper as shown, with upper edge to horizontal line and with outer edge to vertical line.
  4. Dimension -a- = 8.5 mm.
  5. Dimension -b- = 15.5 mm.

Adhering centering pins on side impact molding

Note. Adhesive and centering pin are in delivery casing of side impact molding.

  1. Remove protective foil from the double-sided adhesive -3- and adhere it onto centering pin -4-.
  2. Remove second protective foil and position centering pin onto marking -arrow- on side impact molding.
  3. Remove protective foils from double-sided adhesive strips -2- and press side impact molding -1- onto bumper.

Positioning license plate mounting holes

There are four centering punch marks on license plate area of bumper cover which must be drilled through for securing a license plate (dimensions 115 x 520 mm).

If centering punch marks are not visible, proceed as follows

  1. Determine vertical bisecting line from Audi emblem to center of grill on bumper.
  2. Determine horizontal bisecting line: Dimension -a- = dimension -a- (divide measurement of license plate area by 2 to determine dimension -a-.
  3. Determine mounting points for license plate symmetrically as follows: Dimension -x- = 139 mm Dimension -y- = 62 mm

Scheme 6

Scheme 6: Removing
Scheme 6: Removing
  1. To ease repair work, remove front noise insulation completely.
  2. For this purpose, remove bolts and quick release screws -1- and -2-. Rear noise insulation (quick release screws -3-) remains installed.
  3. Remove left and right front wheels.
  4. Loosen left and right wheelhousing liners in front area -arrows-.
  5. Pull back wheelhousing liner -arrow A-.
  6. Remove bolt -2- and nuts -1-.
  7. Unclip bumper rear edge from catch -arrow B-.
  8. Repeat procedure on opposite side of the vehicle.
  9. Release catches -1- to -4- using a screwdriver -arrow- and remove air inlet grid on left and right on bottom part of bumper.
  10. Unthread left and right -arrow- retaining bolts until bumper is fully released, then remove bumper.
  11. Pull lock carrier slightly toward front.
  12. If installed, disconnect hose -1- to headlight cleaning system and reserve washer fluid in a clean container for reuse.
  13. Disconnect harness connector(s) -2- to bumper.

Installing

Installation is reverse of removal, noting the following

Note. Before installing bumper, check for the presence of threaded pins at bumper rear edge as well as expanding clips and sleeves in the fenders. Always replace bumper retaining bolts.

  1. Filler washer fluid reservoir to the proper level and operate the windhshield washers, then check for leaks.
  2. Slide bumper onto impact absorber and re-connect hose -1- of headlight cleaning system and electrical harness connectors -2-.
  3. Move bumper into installation position. Make sure that the threaded pins in bumper side edges engage into holes at the fenders.
  4. Install the bumper retaining bolts until the bumper can stay in place without any assistance. Do not tighten completely allowing for any necessary adjustments.
  5. Pull back wheelhousing liner -arrow A-.
  6. Engage bumper rear edge into catch -arrow B-.
  7. Tighten nuts -1- to 4 Nm and bolt -2- to 1 Nm.
  8. Repeat procedure on opposite side of the vehicle.
  9. Tighten left and right retaining bolts for bumper to 23 Nm -arrow-.
  10. Install left and right air inlet grid on bumper. Rest of installation is the reverse of removal.

Bumper to impact absorber, assembly overview

Note. Impact absorber is self-adjusting, i.e. it can compensate for position tolerances in height between bumper and impact absorber when hex socket-head bolts are screwed in. In this way, front bumper is automatically held and secured in the previously set position when hex socket-head bolts -1- are screwed in.

The following list pertains to see scheme 15.

  1. Hex socket-head bolt 23 Nm
  2. Lower carrier bushing Plastic part pressed into adjusting screw. Not sold separately
  3. Lower adjusting screw Screw in completely before installing bumper. Left-hand thread Not sold separately.
  4. Lower threaded bushing Secured against falling out with latching pin. Not sold separately.
  5. Latching pin Not sold separately.
  6. Impact absorber Removing and installing, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet__impact-absorber-removing-and-installing) .
  7. Upper threaded bushing Secured against falling out with latching pin. Not sold separately.
  8. Upper adjusting screw Screw in completely before installing bumper. Right-hand thread Not sold separately.
  9. Bumper cover Removing and installing, see «TWO-PIECE BUMPER COVER, SEPARATING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet__two-piece-bumper-cover-separating)
  10. Nut Part of scope of delivery of crossmember.
  11. Upper carrier bushing Plastic part pressed into adjusting screw. Not sold separately
  12. Crossmember Removing from bumper cover and installing, see «CROSSMEMBER, REMOVING FROM BUMPER COVER AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet__crossmember-removing-from-bumper-cover-and)

Guide piece, removing and installing

The following list pertains to see scheme 16.

  1. Guide piece Bumper removed. Remove bolts -2-.
  2. Bolt 1.5 Nm
  3. Clip
  4. Bumper cover Removing, see «TWO-PIECE BUMPER COVER, SEPARATING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet__two-piece-bumper-cover-separating) On installation bumper cover must engage cleanly in guide piece -1
  5. Collared hex nut 4 Nm Only accessible after front half of wheel housing lining has been unfastened. See «FRONT WHEEL HOUSING LINER, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet__front-wheel-housing-liner-assembly-overview) .

Crossmember, removing from bumper cover and installing

  1. Bumper removed.
  2. Remove horn -4-.
  3. Disconnect hose -5- for headlight washer system on both sides (press release buttons).
  4. Unthread bolts -3- on right spray jet for headlight washer system - spray jet remains installed.
  5. Remove bolts -1- (5x).
  6. Pry off retaining clips -2- (3x).
  7. Swing spray jet for headlight washer system to one side and remove crossmember from bumper cover.

Two-piece bumper cover, separating

  1. Bumper removed.
  2. Remove bolt -2- on both sides.
  3. Release locking tabs for the center piece of air inlet grid and remove it.
  4. Release locking tabs -arrows- and remove lower part -1- of bumper cover.

Impact absorber, removing and installing

  1. Bumper removed.
  2. Remove combination bolts -2-.
  3. Remove nut -3- and pull impact absorber -1- out of crossmember.
  4. When installing tighten combination bolts -2- to 50 Nm and hex nut -3- to 4 Nm.

Bumper cover (sedan), assembly overview

The following list pertains, to see scheme 20.

Scheme 7

Scheme 7: Bumper cover (sedan), assembly overview
Scheme 7: Bumper cover (sedan), assembly overview
  1. Bolt 1 Nm
  2. Wheelhousing liner Removing and installing. See «REAR WHEEL HOUSING LINER, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet__rear-wheel-housing-liner-assembly-overview) .
  3. Combination nut 4 Nm
  4. Special nut 4 Nm
  5. Guide piece Removing and installing, see «GUIDE PIECE, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet)
  6. Clip Installing: see «GUIDE PIECE, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet)
  7. Trim molding
  8. Bolt 2 Nm
  9. Cover Two-piece version One-piece version (for USA) Removing: Remove side luggage compartment trim. See «LUGGAGE COMPARTMENT SIDE TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__luggage-compartment-side-trim-assembly-overview) (except Avant). Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side). Remove special nuts -3- (accessible from luggage compartment). Remove combination nuts -4-. Remove wheel housing liners -2- at rear area. Remove bolts -1- left and right on guide piece -5-. Remove bolts -8-. Unclip side pieces on guide piece. Remove cover. Separating two-piece cover: Disengage locking tabs and separate both pieces of cover.
  10. Side impact molding Replace Side impact moldings are secured to bumper with double-sided adhesive tape. It is not possible to remove without destroying. To remove, pull side impact molding away from bumper. Remove any residual adhesive on bumper. Installation on same bumper Bumper must be free of dust and grease in adhesion area Clean bumper using mineral spirits or cleaning solution D 009 401 04.

Note. Centering holes for centering pins for the exact installation of side impact moldings are already present in bumper

  1. Position centering pins with double-sided adhesive tape onto markings of side impact molding. See «ADHERING CENTERING PINS ON SIDE IMPACT MOLDING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet) .
  2. Remove protective foil from double-sided adhesive tape for side impact molding.
  3. Press side impact molding with attached centering pins firmly onto bumper over the entire surface.

Centering holes for side impact moldings

Note. Centering holes for side impact molding must be drilled on a new bumper before painting.

Scheme 8

Scheme 8: Centering holes for side impact moldings
Scheme 8: Centering holes for side impact moldings
  1. Rear bumper Markings for centering holes are positioned on the inside of the cover -arrows- as shown. Drill through cover at these locations (3x) using a +/- 8.5mm drill bit before painting.

Note. Adhesive -3- and centering pin -4- (3x each) are in delivery casing of side impact molding -1-.

  1. Remove protective foil from the double-sided adhesive -3- and adhere it onto centering pin -4-.
  2. Remove second protective foil and position centering pin onto marking -arrow- on side impact molding.
  3. Remove protective foils from double-sided adhesive strips -2- and press side impact molding -1- onto bumper.

Bumper cover (Avant), assembly overview

  1. Bolt 1 Nm
  2. Wheelhousing liner Removing and installing. See «REAR WHEEL HOUSING LINER, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/mirrors/#exterior-equipment-except-cabriolet__rear-wheel-housing-liner-assembly-overview) .
  3. Combination nut 4 Nm
  4. Special nut 4 Nm
  5. Guide piece Removing and installing, see «GUIDE PIECE, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet)
  6. Clip Installing: see «GUIDE PIECE, REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet)
  7. Supporting strip
  8. Sheet-metal screw 2 Nm
  9. Sealing strip Clipped in cover -12
  10. Trim molding Clipped in cover -12
  11. Side sealing strip Clipped in cover -12
  12. Cover Two-piece version One-piece version (for USA) Removing: Remove side luggage compartment trim. See «SIDE LUGGAGE COMPARTMENT TRIM, ASSEMBLY OVERVIEW»(/audi/a4/b6-2000-2006/remont/gauges-instrument-panels/#interior-trim-except-cabriolet__side-luggage-compartment-trim-assembly-overview) (Avant). Remove bass loudspeaker. See «BASS LOUDSPEAKER -R100- (AVANT), REMOVING AND INSTALLING»(/audi/a4/b6-2000-2006/remont/entertainment-systems/#radio-system-except-cabriolet) Disconnect electrical harness connectors to parking aid sensors at control module (under tail light, left side). Remove combination nuts -3- and special nuts -4- (accessible from luggage compartment). Remove bolts -13-. Remove wheel housing liners -2- at rear area. Remove bolts -1- left and right on guide piece -6- Unclip side-pieces of cover on guide piece. Remove cover. Separating two-piece cover: Disengage locking tabs and separate both pieces of cover. Installing: Install in reverse order of removal. When installing a new bumper cover, insert a new support piece -14- into cover. Disengage support piece only when bumper cover is completely installed. See «DISENGAGING SUPPORT PIECE»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet__disengaging-support-piece) .
  13. Bolt
  14. Support piece Always replace when installing a new bumper cover Disengage only when bumper cover is completely installed. See «DISENGAGING SUPPORT PIECE»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet__disengaging-support-piece) .
  15. Side impact molding Replace Side impact moldings are secured to bumper with double-sided adhesive tape. It is not possible to remove without destroying. To remove, pull side impact molding away from bumper. Remove any residual adhesive on bumper. Installation on new bumper

Note. Centering holes for side impact molding must be drilled on a new bumper before painting.

  1. Position centering holes for side impact moldings on bumper. See «CENTERING HOLES FOR SIDE IMPACT MOLDINGS»(/audi/a4/b6-2000-2006/remont/exterior-body-panels/#bumpers-except-cabriolet) .

Scheme 9

Scheme 9
Scheme 9

Note. Centering holes for side impact molding must be drilled on a new bumper before painting.

Scheme 10

Scheme 10: Centering holes for side impact moldings
Scheme 10: Centering holes for side impact moldings
  1. Rear bumper Markings for centering holes are positioned on the inside of the cover -arrows- as shown. Drill through cover at these locations (3x) using a +/- 8.5mm drill bit before painting.

Note. Adhesive -3- and centering pin -4- (3x each) are in delivery casing of side impact molding -1-.

  1. Remove protective foil from the double-sided adhesive -3- and adhere it onto centering pin -4-.
  2. Remove second protective foil and position centering pin onto marking -arrow- on side impact molding.
  3. Remove protective foils from double-sided adhesive strips -2- and press side impact molding -1- onto bumper.

Disengaging support piece

WARNINGNever disengage support piece in the removed condition - danger of injury.

When re-installing the old bumper cover, the old support piece may remain installed.

  1. When replacing the bumper cover, a new support piece must be clipped into the bumper cover from below.
  2. After completely installing bumper cover, disengage support piece by pulling on disengaging cord -arrow-.

Note. By pulling disengaging cord, tension is released from support piece and reinforces the bumper cover against the crossmember.

Scheme 11

Scheme 11
Scheme 11
  1. Bumper removed.
  2. Remove bolts -1- and detach guide piece -2-.
  3. Tightening torque 1.5 Nm.
  4. Clip -3-.

Crossmember for bumper, assembly overview

Note. Bumper cover removed.

The following list pertains to see scheme 28.

  1. Impact absorber
  2. Bolt 10 Nm 4x
  3. Bolt 20 Nm 2x
  4. Nut 20 Nm 2x
  5. Cross member

Crossmember for bumper (USA vehicles), assembly overview

Note. Bumper cover removed.

The following list pertains to see scheme 29.

  1. Impact absorber
  2. Bolt 10 Nm 4x
  3. Bolt 20 Nm 2x
  4. Nut 20 Nm 2x
  5. Cross member

Crossmember for bumper (vehicles with trailer hitch), assembly overview

Note. Bumper cover removed

The following list pertains to see scheme 30.

  1. Trailer hitch carrier
  2. Bolt 60 Nm 4x
  3. Nut 23 Nm 2x
  4. Mounting clamps 4x
  5. Spacer 2x
  6. Bolt 23 Nm 2x
  7. Cross member

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