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Bumper Audi A6 C5

Exterior Body Panels 41 illustrations ~2556 words

Note. The following list refers to items in (Scheme 27).

Assembly overview

  1. Air inlet grille To remove pull grille forward
  2. Air inlet grille To remove pull grille forward
  3. Screw 2.5 Nm 3x
  4. Bumper cover Together with impact absorber. For removing and installing, see «FRONT BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) . Cross member from bumper cover removing and installing. See «CROSS MEMBERS FOR BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  5. Screws 2.5 Nm (22 in. lb) 3x
  6. Retainer For headlight washer nozzle
  7. Lid For headlight washer nozzle
  8. Impact absorber
  9. Socket head bolt 23 Nm (17 ft. lb) 2x Install after bumper installation Height adjustment to cross member is self-compensating. See «BUMPER, FASTENING TO IMPACT ABSORBER (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  10. Horn
  11. Cross member From bumper cover. For removing and installing, see «CROSS MEMBERS FOR BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  12. Nut 11 Nm (8 ft.lb)
  13. Bolt 50 Nm (36 ft. lb) 6x
  14. Impact absorber Removal and installation, «IMPACT ABSORBERS, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper)
  15. Torx(R) bolt 1.5 Nm (13 in. lb) 2x
  16. Bracket For fog light
  17. Fog light Removing and installing Up to 2000 models, see «FOG LIGHTS -L22- AND -L23-, SERVICING»(/audi/a6/c5-1997-2001/remont/cruise-control-systems/#lights-switches-exterior-up-to-2000) . For 2001 models and newer, see «FOG LIGHTS»(ref-196302-S15264365382005100900000) .
  18. Rivet 12x
  19. Torx(R) bolt 4 Nm (3 ft. lb) 4x
  20. Headlight washer nozzel assembly For headlight cleaning
  21. Torx(R) bolt 25 Nm (18 ft. lb) 4x
  22. Bumper trim piece
  23. Rivet
  24. Nut 4 Nm (3 ft. lb) 6x
  25. Sleeve Prevents damage to paint surface of bumper cover and fender during removal and installation process
  26. Screw mount 6x Install sleeve -25- before bumper cover installation
  27. Fog light cover for fog light Removal and installation, see «FOG LIGHT COVER, REMOVING AND INSTALLING (AUDI RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper)
  28. Screw 1.5 Nm (13 in. lb) 4x

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28: Removing
Scheme 28: Removing

Scheme 29

Scheme 29
Scheme 29
  1. Pull air grille forward -arrow
  2. Remove screws -1- and -3
  3. Swivel fog light cover -2- to outside edge of bumper cover - arrow
  4. Remove cover

Special tools, test equipment and auxiliary items

  1. 3094 Hose Clamps Up To 25MM Dia.

Removing

Note. All wiring harness straps that have been cut or loosened during removal process must be replaced during installation process.

Scheme 30

Scheme 30: Removing
Scheme 30: Removing

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34
  1. Remove both front wheels
  2. Remove screws -1-, -2-, -3- and -4- and loosen quick-locking attachments for noise insulation panel
  3. Turn front half of wheel housing bowl toward rear.
  4. Remove nuts -1- on both sides of vehicle
  5. To remove side cheeks of the bumper from guide carefully pull out in direction of -arrow-.
  6. Remove screws -1- NOTE: Items -2- and -3- are not apart of this repair procedure.
  7. Pull cover forward from both sides starting from -arrow
  8. Remove left and right retaining screws -arrow- for bumper
  9. Pull the bumper forward.
  10. Clamp headlight washer nozzel hose using tool 3094 Hose Clamp
  11. In addition, release water hose pressure by removing key
  12. Disconnect electrical connector
  13. Remove bumper assembly

Note. Removal of bumper requires the assistance of a second technician

Installing

Installation is reverse of removal. In addition, the following is to be considered

Note. Replace all wiring harness straps in previous locations. Clips must be installed before bumper assembly is installed. See BUMPER COVER, ATTACHING TO FENDER (RS6 ONLY) . Impact absorber is installed vertical to the cross member and has height compensating elements. See BUMPER, FASTENING TO IMPACT ABSORBER (RS6 ONLY) .

  1. Make sure that the sleeve on screw mounting is attached to protect fender from scratching when installation of bumper is taking place
  2. Lock cover into guide

Scheme 35

Scheme 35: Tightening torque
Scheme 35: Tightening torque

Guide, removing and installing (RS6 only)

Note. The following list refers to items in (Scheme 36).

  1. Guide Bumper removed To remove, unscrew self-tapping Phillips-head screw -2-.
  2. Self-tapping screw 1 Nm (9 in.lb)
  3. Clip
  4. Bumper cover For removing, see «FRONT BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) . When installing, bumper cover must latch cleanly into guide -1
  5. Nut 6 Nm (4 ft.lb) Accessible only after loosening front half of wheelhousing liner. See «WHEELHOUSING LINERS, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/mirrors/#exterior-equipment) or «WHEEL HOUSING LINER, REMOVING AND INSTALLING (AUDI RS6)»(/audi/a6/c5-1997-2001/remont/mirrors/#exterior-equipment) .

Scheme 36

Scheme 36
Scheme 36

Note. The following list refers to items in (Scheme 37).

  1. Bumper cover Slide on together with cross member and impact absorber. Clip into left and right guide on fender. Install flanged nuts -4- at fenders.
  2. Expanding clip Expanding clips must be pressed in before installing bumper cover -1- in fender
  3. Fender
  4. Flanged nut 6 Nm (4 ft.lb)

Scheme 37

Scheme 37
Scheme 37

Note. The bushings in the impact absorber compensate for tolerances in the height between the bumper and the impact absorber when the socket-head bolts are installed. The front bumper is held to the previously set position when socket-head bolts -1- are installed.

Note. The following list refers to items in (Scheme 38).

  1. Socket-head bolt 23 Nm (16 ft.lb) M8 x 132
  2. Carrier bushing, lower Plastic part, pressed into adjusting screw No replacement
  3. Adjusting screw, lower Screw fully in before installing bumper Left-hand thread No replacement
  4. Threaded bushing, lower Secure with locking pin No replacement
  5. Locking pin No replacement
  6. Impact absorber For removing and installing, see «IMPACT ABSORBERS, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  7. Threaded bushing upper Secure with locking pin No replacement
  8. Adjusting screw - upper Screw fully in before installing bumper Right-hand thread No replacement
  9. Bumper cover For removing and installing, see «FRONT BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  10. Nut Supplied with replacement cross member
  11. Carrier bushing - upper Plastic part, pressed into adjusting screw No replacement
  12. Cross member For removing and installing, see «CROSS MEMBERS FOR BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .

Scheme 38

Scheme 38
Scheme 38
  1. VAS 5072 Pop Rivet Pliers
  2. Eye protection
  3. Drill
  4. Pop rivet
  1. Remove bumper. See «FRONT BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  2. Remove fog light

See FOG LIGHTS .

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43
  1. Carefully pull headlight washer cover upward to expose mounting plates -arrow
  2. Remove water hose -4- on headlight washer nozzle (depress release key).
  3. Repeat procedure for opposite side of vehicle
  4. Remove nut -1- and screws -2
  5. Remove horn assembly and headlight washer connector
  6. Remove screws -3- and remove spraying nozzle for headlight washer
  7. Drill out pop rivets -1-, -2- and -3- on bumper
  8. Remove for fog lights
  9. Remove screw -arrow- at the left and right of cross member
  10. Remove screws -arrow- for cross members
  11. Remove cross member and impact absorber from bumper

Installation is reverse of removal

Tightening torques

ComponentNm
Cross member Inner2.5 (22 in.lb)
Cross member Outer1 (9 in.lb)
Horn11 (8 ft.lb)

TIGHTENING TORQUES: CROSS MEMBERS (RS6)

  1. Remove bumper. See «FRONT BUMPER COVER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  2. Remove screws -arrow
  3. Remove impact absorber from side member

Installation is reverse of removal

Scheme 44

Scheme 44: Installing
Scheme 44: Installing
ComponentNm
Impact absorber50 (36 ft.lb)

TIGHTENING TORQUES: IMPACT ABSORBER (RS6)

Note. The following list refers to item in (Scheme 45).

  1. Bumper cover Removing: Front tires removed Front half of wheelhousing loosened. See «WHEELHOUSING LINERS, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/mirrors/#exterior-equipment) or «WHEEL HOUSING LINER, REMOVING AND INSTALLING (AUDI RS6)»(/audi/a6/c5-1997-2001/remont/mirrors/#exterior-equipment) . Unscrew flanged nuts -10- on both sides. Unscrew screw w/washer assembly -6- from wheelhousing liner -5-. Remove socket-head bolts -7- and remove bumper cover together with impact absorber toward front. Installing: NOTE: Before installing the bumper, the expanding clips must be pressed in to the fender. See «BUMPER COVER, ATTACHING TO FENDER»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) . When installing the tabs, the bumper cover must latch into clip -4-. Latch bumper cover -1- into guide -2-. Tighten flanged nuts -10- to 6 Nm (53 in. lb). Screw in socket-head bolt -7- and tighten to 23 Nm (17 ft lb). NOTE: The impact absorber is installed vertical to the cross member and has height compensating elements. See «BUMPER, FASTENING TO IMPACT ABSORBER»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  2. Guide For removing and installing, see «GUIDE, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  3. Fender
  4. Clip When installing bumper cover -1-, tab must latch into clip -4
  5. Wheelhousing liner
  6. Screw w/washer assembly 1 Nm (9 in. lb)
  7. Socket-head bolt Install after bumper installation Height adjustment to cross member is self-compensating. See «BUMPER, FASTENING TO IMPACT ABSORBER»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  8. Air inlet grill
  9. Air inlet grill
  10. Flanged nut 6 Nm (53 in. lb)

Scheme 45

Scheme 45
Scheme 45

Note. The following list refers to items in (Scheme 46).

  1. Bumper cover Slide on together with cross member and impact absorber. Clip into left and right guide on fender. Install flanged nuts -4- at fenders.
  2. Expanding clip Expanding clips must be pressed in before installing bumper cover -1- in fender
  3. Fender
  4. Flanged nut 6 Nm (53 in. lb)

Scheme 46

Scheme 46
Scheme 46

Note. The bushings in the impact absorber compensate for tolerances in the height between the bumper and the impact absorber when the socket-head bolts are installed. The front bumper is held to the previously set position when socket-head bolts -1- are installed.

Note. The following list refers to items in (Scheme 47).

  1. Socket-head bolt M8 x 132 23 Nm (17 ft lb)
  2. Carrier bushing, lower Plastic part, pressed into adjusting screw No replacement
  3. Adjusting screw, lower Screw fully in before installing bumper Left-hand thread No replacement
  4. Threaded bushing, lower Secure with locking pin No replacement
  5. Locking pin No replacement
  6. Impact absorber For removing and installing, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper__impact-absorber-removing-and-installing) .
  7. Threaded bushing upper Secure with locking pin No replacement
  8. Adjusting screw, upper Screw fully in before installing bumper Right-hand thread No replacement
  9. Bumper cover For removing and installing, see «FRONT BUMPER, REMOVING, INSTALLING AND ASSEMBLY OVERVIEW»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  10. Nut Supplied with replacement cross member
  11. Carrier bushing, upper Plastic part, pressed into adjusting screw No replacement
  12. Cross member For removing and installing, see «CROSSMEMBER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper__crossmember-removing-and-installing) .

Scheme 47

Scheme 47
Scheme 47

Guide, removing and installing

Note. The following list refers to items in (Scheme 48).

  1. Guide Bumper removed To remove, unscrew self-tapping Phillips-head screw -2-.
  2. Self-tapping Phillips-head screw 1 Nm (9 in. lb)
  3. Clip
  4. Bumper cover Removing, see «FRONT BUMPER, REMOVING, INSTALLING AND ASSEMBLY OVERVIEW»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) When installing, bumper cover must latch cleanly into guide -2
  5. Nut 6 Nm (53 in. lb) Accessible only after loosening front half of wheelhousing liner. See «WHEELHOUSING LINERS, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/mirrors/#exterior-equipment) or «WHEEL HOUSING LINER, REMOVING AND INSTALLING (AUDI RS6)»(/audi/a6/c5-1997-2001/remont/mirrors/#exterior-equipment) .

Scheme 48

Scheme 48
Scheme 48

Crossmember, removing and installing

  1. Remove bumper.
  2. Remove Torx(R) screws (arrows) (10x) and remove crossmember.

Note. For vehicles with the headlight washer system, remove only one spray jet.

Scheme 49

Scheme 49
Scheme 49

Impact absorber, removing and installing

  1. Remove bumper.
  2. Remove bolts -2-.
  3. Remove nut -3- and pull out impact absorber -1- from long member.

Scheme 50

Scheme 50
Scheme 50

When installing

  1. Bolts -2- tightening torque: 50 Nm (37 ft lb)
  2. Nut -3- tightening torque: 4 Nm (35 in. lb)

Note. The following list refers to (Scheme 51).

  1. Rear bumper cover For removing and Installing, see «REAR BUMPER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  2. Self-tapping convex head screw 1 Nm
  3. Wheel housing liner
  4. Guide For removing and installing, see «GUIDE, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  5. Hex nut 6 Nm 4x
  6. Hex nut 6 Nm 6x
  7. Socket head bolt 23 Nm 4x
  8. Socket head bolt 2x
  9. Impact absorber For removing and installing, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  10. Hex nut 23 Nm 2x
  11. Cross member For removing and installing, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  12. Impact absorber
  13. Clip For grilles
  14. Sleeve Used to protect fender from damage that might occur during installation of bumper
  15. Screw mount 6x Attach before installation of sleeve
  16. Center grille Removing: Remove Tie-clips 13- and remove grille
  17. Screw 1.5 Nm 2x
  18. Outside grille Removing: Remove Tie-clips 13- and remove grille

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52: Removing
Scheme 52: Removing
  1. Remove trunk cover lining
  2. Disconnect connector -1- for Auxiliary Antenna (Telematic) -R90-, in addition, press ring in direction of -arrow- to sagegaurd.
  3. Loosen trunk lining up to backrest. See «TRIM PANELS (SEDAN)»(/audi/a6/c5-1997-2001/remont/exteriorinterior-trim/#interior-trim) .
  4. Remove tools

Vehicles with rear parking assistance

Scheme 53

Scheme 53
Scheme 53

Scheme 54

Scheme 54
Scheme 54
  1. Remove screws -arrows
  2. Disconnect connectors
  3. Remove -2
  4. Remove noise insulation -1
  5. Disconnect connector -1- at rear parking assistance control module. NOTE: Connectors -2- and -3- remain connected.
  6. Separate wiring harness to bumper.

All

Scheme 55

Scheme 55
Scheme 55

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57
  1. Remove nuts -arrows- in trunk
  2. Remove screws -arrow- on left and on right at lower surface of bumper.
  3. Remove screws -1
  4. To remove side cheeks of the bumper from guide carefully pull out in direction of -arrow-.
  5. Remove bumper and route wiring harness through body opening.

Installation is reverse of removal, although following is to be considered

  1. Make sure that retaining clips -2- are installed into -3- before attaching part -1

Scheme 58

Scheme 58
Scheme 58
ComponentsNm (lb)
Bumper (Installed) Body4 (3 ft.lb)
Bumper (Installed) Guide1 (9 in.lb)

TIGHTENING TORQUES: REAR BUMBER (RS6)

  1. 80-200 Pry Lever

Scheme 59

Scheme 59: Removing
Scheme 59: Removing
  1. Remove rear bumper. See «REAR BUMPER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  2. Remove screws -arrow
  3. With Pry Lever 80-200, pry off clips for antenna
  4. Remove cross member including impact absorber
  5. Remove nuts -1
  6. Remove screws -4- from cross member -2
  7. Remove impact absorbers -3- from cross member

Scheme 60

Scheme 60
Scheme 60

Installation is reverse of removal

ComponentNm (lb)
Impact abosorber (Installed) Cross member23 (17 ft.lb)
Impact abosorber (Installed) Side member23 (17 ft.lb)

TIGHTENING TORQUES: IMPACT ABSORBERS (RS6)

  1. Remove rear bumper. See «REAR BUMPER, REMOVING AND INSTALLING (RS6 ONLY)»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper) .
  2. Remove bolts -1- and remove guide -2

Scheme 61

Scheme 61
Scheme 61

Installation is reverse of removal, although following is to be considered

  1. Make sure that retaining clips -3- are installed into side part before installing guide -1

Scheme 62

Scheme 62
Scheme 62
ComponentNm (lb)
Guide (at fenders)1 (9 in.lb)

TIGHTENING TORQUES: GUIDE (RS6)

Note. The following list refers to items in (Scheme 63).

  1. Bolt w/washer assembly 23 Nm (17 ft lb)
  2. Impact absorber Removing and installing, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper)
  3. Cross member Bumper cover removed Remove bolt w/washer assembly and remove cross member from long member.
  4. Lower back panel trim To remove, remove self-tapping Phillips-head screws -5- (6x)
  5. Self-tapping Phillips-head screw 1.5 Nm (13 in. lb)
  6. Bumper cover Removing: Unscrew flanged nuts -10- (accessible through luggage compartment). Luggage compartment trim must be partially disassembled Remove flanged nuts -11- (accessible through trunk under tail light).
  7. Guide Removing and installing, see «GUIDE, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper)
  8. Screw w/washer assembly 1 Nm (9 in. lb)
  9. Wheelhousing liner
  10. Flanged nut (2x) 6 Nm (53 in. lb)
  11. Flanged nut (2x) 6 Nm (53 in. lb)
  12. Seal

Scheme 63

Scheme 63
Scheme 63

Removing bumper and cross member

Scheme 64

Scheme 64: Impact absorber, removing and installing
Scheme 64: Impact absorber, removing and installing
  1. Remove bolt -2- and impact absorber -1- from cross member -3-.
  2. When installing crossmember -3-, tighten bolt -2- to 23 Nm (17 ft lb).
  1. Remove bumper.
  2. Remove screw w/washer assembly -1- and remove guide piece -2-. Tightening torque: 1 Nm (9 in. lb) Item -3-: clips

Scheme 65

Scheme 65
Scheme 65

Side panel, fastening

  1. Expanding clips -2- must be pressed in before installing cover -1- to side panel -3-.

Scheme 66

Scheme 66
Scheme 66

Note. The procedure for removing and installing the bumper is identical for the Avant and the sedan.

Note. The following list refers to items in (Scheme 67).

  1. Bolt w/washer assembly 23 Nm (17 ft lb)
  2. Impact absorber Removing, see «IMPACT ABSORBER, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper)
  3. Cross member Cover removed Remove bolt w/washer assembly -1- and remove cross member from long member.
  4. Support part, center
  5. Support part, right
  6. Torx(R) screw 1.5 Nm (13 in. lb) Used to fasten support parts left, right and center.
  7. Lower back panel trim To remove, remove self-tapping screws -8
  8. Self-tapping screws 1.5 Nm (13.in. lb)
  9. Cover Removing: To remove, remove flanged nuts - 13- and - 14 - (accessible through luggage compartment). Luggage compartment trim must be partially disassembled.
  10. Guide piece Removing, see «GUIDE, REMOVING AND INSTALLING»(/audi/a6/c5-1997-2001/remont/exterior-body-panels/#bumper)
  11. Screw w/washer assembly 1 Nm (9 in. lb)
  12. Wheelhousing liner
  13. Flanged nuts (2x) 6 Nm (53 in. lb)
  14. Flanged nuts (2x) 6 Nm (53 in. lb)
  15. Support part, left
  16. Seal

Scheme 67

Scheme 67
Scheme 67

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