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Bumper Audi A8 D3

Exterior Body Panels 1 illustration ~2213 words

Contact corrosion!

With the extensive use of aluminum construction, corrosion caused by contact between dissimilar metals may result if the wrong fastening components (screws, bolts, nuts, washers, rivets, plugs, grommets, adhesives, etc.) are installed.

For this reason, the manufacturer only installs fastening components that have a special surface coating, recognized by its greenish color, and only uses rubber parts, plastic parts and adhesives that are electrically non-conductive.

These parts, compatible for use with aluminum, are also available as replacement parts.

Use only Genuine Parts!

If there is any doubt about whether the old parts are suitable for re-use, always install new replacement parts.

CAUTIONUse only genuine Audi A8 parts! All accessories must be approved by Audi of America, Inc. Damage from contact corrosion caused by improper assembly with unsuitable parts is NOT covered under warranty!

Note. The following list refers to (Scheme 8).

  1. Center air inlet grill
  2. Screw (2x) 1 Nm (9 in. lb)
  3. Bumper cover Removing and installing. See «FRONT BUMPER COVER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  4. Filler panel
  5. Expanding clip (18x)
  6. Impact absorber (2x) Removing: Remove bumper. See «FRONT BUMPER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Remove A/C pressure switch. See «A/C REFRIGERANT SYSTEM (R-134A), VALVES AND SWITCHES»(/audi/a8/d3-2002-2005/remont/automatic-hvac-system/#air-conditioning__ac-refrigerant-system-r-134a-valves-and) . Remove nuts (or bolts) -7- and remove impact absorber. Checking. See «IMPACT ABSORBERS, TESTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__impact-absorbers-testing) .
  7. 23 Nm (17 ft lb) 2x
  8. Bolt 12 Nm (9 ft lb)
  9. Nut
  10. Bracket Different versions on left and right-sides Adjusting. See «FRONT BUMPER, ADJUSTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  11. Nut
  12. Bumper carrier Removing: Remove bumper. See «FRONT BUMPER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Unclip expanding clip -5-. Adjusting. See «FRONT BUMPER COVER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  13. Socket-head screw 65 Nm (48 ft lb)
  14. Air inlet grill
  15. License plate holder Removing and installing. See «LICENSE PLATE HOLDER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__license-plate-holder-removing-and-installing) .
  1. Remove noise insulation panel. See «NOISE INSULATION PANEL, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#body-front__noise-insulation-panel-removing-and-installing) .
  2. Unclip air inlet grill at left and right.
  3. Unclip air guide for generator on right-side a bumper cover.
  4. For vehicles with headlight cleaning system, unclamp hose at T-connector on right-side using 3094 hose clamps.
  5. Pull off hose at T-connector.
  6. Remove clips (3x) in area of front wheelhousing liner and remove both nuts at wheelhousing.
  7. Remove bolts -1-.
  8. Remove bumper -4- toward front.

Adjusting at impact absorbers

  1. Unclip air inlet grill on left and right sides.
  2. Remove bolts -1-.
  3. Insert hex wrench -5- into threaded sleeve -4- through opening for air inlet grill.
  4. Adjust threaded sleeve -4- up or down in impact absorber -3-.

Adjusting at bracket

  1. Loosen bolt -1- of bracket -2- several rotations.
  2. Adjust height of bumper to fender by shifting bracket -2- forward or backward as needed.
  1. Bumper removed
  1. Remove spray jets on vehicles with headlight cleaning system. See «HEADLIGHT WASHER NOZZLES»(ref-150488-S16882769652002111500000) for up to m.y. 1999 and «HEADLIGHT WASHER JETS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/wiperwasher-systems/#windshield-wiper-and-washer-system) for m.y. 2000 on.
  2. Press pins -4- of expanding clips -1- out and pull out expanding clips. see scheme 6
  3. Lift bumper carrier -2- out of bumper cover -3-. see scheme 6 NOTE: During installation, pins must audibly engage in expanding clips.

License plate holder, removing and installing

  1. Remove screws -2-.
  2. Push retaining tabs -3- (5x) in direction of arrow.
  3. Pull out license plate holder -1-.

Note. The following list refers to see scheme 8.

  1. Hex bolt 21 Nm
  2. Impact absorber 2 pieces Removing: Remove bumper. See «FRONT BUMPER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Remove pressure switch. See «A/C REFRIGERANT SYSTEM (R-134A), VALVES AND SWITCHES»(/audi/a8/d3-2002-2005/remont/automatic-hvac-system/#air-conditioning__ac-refrigerant-system-r-134a-valves-and) . Remove hex bolt -1- and pull out impact absorber. Checking. See «IMPACT ABSORBERS, TESTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__impact-absorbers-testing) .
  3. Hex bolt 10 Nm
  4. Hex nut
  5. Bracket Different versions on left and right sides Adjusting. See «ADJUSTING HEIGHT AT BRACKET»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__adjusting-height-at-bracket) .
  6. Bumper carrier Removing: remove bumper Unclip expanding clip -item 5- and remove bumper carrier from cover and spoiler.
  7. Nut
  8. Expanding clip 18 pieces Unclipping. See «CLIP FOR BUMPER COVER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  9. Hex bolt 65 Nm
  10. Trim Removing and installing. See «FRONT TRIM AND SPOILER, ASSEMBLY OVERVIEW»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__front-trim-and-spoiler-assembly-overview) .
  11. Bumper cover
  12. Front spoiler Can be replaced individually Removing and installing. See «FRONT TRIM AND SPOILER, ASSEMBLY OVERVIEW»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__front-trim-and-spoiler-assembly-overview) .
  13. Air guide grill, external
  14. Air guide grill, center
  15. License plate holder

Adjusting height at bracket

  1. Loosen bolt -1- of bracket -2- several rotations.
  2. Adjust height of bumper to fender by shifting bracket forward or rearward.
  1. remove noise insulation.
  2. Unclip air inlet grill at left and right.
  3. Unclip air guide for generator on right side a bumper cover.
  4. For vehicles with a headlight cleaning system, unclamp hose at T-connector on right side using 3094 hose clamps.
  5. Pull off hose at T-connector.
  6. Remove clips (3x) in front region of wheelhousing liner and remove both nuts at wheel housing.
  7. Remove bolts -1-. see scheme 10
  8. Remove bumper -4- toward front.

Adjusting height at impact absorber

  1. Unclip air inlet grill at left and right.
  2. Remove bolts -1-.
  3. Insert hex socket wrench -5- into threaded sleeve -4- through opening for air inlet grill.
  4. Adjust threaded sleeve -4- up or down in impact absorber -3-.

Adjust height at bracket

  1. Loosen bolt -1- of bracket -2- several rotations.
  2. Adjust height of bumper to fender by shifting bracket forward or rearward.

Front trim and spoiler, assembly overview

Note. The following list refers to see scheme 14.

  1. Bumper cover
  2. Trim Before removing, bumper must be removed. To remove, remove Philips-head screws -3- and -4-. Disengage locking lugs of retaining clamp and remove trim toward front. See «FRONT TRIM, REMOVING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__front-trim-removing) . Before installing trim, press retaining clamps into bumper cover
  3. Phillips-head screw
  4. Phillips-head screw
  5. Bumper carrier Removing: Remove clips -8- from upper and lower sides. See «CLIP FOR BUMPER COVER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  6. Spoiler Removing: remove bumper. Remove hex bolt -7-. Remove clips from underside. See «CLIP FOR BUMPER COVER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  7. Hex bolt 21 Nm
  8. Clip Qty: 15
  1. To remove, pull out locking pin -2- as shown.
  2. Remove clip -2- from bumper cover.
  3. To install, clip is pressed into bumper and secured by inserting locking pin.

Front trim, removing

  1. Bumper removed
  1. Remove Phillips-head screw -4-. see scheme 16
  2. Press retaining clamp -3- together lightly using pliers and slide trim out of bumper cover -2-.
  3. Remove Phillips-head screw -3-.
  4. Press locking lugs of retaining clamp -3- together lightly using pliers and slide trim out of bumper cover -2-. see scheme 17
  5. Disengage retaining clamp -1- to get and slide trim completely out of bumper cover.

Front trim, installing

  1. First, press retaining clamps -2- into bumper cover.
  2. Slide trim -1- onto retaining clamps.
  3. Retaining clamps must audibly engage during this.
  4. Re-install Phillips-head screws -4- into retaining clamps -3-.

Note. The following list refers to see scheme 20.

  1. Nut (2x)
  2. Bracket Adjusting. See «REAR BUMPER, ADJUSTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  3. Bolts (2x) 12 Nm (9 ft lb) Remove inside luggage compartment. Remove grommet. Bolt at right-side is not accessible until battery is removed.
  4. Bolt 2.5 Nm (22 in. lb)
  5. Cover For rear crossmember To remove and install, remove rear bumper. See «REAR BUMPER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  6. Impact absorber Removing: Remove rear bumper. See «REAR BUMPER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Remove nuts (or bolts) -7- and remove impact absorber. Testing. See «IMPACT ABSORBERS, TESTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__impact-absorbers-testing) .
  7. 23 Nm (17 ft lb) 3x
  8. Expanding clip (18x)
  9. Bumper carrier Removing: Remove bumper. See «REAR BUMPER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Unclip expanding clips -8-. Adjusting. See «REAR BUMPER, ADJUSTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  10. Bracket To replace square nut in bracket, bend up aluminum retaining piece or push it together if necessary.
  11. Socket-head bolt 65 Nm (48 ft lb) Bolt at right is not accessible until undercar aerodynamic cover is removed. See «UNDERCAR AERODYNAMIC COVERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/mirrors/#exterior-equipment__undercar-aerodynamic-covers-removing-and-installing) .
  12. Bumper cover Removing and installing. See «REAR BUMPER COVER, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  1. Remove undercar aerodynamic cover. See «UNDERCAR AERODYNAMIC COVERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/mirrors/#exterior-equipment__undercar-aerodynamic-covers-removing-and-installing).
  2. For vehicles with parking assistance, remove harness connectors for parking assistance at sensors.
  3. Remove bolts -2-. see scheme 21
  4. Remove bumper -1- toward rear.
  1. Remove middle undercar aerodynamic cover. See «UNDERCAR AERODYNAMIC COVERS, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/mirrors/#exterior-equipment__undercar-aerodynamic-covers-removing-and-installing) .
  2. Remove bolts -2-.
  3. Insert hex wrench -5- into threaded sleeve -2-.
  4. Adjust threaded sleeve -2- up or down in impact absorber -3-.
  1. Remove battery.
  2. Remove rear panel trim and luggage compartment side trim. See «LUGGAGE COMPARTMENT TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim__luggage-compartment-trim-removing) .
  3. Pull off rubber cover and loosen bolts of bracket -4- several rotations.
  4. Adjust height of bumper to fender by shifting bracket forward or backward as needed.
  1. Bumper removed
  1. For vehicles with parking assistance, remove sensor for parking assistance. See «SENSOR FOR PARKING ASSISTANCE, REAR, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/steering-column-switches/#lights-switches-exterior).
  2. Press pins -2- of expanding clips -1- out and pull out expanding clips. see scheme 24
  3. Lift bumper carrier -4- out of bumper cover -3-. NOTE: During installation, pins must audibly engage expanding clips.

Note. The following list refers to see scheme 25.

  1. Nut 2 pieces
  2. Bracket Adjusting. See «REAR BUMPER, ADJUSTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  3. Screw 12 Nm 2 pieces Unscrew inside luggage compartment Remove grommet Bolt at right is not accessible until battery is removed
  4. Gliding piece Removing. See «REMOVING GUIDE»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__removing-guide) .
  5. Impact absorber Removing: Remove bumper. Remove hex bolt -6- and pull impact absorber out of long member. Checking. See «IMPACT ABSORBERS, TESTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__impact-absorbers-testing) .
  6. Hex bolts 23 Nm
  7. Right trim Remove and install as done for front trim. See «FRONT TRIM, REMOVING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__front-trim-removing) .
  8. Center trim Remove left and right trim before removing
  9. Clip To remove, unclip bumper carrier. See «CLIP FOR BUMPER COVER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  10. Bumper carrier Removing: Remove bumper. Unclip expanding clips. Adjusting. See «REAR BUMPER, ADJUSTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  11. Bumper cover Can be replaced individually
  12. Rear spoiler Can be replaced individually Removing and installing. See «TRIM AND REAR SPOILER, ASSEMBLY OVERVIEW»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__trim-and-rear-spoiler-assembly-overview) .
  13. Cylinder bolt 65 Nm

Removing guide

  1. Bumper removed
  1. Remove hex nuts -1- and take off guide.
  2. When installing, tighten hex nuts to 2 Nm.

Trim and rear spoiler, assembly overview

Note. The following list refers to see scheme 27.

  1. Bumper cover Can be replaced individually Remove bumper. Remove clips -5- from upperside. See «CLIP FOR BUMPER COVER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Remove hex bolts -9- Disengage locking mechanisms on cover and remove bumper cover.
  2. Bumper carrier Removing: Remove bumper. Unclip expanding clip -5- and remove bumper carrier from cover and spoiler.
  3. Center trim To avoid damage from scratches, first remove left and right trim Remove Phillips-head screws -10- on both ends of trim. Press locking lugs of retaining clamp together using pliers and slide trim out of bumper cover.
  4. Left trim Remove and install as done for front trim
  5. Expanding clip Qty: 18 Unclipping. See «CLIP FOR BUMPER COVER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .
  6. Rear spoiler Can be replaced individually Remove bumper. Remove hex bolts -9- Remove clips -5- from underside. See «CLIP FOR BUMPER COVER»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) . Disengage locking mechanisms on cover and remove spoiler.
  7. Torx bolts 1 Nm
  8. Ultrasound sensor Remove bumper. Disconnect electric harness connector -7- and remove bolt -7-. Press locking mechanisms slightly apart and remove sensor.
  9. Hex bolt 21 Nm
  10. Phillips-head screw 1 Nm
  1. To remove, pull out locking pin -2- as shown.
  2. Remove clip -2- from bumper cover.
  3. To install, clip is pressed into bumper and secured by inserting locking pin.

Note. The following list refers to see scheme 29.

  1. Bracket
  2. Guide Removing and installing. See «GUIDE, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper__guide-removing-and-installing) .
  3. Bumper cover Slide bumper cover into guide -2- and bracket -1- as shown in illustration. Bumper cover must be guided into both guide -2- and bracket -1-. Tighten machine screw -5- to 65 Nm.
  4. Rear spoiler Can be replaced individually
  5. Machine screw 65 Nm

Guide, removing and installing

  1. Remove hex bolt -1- and take off guide -2-.
  2. When installing, tighten hex bolts to 10 Nm.
  1. Middle underbody cover removed.
  1. Remove bolts -2-.
  2. Insert hex socket wrench -5- into threaded sleeve -2-.
  3. Adjust threaded sleeve -2- up or down in impact absorber -3-.
  1. Remove battery.
  2. Remove rear panel trim and luggage compartment side trim See «LUGGAGE COMPARTMENT TRIM, REMOVING AND INSTALLING»(/audi/a8/d3-2002-2005/remont/gauges-instrument-panels/#interior-trim__luggage-compartment-trim-removing) .
  3. Pull off rubber cover and loosen screws on bracket -4- a few rotations.
  4. Adjust height of bumper to fender by shifting bracket forward or rearward.

Impact absorbers, testing

Note. Impact absorber must always be tested if there is any doubt about its reusability.

Step I: Visual inspection

  1. Perform visual test.

Scheme 8

Scheme 8
Scheme 8
  1. Impact absorbers not broken or bent
  2. No gel leakage Specified length: -a- = 126 mm +/- 1 mm (4.96 in. +/- 0.04 in.) Reuse of impact absorber is possible if visible compression tracks do not exceed 30 mm (1.18 in). If visible compression tracks exceed 30 mm (1.18 in)
  1. Perform function test (test step II). See «STEP 2: FUNCTIONAL TESTING»(/audi/a8/d3-2002-2005/remont/exterior-body-panels/#bumper) .

Note. A broken threaded sleeve can be replaced separately. External oil-like marks are caused by a protecting fluid used by the manufacturer.

Special tools and equipment

  1. VW401 thrust plate
  2. VW402 thrust plate
  3. VAG1290A

Functional testing

  1. Mark impact absorber above collar. Dimension -b-: 45 mm
  2. Using VAG1290A press, compress impact absorber to marking. NOTE: There are no specifications regarding compression speed and force required.
  3. Release press.
  1. Impact absorber may be reused if it returns to original length within maximum of 10 minutes.
  2. Impact absorber must be replaced if it does not return to original length within maximum of 10 minutes.

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