Audi Workshop Service and Repair Manuals

Exploded view of front bumper as of Model Year 2006

1 -

Bolt

q

6 Nm

2 -

Bolt

q

23 Nm

3 -	Bumper cross member

q	Bumper cover removed

q	Removal involves unscrewing the bolts -2-.

q	Unplug the connectors to the horns and detach the bumper cross member to the front from the impact absorbers.

4 -

Pop rivet

5 -

Horn

q	To remove, drill off the rivet heads.

6 -

Support

Make sure the support bracket extends on screwing in the adjusting screw.

q	Before fitting the bumper cover, set the adjusting screw of the support → Fig.

q	Tighten the adjusting screw with a long Torx wrench -T 30- through the holes in the cover -arrows- to 2 Nm.

q	To remove, drill the heads off the pop rivets.

7 -

Pop rivet

8 -

Horn

9 -	Wing brace

10 -

Guide

q	The side section of the bumper cover must be clipped in between the wing and guide → Fig.

11 -

Bolt

q

1 Nm

12 -

Bolt

q

1 Nm

13 -	Bumper cover

On installation, the assembly/attachment sequence described below must be observed to ensure correct fitting.

–	Position the cover on the vehicle and first clip the left and right side sections into the guides -10-.

–	Tighten the nuts at the wing mounting flange → Fig.

–	Tighten the bolts -12- at the wheel housing liner.

–	Loosely screw in the bolts -1-.

q	Close the bonnet and check the alignment of the cover.

q	Correct the position of the cover if necessary and tighten the bolts -12-.

q	Tighten the bolt at the support to 2 Nm → Fig.

q	Removing and installing bumper cover → Chapter

q	Removing and installing cross member → Chapter

Wing mounting flange –  On installation, make sure the clips -2- are attached to the studs. –  Tighten the nuts -4- after inserting the bumper cover -1- in the wing -3-. 4 -  Nut 4 Nm

Adjusting support   Note t  Make sure the support bracket -4- extends on screwing in the adjusting screw -3-. t  If the support bracket does not extend, apply a small droplet (tiny amount) of locking fluid “D 000 600 A2” to the thread of the adjusting screw -3- and allow the locking fluid to harden. t  Screw in the adjusting screw as far as dimension -a-. t  The increased friction causes the support bracket to extend on screwing in the adjusting screw. –  Before fitting the bumper cover -1-, set the adjusting screw -3- of the support -5- to dimension -a- = 21 mm +1 mm. –  The support bracket -4- must be fully screwed in (left-hand thread). –  The adjusting screw -3- and support bracket -4- are part of the scope of delivery of the support and are not replacement parts. –  Screwing in the screw -3- screws out the support bracket -4-, causing it to hold the mount -2- of the bumper cover -1- in the specified position. –  The support -5- is attached to the bumper cover -6- with pop rivets.

Clamping pins for noise insulation –  On removing the bumper cover -1-, turn the clamping pins -2- through 180° and pull them out of the speed nut -4- of the noise insulation -3-.

Removing guide –  Bumper cover removed –  Unscrew the bolts -3- and pull the guide -2- downwards out of the wing -1-. –  On installation, the bumper cover -4- must engage properly in the guide.

Brace for wheel housing liner –  For securing the front wheel housing liner -3-. –  On installing the brace -1-, tighten the bolt -2-. 2 -  Bolt 10 Nm