Audi A6 C5 Front Bumper Removal - VAG Links
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-21jatFront bumperFront bumper,removing, installingand assembly overview1 - Bumper coverRemoving:Front tires removedFront half ofwheelhousingloosenedPage66-40- Unscrew flangednuts -10- on bothsides.- Unscrew screw w/washer assembly-6- fromwheelhousingliner -5-.http://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (1 of 18)5/22/2006 5:40:46 PMSearchAdvancedSearchVersion: 2.5r01sp0003
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior- Remove sockethead bolts -7and removebumper covertogether withimpact absorbertoward front.Installing:Note:Before installing thebumper, theexpanding clipsmust be pressed into the fenderPage 63-24 .When installing thetabs, the bumpercover must latchinto clip -4-.http://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (2 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-22- Latch bumpercover -1- intoguide -2-.- Tighten flangednuts -10- to 6 Nm(53 in. lb).- Screw in sockethead bolt -7- andtighten to 23 Nm(17 ft lb).Note:The impact absorber isinstalled vertical to the crossmember and has heightcompensating elementsPage 63-25 .2 - GuideRemoving andPageinstalling63-283 - Fender4 - Cliphttp://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (3 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body ExteriorWhen installingbumper cover -1-,tab must latch intoclip -4-http://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (4 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-235 - Wheelhousing liner6 - Screw w/washerassembly1 Nm (9 in.lb)7 - Socket-head boltInstall after bumperinstallationHeight adjustmentto cross member isself-compensatingPage 63-258 - Air inlet grill9 - Air inlet grill10 - Flanged nut6 Nm (53 on Goto&type repair&id AUDI.C5.BD01.63.2 (5 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-24Bumper cover,attaching to fender1 - Bumper cover- Slide on togetherwith crossmember andimpact absorber.- Clip into left andright guide onfender.- Install flangednuts -4- atfenders.2 - Expanding clipExpanding clipsmust be pressed inbefore installingbumper cover -1- infender3 - Fender4 - Flanged nut6 Nm (53 on Goto&type repair&id AUDI.C5.BD01.63.2 (7 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-25Bumper, fastening toimpact absorberNote:The bushings in theimpact absorbercompensate fortolerances in the heightbetween the bumper andthe impact absorberwhen the socket-headbolts are installed.The front bumper is heldto the previously setposition when sockethead bolts -1- areinstalled.1 - Socket-head bolt M8x 13223 Nm (17 ftlb)2 - Carrier bushing,lowerPlastic part,pressed intoadjusting n Goto&type repair&id AUDI.C5.BD01.63.2 (9 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body ExteriorNoreplacement3 - Adjusting screw,lowerScrew fully inbefore /127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (10 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-264 - Threaded bushing,lowerSecure with lockingpinNoreplacement5 - Locking pinNoreplacement6 - Impact absorberRemoving andPageinstalling63-307 - Threaded bushingupperSecure with lockingpinNoreplacement8 - Adjusting ?action Goto&type repair&id AUDI.C5.BD01.63.2 (11 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body ExteriorScrew fully inbefore //127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (12 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-279 - Bumper coverRemoving andPageinstalling63-2110 - NutSupplied withreplacement crossmember11 - Carrier bushing,upperPlastic part,pressed intoadjusting screwNoreplacement12 - Cross memberRemoving ervlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (13 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-28Guide, removing andinstalling1 - GuideBumper removed- To remove,unscrew selftapping Phillipshead screw -2-.2 - Self-tapping Phillipshead screw1 Nm (9 in.lb)3 - Clip4 - Bumper coverRemoving63-21PageWhen installing,bumper cover mustlatch cleanly intoguide -25 - Nuthttp://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (15 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior6 Nm (53 in.lb)Accessible onlyafter loosening fronthalf ofwheelhousing linerPage n Goto&type repair&id AUDI.C5.BD01.63.2 (16 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-29Crossmember, removing and installing- Removebumper.- Remove Torx screws (arrows) (10x) andremove crossmember.Note:For vehicles with the headlight washer system, removeonly one spray jet.http://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.63.2 (17 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior63-30Impact absorber, removing and installing- Removebumper.- Remove bolts 2-.- Remove nut -3- and pull out impact absorber -1from long member.When installing:Bolts -2- tightening torque: 50 Nm (37 ftlb)Nut -3- tightening torque: 4 Nm (35 on Goto&type repair&id AUDI.C5.BD01.63.2 (18 of 18)5/22/2006 5:40:46 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior66-40jatWheelhousingliners, removingand installingWheelhousing liner,front1 - Fender2 - Torx(T25)bolt1.5 Nm (13 in.lb)3 - Wheelhousingliner, frontRemove frontwheel prior toremovingwheelhousinglinerRemoving:- Releaseclampingpins -6-.http://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.66.11 (1 of 4)5/22/2006 5:43:42 PMSearchAdvancedSearchVersion: 2.5r01sp0003
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior- RemoveTorx bolts-2- (Qty. 3).- Disengagewheelhousingliner fromfender andpull out indownwarddirection.4 - Expanding nutsQty.135 - Sill panel trimhttp://127.0.0.1:8080/audi/servlet/ESIS?action Goto&type repair&id AUDI.C5.BD01.66.11 (2 of 4)5/22/2006 5:43:42 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior66-41Wheelhousing liner,rear1 - RearwheelhousinglinerRemove rearwheel beforeremovingwheelhousingliner- Removescrews -2and cap nut 4-.- Removewheelhousingliner and pullout indownwarddirection.2 - Self-tappingscrew1.5 Nm (13 on Goto&type repair&id AUDI.C5.BD01.66.11 (3 of 4)5/22/2006 5:43:42 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior3 - Expanding nut4 - Cap nut1.5 Nm (13 on Goto&type repair&id AUDI.C5.BD01.66.11 (4 of 4)5/22/2006 5:43:42 PM
Audi A6 Sedan 1998-2004, Audi A6 Avant 1999-2004, Audi allroad quattro 2001-2004, Audi S6 Avant 2002-2004, Audi RS6 2003-2004 - Body Exterior j a t 63-21 Front bumper Front bumper, removing, installing and assembly overview 1 - Bumper cover Removing: Front tires removed Front half of wheelhousing loosened Page 66-40 - Unscrew flanged nuts -10 .
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Installing the Front Bumper Flare 9. Align the ends of the front bumper flare with the edge of the front bumper. Using a felt-tip pen, mark the edge of the front bumper through the three holes in the bumper flare. Remove the front bumper flare. Use an awl to create holes for the screw
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