DIY: How to remove the front bumper or front bumper cover. For the B6/7 S4s and RS4s but most other Audis are very similar in concept.
Important Note #1: The grey RS4 that was used for pictures of how to remove the front bumper had a European front bumper so it might be slightly different but it should be very similar to the USA bumper. I personally think that the European bumper looks better but that is just my opinion.
Important Note #2: On the B6 cars I cheat by taking out the headlights so if you have already done so then you can skip to step 5.
- Remove the front wheels to make it easier to get more access to the fender liner screws. The vast majority of the time the front wheel lug bolts are 17mm bolts. Then place the front wheels out of the way somewhere nearby.
Important Note #3: A lot of you have probably already done this before multiple times and know short cuts like turning the front wheels to each lock to get around doing step one. But I wanted to target this DIY to people that have never done this before so I included remove the wheels as step one.
- Remove the one plastic pin (RS4s sometimes have multiple plastic pins) on the inside edge of the fender liner and the T25 Torx fender liner screws on the front half of the fender liner on both sides of the car. There are a shit ton of T25 Torx screws and the idea is to get the front half of the fender liners loose enough to move them out of the way.
Important Note #4: On the RS4s, there are three T25 Torx screws around the brake air ducts opening that hold the air ducts to the fender liner. You can leave those three screws in place and just move the half of the fender liner out of the way with the air duct still attached.
B6/7 S4 front left fender liner:
B7 RS4 front left fender liner: Do you notice the air duct opening that I mentioned before?
- RS4 specific step - Remove the T20 or T25 Torx bolt that goes up through the bottom of the end of the bumper into the rubber piece at the bottom of the fender liner.
- Once the fender liner is free enough to move out of the way then I like to tuck it behind the brake rotor and brake caliper towards the other half of the fender liner that is still attached.
- Remove the one or two T25 Torx screws that hold the edge of the front bumper to the supporting braces.
- Remove the 10 mm nuts that hold the front bumper to the front edge of the fender. There are three nuts on the B6 S4s and two on the B7 S4s/RS4s. I go through the opening where the headlights were to get the three nuts on the B6 S4s. The B7 S4s/RS4s require going through the fender liner opening to remove the two nuts.
B7 S4/RS4 Driver’s side. The passenger’s side is very similar so I only took a pic of one side:
- B7 S4/RS4 specific step - Remove the three T30 Torx screws that hold the top of the front bumper on.
- B6 S4 specific step - Remove the front fog light grills. There is a flat head screw on the side of the fog light grill that is a half turn screw. Then the fog light grill pops out and you have to angle it to get it out.
- B6 S4 specific step - Remove the two 6 mm allen bolts that go up through the opening where the fog light grill was. These bolts feel like they are a mile long but there is a rubber isolator that holds the bolts in so you have to pull them down and out once they start to just spin in place. These two bolts secure the metal crash bar to the low speed impact shocks.
- Reach down and pop the lower side portion of the front bumper free from the fender on the driver’s side and pull the bumper back enough to expose the wires and hoses. This is scary if you have never done it before but there are plastic tabs that hold the side of the front bumper on.
- Disconnect the electrical connectors behind the driver’s side of the front bumper. There are two on the S4s and three for the RS4s. Also disconnect the fluid line for the headlight washers. I clamp off the line with locking vice grips and put a hose cap over the end on the S4s. For the RS4s I disconnect the line from the headlight washer pump and put a hose cap over the end. Or of course you could always let all your washer fluid pour out all over the ground if you don’t care but I don’t like to make a bigger mess than needed.
B6/7 S4 headlight washer fluid line:
B7 RS4 headlight washer fluid line/pump:
Hold the middle of the front bumper on place with your right hand. Then reach down and pop the lower side portion of the front bumper free from the fender on the passenger’s side and pull the bumper back just like in step 10.
Now that the front bumper is free from the car, go ahead and remove it. Set it off to the side. If it is a B6 with a front license plate then I tend to set it facing down on the license plate. With the B7 cars I tend to set the bumper down on the sides facing up.
Reinstall is the reverse of removal but here are some tips.
T1. When you put the front bumper back on be careful to not scratch the paint on the fender by where the studs go through that the 10 mm nuts go on.
T2. When you tighten the two or three 10 mm nuts, push the edge of the front bumper that is under the headlight so that it is lined up with the fender. Otherwise your bumper will be crooked and it will look bad.
T3. The B7s require adjusting of the height of the front bumper to get it flush against the headlights and hood. When you put the front bumper back on make sure that the slots of the bumper line up with the height adjuster notches. The height adjusters are on the crash bar. You can turn them with a long T25 Torx to adjust the height of the bumper. To get to the adjusters you need to go through the two holes that are in front of two of the three places where there are T30 Torx screws on top of the bumper. Once you have adjusted the front bumper it should line up headlights and hood so that there is no gap around the headlights and there is very little gap between the front bumper and the hood.