Up to VIN 400 000
Front Bumper
Assembly overview: up to Vehicle Identification Number (VIN) 400 000
Special tools, testers and auxiliary items required
• Socket (T 40078)
• Use socket (T 40078) to screw in cap nuts on fender bolts.
1 - Socket head bolt
• 26 Nm
2 - Air intake grille
• S4, removing => [ Air intake grille for S4 ].
3 - Clamping pin
• To disassemble, rotate 180°.
4 - Side impact molding
• Replace
• Side impact moldings are secured to bumper with double-sided adhesive tape.
• It is not possible to remove without destroying.
• To remove, pull side impact molding away from bumper.
• Remove any residual adhesive on bumper.
• Installation on same bumper
• Bumper must be free of dust and grease in adhesion area
• Clean bumper using petroleum spirits or cleaning solution D 009 401 04.
Note: Centering holes for centering pins for the exact installation of side impact moldings are already present in bumper
• Position centering pins with double-sided adhesive tape onto markings of side impact molding => [ Adhering centering pins on side impact molding ] Description and Operation.
• Remove protective foil from double-sided adhesive tape for side impact molding.
• Press side impact molding with attached centering pins firmly onto bumper over the entire surface.
• Installing on new bumper
Note: Centering holes for side impact molding must be drilled on the new bumper before painting.
• Position centering holes for side impact moldings on bumper => [ Side Impact Molding Centering Holes ] Description and Operation.
• Apply side impact moldings to bumper as described above.
5 - Bumper
• With crossmember
• Bumper, removing and installing => [ Front Bumper ] Front Bumper
• Removing and installing crossmember => [ Front Bumper Crossmember ] Service and Repair
• Separating two-piece bumper cover => [ Front Bumper Cover, Separating ] Front Two-Piece Bumper Cover
• Positioning license plate mounting holes => [ Positioning license plate mounting holes ] Description and Operation
6 - Guide piece
• Removing and installing => [ Guide Piece ] Front Guide Piece
7 - Expanding clip
• 6x
• Must be inserted into fender before installing bumper cover
8 - Grommet
• 2x
• Must be inserted into fender before installing bumper cover
9 - Shock absorber
• self-aligns to correct height in crossmember => [ Front Bumper Mounting to Shock Absorber ]
10 - Fender
11 - Special nut
• 4 Nm
12 - Wheel housing liner
13 - Bolt
• 1 Nm
• 2x
Assembly overview: as of Vehicle Identification Number (VIN) 400 001
1 Combination bolt
• 6 Nm
2 Socket head bolt
• 23 Nm
3 Bumper
• Bumper cover removed.
• To remove, unscrew socket head bolts - 2 -.
• Disconnect harness connectors to signal horns and remove bumper from shock absorbers toward front.
4 Pop rivet
5 Signal horn
• To remove, drill off rivet heads.
6 Support piece
• When turning adjustment screw, make sure mounting bracket is raised
• Before assembling bumper cover, adjustment screw for support piece must be adjusted => [ Adjusting support piece ]
• Tighten adjustment screw to 2 Nm with a long Torx wrench - T 30 - through holes in cover - arrows -.
• To disassemble, drill off pop rivet heads.
7 Pop rivet
8 Signal horn
9 Brace for fender
10 Guide piece
• Side piece of bumper cover must be clipped in between fender and guide piece => [ Removing guide piece ]
11 Torx screw
• 1 Nm
12 Combination screw
• 1 Nm
13 Bumper cover
• While installing, the following sequence described for assembling/bolting must be observed for correct assembly.
- Set cover onto vehicle and first clip the left and right side piece into guide parts - 10 -.
- Tighten cap nuts on fender bolts to 4 Nm => [ Fender bolts ].
- Tighten bolts - 12 - to wheel housing liner.
- Loosely thread in bolts - 1 -.
• Close hood and check cover for projection and recess.
• If necessary, correct the cover position and tighten bolts - 12 - to 6 Nm.
• Tighten bolt on support piece to 2 Nm.
• Bumper, removing and installing => [ Front Bumper ] Front Bumper
• Removing and installing crossmember => [ Front Bumper Crossmember ] Service and Repair
RS 4 assembly overview
• Removal and installation is performed as with standard production bumpers as of Vehicle Identification Number (VIN) 400 001.
• Only differing steps are described.
1 Combination screw
• 6 Nm
2 Bumper cover
• Removal and installation as with standard production.
• While installing, the following sequence described for assembling/bolting must be observed for correct assembly.
- Set cover onto vehicle and first clip the left and right side piece into guide parts - 10 -.
- Tighten cap nuts on fender bolts to 4 Nm => [ Fender bolts ].
- Tighten bolts - 12 - to wheel housing liner.
- Loosely thread in bolts - 1 -.
• Close hood and check cover for projection and recess.
• If necessary, correct the cover position and tighten bolts - 12 - to 6 Nm.
• Tighten bolt on support piece to 2 Nm=> [ Adjusting support piece ].
• Bumper, removing and installing => [ Front Bumper ] Front Bumper
• Removing and installing crossmember => [ Front Bumper Crossmember ] Service and Repair
3 Guide piece
4 Torx screw
• 1 Nm
5 Brace for fender
6 Bumpers
7 Support piece
• When turning adjustment screw, make sure mounting bracket is raised
• Before assembling bumper cover, adjustment screw for support piece must be adjusted => [ Adjusting support piece ]
• Tighten adjustment screw to 2 Nm with a long Torx wrench - T 30 - through holes in cover - arrows -.
• To disassemble, drill off pop rivet heads.
8 Front spoiler
• Remove screws - 10 -.
• Slide spoiler back slightly out of the guides in bumper cover.
• Remove spoiler downward.
9 Expanding rivet
10 Combination screw
• 2 Nm
11 Spring nut
Fender bolts
- Make sure when installing that the clips - 2 - are inserted onto threaded pins.
- Tighten cap nuts - 4 - to 4 Nm after inserting bumper cover - 1 - into fender - 3 -.
Adjusting support piece
• When turning adjustment screw - 3 -, make sure mounting bracket - 4 - is raised.
• If mounting bracket is not raised, place a small drop (very small!) of locking compound D 000 600 A2 on the adjustment screw threads - 3 - and allow locking compound to dry.
• Turn adjustment screw up to dimension - a -.
• The mounting bracket is raised when adjustment screw is turned due to the increased friction.
- Before installing bumper cover - 1 -, adjust adjustment screw - 3 - for support piece - 5 - to dimension - a -= 21 mm +1 mm.
- Mounting bracket - 4 - must be screwed on completely (left-hand thread) for this.
- Adjustment screw - 3 - and mounting bracket - 4 - belong to delivery casing for support piece and are not replacement parts.
- While screwing in bolt - 3 -, mounting bracket - 4 - screws out and holds the carrier part - 2 - of bumper cover - 1 - in the designated position.
- Support piece - 5 - is secured to bumper - 6 - with pop rivets.
Clamping pins for noise insulation
- When removing bumper cover - 1 -, rotate clamping pins - 2 - 180° and pull out of speed nuts - 4 - of noise insulation - 3 -.
Removing guide piece
- Bumper cover removed
- Unscrew bolts - 3 - and pull guide piece - 2 - downward out of fender - 1 -.
- When installing, cover - 4 - for bumper must engage cleanly in guide piece.
Brace for wheel housing liner
- For mounting front wheel housing liner - 3 -.
- When installing brace - 1 -, tighten bolt - 2 - to 10 Nm.
Air intake grille for S4
- Remove phillips head bolt - arrow -.
- Press air intake grille - 2 - on the inside of bumper cover - 2 - as shown toward rear out of locking mechanism.
- Remove air intake grille toward front out of bumper cover.