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fly300kts
07-18-2009, 09:30 PM
Hi Guys,

Because some of you are sometime looking for a DIY (there is one on the FAQ but a lot of pictures are missing) and since I had a car today undergoing LED surgery, I decided to take some pictures and make my own in order to share.
To start, I did a breakdown with the different tools setup and I will refer these setups during the DIY. The tools I am describing here below here are for reference and in some case, alternate tooling can be used.

Time = 15mn
Difficulty = 3

The Tools

10mm Socket
Socket Extensions
T30 Extended
T25 Bit

Setup 1
T30 extended – Length 180mm / 7 Inch
I bought this tool on Ebay for $8. I have seen that some of you are using a flat screwdriver with a width that fit the T30 head. A T25 will work as well but has more play.

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P1.jpg

Setup 2
A piece of metal about 2mm thick

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P2.jpg

Setup 3
Torks bit T25

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P3.jpg

Setup 4
10mm socket with 2 extensions. Total Length = 285mm / 11 Inch

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P4.jpg

Setup 5
10mm socket with 2 extensions, one of them is flexible, like a spring. Total Length = 285mm / 11 Inch.

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P5.jpg
http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P6.jpg

Let’s start.
Using Setup 2, remove the 3 locking pins under the bumper

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P7.jpg

On this top view, I have circled the 11 screws location (2 of them are optional, I’ll explain that later)

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P8.jpg

On the following set of pictures, circled in RED, the screws that need to be removed and circled in blue, the screws that only need to be loosen (3 turns should be enough).

Setup 1
Driver Headlight

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P9.jpg
http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P10.jpg
http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P11.jpg

Passenger Headlight

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P12.jpg
http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P13.jpg

Now, the 2 following locations are optional. I do loosen these because:
1/ Sometimes they are really tight and the bumper is really difficult to pull off or reinstall.
2/ When I reinstall the bumper, I want to make sure that the gaps between the bumpers and the hood are even and identical.
Here, you just need to loose them up, about 1 turn.

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P10B.jpg

Here is a close up of the Torks head inside

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P14.jpg

You are done with the top. Let’s start the sides:

Setup 3
Driver side: Start the car and fully turn the wheels to the right. Remove the 2 screws.

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P15.jpg

Pull the plastic fender and remove the 2 screws

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P16.jpg

Setup 4
If you now look closely inside, you will see the two 10mm nut that need to be removed.

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P17.jpg

Now, pull the fender toward the outside to release the clip

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P18.jpg

Important detail: On the following picture, the highlighted part locks with the bumper. A better picture, on the right side shows it locked in place. Make sure to remember that when you reinstall your bumper.

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P19.jpg

You are done with the Driver side, now the passenger side where the process is the same.

Remove the 2 screws

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P20.jpg

Remove the 2 screws

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P21.jpg

Here they are !!

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P22.jpg

Here is the picture that I was previously referring to where you can see the tab locked in place with the fender.
In Blue, the fender lip
In Red, the locking tab

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P23.jpg

Earlier, I was talking about the bumper height adjusters. Here is a close up

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P24.jpg
http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P25.jpg

And this is the bumper part that slides into them.

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P26.jpg

When you are done, slide the bumper back on place.
On the passenger side, there is enough room to stick you hand and reinstall both nuts with your hand. Then, I use the Setup 4 to tight them up.
On the Driver side, you don’t have enough room to do the same and be cause they are not perpendicular (pointing towards the center of the car) this is when I use the Setup 5.

Here is a picture

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P27.jpg

I hope this helps.
If the Admins what to add this DIY to the FAQ, I have no problem with that
Good luck and I am around if any question [up]

Phil

05.5SilverS4
07-18-2009, 09:43 PM
Great work as always.. Admins DIY this!!

fly300kts
07-18-2009, 09:48 PM
Thank you [up]

Spongebob05
07-18-2009, 10:00 PM
Nice write up....i didn't know it would be so much trouble to take out a bumper..

WayzataAudi
07-18-2009, 10:21 PM
wow, ive taken my bumper off like three times..but there are things in this write up that i didnt even know about (locking tab on the inside of fender) who knew? haha seriously, STICKY! or DIY for sure... [hail]

gto093
07-18-2009, 10:21 PM
great write up as always!

maka
07-18-2009, 10:42 PM
++++ REP amazing. makes me worry about taking off my bumper.

A4 Centaur
07-18-2009, 10:59 PM
You are the man! Now if I could just figure out where those control wires go under the dash for the self leveling Bi-Xenons.[wrench]

assassinroon
07-19-2009, 06:34 AM
thanks fly was kinda bummed the old diy didnt have the pics

sinceday1
07-19-2009, 07:36 AM
Awesome write up! Fly strikes once again.[wrench]

fly300kts
07-19-2009, 08:28 AM
Thank you Guys, thank you.
My next DIY will be the fuel sender & fuel filter replacement. Got the parts but to hot in Florida today[headbang]. I going to take the Vrod for a spin [:D]

BigBlk
07-19-2009, 08:38 AM
The pics are a definate help, my bumper is coming off today. We'll see how it goes.

kitae80325
07-19-2009, 10:47 AM
wow.....wht a detailed diy...awesome!

SDA4
07-19-2009, 11:37 AM
Your the man Phil [up]

orbovi
07-19-2009, 02:56 PM
setup 5 is damn helpful for getting around the fluid reservoir. i'll be getting in touch with you soon about upgrading. very nice DIY

freeflow
07-19-2009, 03:17 PM
[hail] [up] [hail]


http://www.superphil.com/newindexr%20copy.jpg

fly300kts
07-19-2009, 03:23 PM
^^^ LOL

fly300kts
07-20-2009, 05:08 AM
setup 5 is damn helpful for getting around the fluid reservoir. i'll be getting in touch with you soon about upgrading. very nice DIY

Let me know, I'm here

Phil

MichiganAudiDvr
07-20-2009, 06:46 AM
+1 for this DIY - I wish I had it when I took my bumper off the first time.

Raistlin
07-20-2009, 07:13 AM
Great write up, I have been putting of the S4 grill mod for my non sline because of the bumper removal. Maybe now I can finish modding the grill and actually install it.

Rosinbag
07-20-2009, 09:13 AM
That is a kicks-ass DIY. Thanks very much, Phil!

redlabel81
07-20-2009, 02:34 PM
Once again! Great job Phil :) Bumper comming of any day now.

audi_girl
08-13-2009, 02:55 PM
Amazing write-up! Thanks a mill because I'm about to install my FMIC.

fly300kts
08-13-2009, 03:12 PM
^^^ Your welcome. No more Bumper fear [:D]

NorcalPB
08-13-2009, 03:37 PM
Very nice, that's the first clear picture of the 10mm nuts I've seen on the car.

shin4ever00
08-13-2009, 05:51 PM
DUDE.....Thanks for this
Took me 6hr to remove the bumper (as I am not mechanically inclined)
But I never would have been able to pull it off without this.

Great work!!! [wrench]

fly300kts
08-13-2009, 05:58 PM
^^ Your welcome [up]
Now, it taKes me 10 mn but don't worry, you will do better next time [;)]

Eternalmind
08-13-2009, 06:00 PM
DUDE.....Thanks for this
Took me 6hr to remove the bumper (as I am not mechanically inclined)
But I never would have been able to pull it off without this.

Great work!!! [wrench]

6 hours?! holy crap! it took me like 20 minutes to take mine off the first time, but like an hour to get it back on...stupid alignment posts [headbang]

great writeup! it's always nice to know what you're getting into ahead of time. i especially like the tools list...very helpful [up]

[wrench]

ZEM930
08-13-2009, 07:13 PM
Once again rep for you!

felondnb
08-14-2009, 02:45 AM
excellent work - thanks!

Doctor
08-14-2009, 03:59 AM
I wish this thread existed the first time I removed my bumper.
Thanks Phil, you have saved a lot of people with this, for sure.

PS: My bumper sits lower than it should, having a larger gap between the bumper and hood, but at least it has happened both sides so it looks symmetrical... :P
Too bored to remove it and fix it though...Noooooooo way....

iconoclast
08-15-2009, 05:10 AM
thank you.

denisk
08-15-2009, 08:23 AM
amazing. thanks. sticky

felondnb
12-31-2009, 07:09 AM
One thing to note is that the 10mm nuts shown below need a deep socket as when I got to that stage the socket was just spinning on the end of the bolt [>_>]

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P17.jpg

Also on my RHD car, I couldn't see the bolts on the driver's side (your passenger's side), so I gave up & tightened all the nuts/torx screws again.

Really want to get my RS4 grill on [headbang]

AudiCruisn
01-09-2010, 11:53 AM
just installed xenons, couldn't have done it without this DIY.

THANK YOU!!!

http://www.jasonfryer.com/images/xenon1.jpeg
http://www.jasonfryer.com/images/xenon2.jpeg

$lick
01-09-2010, 12:54 PM
I also want to say thank you. I just did the cc mod, painted headlight housing graphite gray and installed rs4 grill last night and this diy was a tremendous help. here are the results

http://i279.photobucket.com/albums/kk127/megz974/89d97bcc.jpg

http://i279.photobucket.com/albums/kk127/megz974/8c1b930e.jpg

And here's my little helper giving me a hand installing rs4 rsb last night
http://i279.photobucket.com/albums/kk127/megz974/8acc6e3c.jpg

fly300kts
01-09-2010, 01:50 PM
Your welcome Guys, it is a pleasure to share with this Community [up]
To the Admins, you could post a link of this one in the FAQ's. The actual one is pretty weak with missing pics.

Just my 2 cent

Phil

Doctor
01-26-2010, 08:13 AM
Your welcome Guys, it is a pleasure to share with this Community [up]
To the Admins, you could post a link of this one in the FAQ's. The actual one is pretty weak with missing pics.

Just my 2 cent

Phil

Agreed

joeygriebel
06-30-2010, 04:52 PM
awesome DIY!!! thanks

fly300kts
06-30-2010, 05:08 PM
awesome DIY!!! thanks

Your welcome

Phil

jstryz
08-02-2010, 12:42 PM
Great DYI however I can not see the pictures.
where are they?

fly300kts
08-02-2010, 12:55 PM
Check your Browser because they are present, no broken link

Phil

2006SLine
09-06-2010, 01:46 PM
Anyone know how to adjust the gap between the hood and grill/bumper once you take it off? I got a bigger than normal gap and would like to make that go away after replacing my grill. Thanks.

2006SLine
09-10-2010, 06:45 PM
I wish this thread existed the first time I removed my bumper.
Thanks Phil, you have saved a lot of people with this, for sure.

PS: My bumper sits lower than it should, having a larger gap between the bumper and hood, but at least it has happened both sides so it looks symmetrical... :P
Too bored to remove it and fix it though...Noooooooo way....

Do you have to take the bumper back off to adjust the gap? If so, how do you adjust it? I couldn't figure out how to adjust mine when it was loose, seems like it kind of just fits back in however it came off.

acbrooks2
10-08-2010, 02:34 PM
having major issues with the tricky bolts on the drivers side wheel well. They dont seem to tighten at all - where can I get spare ones?

Doctor
10-08-2010, 02:39 PM
Do you have to take the bumper back off to adjust the gap? If so, how do you adjust it? I couldn't figure out how to adjust mine when it was loose, seems like it kind of just fits back in however it came off.

I think u have to take it off again....

jimrobbington
10-08-2010, 03:08 PM
Great DIY, Phil, and BTW, you have some hairy-ass knuckles!

AWDTURBO
11-04-2010, 06:23 AM
I can never get my bumper to align 100% :(

beantown
11-22-2010, 03:06 PM
Phil gotta give my praise on this write-up as well. Super helpful. Thanks

AWDTURBO
12-03-2010, 05:55 AM
Any of you guys looking for the T30 parts, i found it on ebay $7.00 shipped

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=110508404282&var=410001911142&ssPageName=STRK:MEWAX:IT#ht_1512wt_905

Renga
04-18-2011, 03:56 AM
Do you have to take the bumper back off to adjust the gap? If so, how do you adjust it? I couldn't figure out how to adjust mine when it was loose, seems like it kind of just fits back in however it came off.

X2

fly300kts
06-07-2011, 05:19 AM
Here is another DIY I made specially to address the gap adjustment:

http://www.audizine.com/forum/showthread.php/414080-Bumper-hood-gap-adjustment-after-bumper-removal?highlight=gap

Phil

B5 Quattro
01-10-2012, 08:56 AM
Thanks again.

fly300kts
01-16-2012, 05:07 PM
Thanks again.

Your welcome

Phil

milk
12-30-2013, 04:31 PM
My 10mm socket is too shallow to reach the nut - is this a common issue?

Der König
12-30-2013, 04:43 PM
My 10mm socket is too shallow to reach the nut - is this a common issue?

Yeah you need a deep socket. If you need it off it can be done with a box wrench and a lot of patience haha. Best bet deep socket though.

Sent with voodoo black magic to your face receivers

peb
01-20-2014, 11:12 PM
Setup 1
Driver Headlight

http://i31.photobucket.com/albums/c395/fly300kts/Bumper%20DIY/P9.jpg


Fuck that blue screw. Fuck it in the ass.

Warning to those that haven't done this before. A t30 socket bit on the end of a 1/4 extensions did NOT work for me. The 1/4 extension or the t30 socket is too fat to get the t30 angled right to get on the screw. (at least for me anyway..) I had to drive all over the area to find something that would work. In the end I managed to use a t30 screwdriver bit on the end of a 6" screw driver extension.

aluthman
01-21-2014, 06:31 AM
Fuck that blue screw. Fuck it in the ass.

Warning to those that haven't done this before. A t30 socket bit on the end of a 1/4 extensions did NOT work for me. The 1/4 extension or the t30 socket is too fat to get the t30 angled right to get on the screw. (at least for me anyway..) I had to drive all over the area to find something that would work. In the end I managed to use a t30 screwdriver bit on the end of a 6" screw driver extension.

I had to buy a T30 screwdriver with an extra long shank to get that screw. I don't remember having the issue with the halogen lights, only the bi-xenons.

Der König
01-21-2014, 06:38 AM
Fuck that blue screw. Fuck it in the ass.

Warning to those that haven't done this before. A t30 socket bit on the end of a 1/4 extensions did NOT work for me. The 1/4 extension or the t30 socket is too fat to get the t30 angled right to get on the screw. (at least for me anyway..) I had to drive all over the area to find something that would work. In the end I managed to use a t30 screwdriver bit on the end of a 6" screw driver extension.

Definitely worked for me. If you have the Stanley torx set and a 1/4 extension the fit is perfect.

Sent with voodoo black magic to your face receivers

2pointOh
03-18-2014, 04:36 PM
http://img.tapatalk.com/d/14/03/19/e4e5eva6.jpg

Sorry to bump this, but I'm having trouble lining up the top screw for my headlight. Since I removed, adjusted, and reinstalled the bumper, the top screw hole doesn't really line up correctly.. But the headlight lines up with the bumper without it in. Any ideas?

Also, I broke the nut under the screw hole, ones coming in Thursday to replace it. Just fyi

Sent from my XT1080 using Tapatalk

milk
03-18-2014, 04:46 PM
I need to adjust mine as well - it's not lining up either... Same side.

2pointOh
03-18-2014, 09:52 PM
I need to adjust mine as well - it's not lining up either... Same side.

Its weird isnt it? Like the bumper sets the light too high... Aligning the lights and bumper is a serious PITA.

Sent from my XT1080 using Tapatalk

2QK4U
03-22-2014, 04:43 PM
I ended up using a KOBALT 6' thin flathead screwdriver. It worked like a charm!
Fuck that blue screw. Fuck it in the ass.

Warning to those that haven't done this before. A t30 socket bit on the end of a 1/4 extensions did NOT work for me. The 1/4 extension or the t30 socket is too fat to get the t30 angled right to get on the screw. (at least for me anyway..) I had to drive all over the area to find something that would work. In the end I managed to use a t30 screwdriver bit on the end of a 6" screw driver extension.

Spridle
04-20-2014, 04:06 AM
Any of you guys looking for the T30 parts, i found it on ebay $7.00 shipped

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=110508404282&var=410001911142&ssPageName=STRK:MEWAX:IT#ht_1512wt_905

Four years later and this link is still active! Thanks and thanks to Phil for such detailed write ups! I need to do the tbelt next weekend, flush the heater core and my drivers side halogen headlight is pointing very high. Looks like the bumper was probably kissed at some point so some 'adjusting' may be in order.