My S6 Avant Fixing Things Thread

[R490]

So, I got bored after selling my Nogaro/nogaro B6 S4 and picked this up as a bit of a project.

'03 with 197k that I got an okay deal on.







So far, it seems like a lot of the repairs needed are cosmetics. The bodywork is very rough to say the least. It lived in Manhattan at one point, and it shows. There's a bunch of bondo on the back quarter (magnet still sticks) and the respray work/blending is not good at all. It definitely got rear ended at some point, but there's no intrusion into the spare tire well etc.

It's mostly stock, but has a Billy Boat exhaust, a VERY expensive sound system, some very dark window tint, and it's lowered. 225/45/17 winter tires on it. I think I'm going to refinish the Avus wheels and give it some Conti DWSs.

Now the questions I have....


I'm not sure what direction I want to take with it yet. Whatever I do, I'd like to put it back to an OEM+ configuration... I don't really want to swap it or anything, I just think it's a fun car because of the rarity and wanted to keep another one on the road.

Issues:
-Power steering whines when cold, then the whine goes away
-Bodywork is shit
-Some broken interior trim
-One side of the rear brakes needs pads (I don't know why the previous, previous owner only replaced one side).
-Intermittent CEL for a P0441- I ordered a purge valve and we will see if that works
-Suspension is too low










I think I want to go back to the original sound system, I hate aftermarket systems.

[NWS6]

These really are great cars, but they have a couple of widely known issues. With 197K, there's two main issues worth focusing on:

1.It would be good to know when the last timing belt service was done. If you don't know, you should just do it now.
2.The other main issue to plan for is the maintenance, or conversion of the Tiptronic transmission. It's a S6 weak point.

[R490]

These really are great cars, but they have a couple of widely known issues. With 197K, there's two main issues worth focusing on:

1.It would be good to know when the last timing belt service was done. If you don't know, you should just do it now.
2.The other main issue to plan for is the maintenance, or conversion of the Tiptronic transmission. It's a S6 weak point.

For sure, I was excited to get my hands on this one. I've only ever seen one other S6 Avant on the road and that was many years ago.

The last timing service was done around 180k, or in 2018~.

I was told the tip was serviced, but I'll likely do it again pretty soon.... I've done it before on my first B5 S4. Not a very fun job. I'll think about a manual swap down the line, but I don't mind the tiptronic gearbox (when they work).

Timing belt looks good. I'll do an age-based change at some point.



Suspension setup. Still seems very low.





Leaking power steering pump banjo bolt. Could this be why it's whining at cold starts when I turn the wheel? I'd say so.



Undercarriage looks pretty good.



More cosmetics from the parts yard...

[NWS6]

The Hotchkis sway bars and Koni shocks are great parts. If you don't like the lower ride height, you could probably find some stock S6 springs without too much trouble or expense.
Good luck getting everything sorted out.

[R490]

The Hotchkis sway bars and Koni shocks are great parts. If you don't like the lower ride height, you could probably find some stock S6 springs without too much trouble or expense.
Good luck getting everything sorted out.

Exactly what I'd like to do. Only problem is that I have no clue what the original color markings for the springs on my car were.

[the green amigo]

Good chance those H&R springs aren't for an avant, might be standard sedan springs which will sag in the rear with extra weight. The S6 springs sit much higher, especially in the front. On my S6 I replaced the fronts with RS6 springs and now the car sits level with same gap front and rear.

[R490]

Good chance those H&R springs aren't for an avant, might be standard sedan springs which will sag in the rear with extra weight. The S6 springs sit much higher, especially in the front. On my S6 I replaced the fronts with RS6 springs and now the car sits level with same gap front and rear.

You're probably 100% correct, that would totally explain why it's so low in the back, despite there being nothing visibly wrong with them.

[the green amigo]

Don't have a side view shot at the moment, but can kind of see how it sits in this pic

PXL_20240209_094236141~2.jpg

[R490]

Don't have a side view shot at the moment, but can kind of see how it sits in this pic

PXL_20240209_094236141~2.jpg

Is that on the proper Avant springs?

[the green amigo]

Is that on the proper Avant springs?

Rear is stock S6 avant springs, fronts are RS6 springs

[jbain2]

You definitely have sedan springs. I recently emailed H&R about the differences between the sedan and Avant. Below are the spring rates they sent me. You can clearly see on yours they are the sedan part number.

Sedan
29797-1

Front: 285 lb’s

Rear: 300 lb’s


Avant
29798-1

Front: 315 lb’s

Rear: 425 lb’s





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[alpine4]

You running wheel spacers? Your Avant looks real good. OP I recommend Bitstein PSS9 coilovers. I have them on my S6 Avant. Been an excellent setup.

[R490]

You definitely have sedan springs. I recently emailed H&R about the differences between the sedan and Avant. Below are the spring rates they sent me. You can clearly see on yours they are the sedan part number.

Sedan
29797-1

Front: 285 lb’s

Rear: 300 lb’s


Avant
29798-1

Front: 315 lb’s

Rear: 425 lb’s





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That 100% explains the bodies in the trunk ride height. I've sourced three stock springs to far, one more left to find. The elusive three magenta one tan. Thanks for the info!

- - - Updated - - -

[alpine4]

What size are those wheels? Was going spacers but the right size wider wheel always better. Stock suspension is a smoother ride. Just can’t rail corners.

[Bordom]

Dude what happened to the Porsche?

Also congrats on picking up an S6!

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[R490]

Dude what happened to the Porsche?

Also congrats on picking up an S6!

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Still got a Porsche haha, just a Macan though. I picked up a '23 WRX base to daily drive after my GLI got totalled.

Thanks! It's a little rough, but I think it's worth saving.

[R490]

Started digging into the car today.....

The previous owner had the passenger side caliper seize up, which explains why only the driver's side rear brake pads had been changed. Whoever worked on it just ignored the seized caliper

Luckily, I was able to find a remanufactured caliper at Autozone the same day. I still have to do the driver's side. This was my first time doing brake pads myself, so lots of lessons learned.





I should have done the disc too, but it's not lipped that bad. Just rusty from sitting.

I replaced the purge valve to hopefully clear the intermittent CEL. While doing the brake bleed, I saw that the ambient air sensor is just loose in the firewall area next to the battery, I need to find out where that's supposed to be. I think on my B5s there was one in the cabin air filter housing near the blower motor and another one up front somewhere.

I tried to do the other side today just to find that the driver-side rear caliper is seized too. I ordered a remanufactured one from Autozone with same-day shipping so I don't have to drive 40 minutes to go pick it up (again).

[R490]

Fixed both of the rear calipers with remanufactured units, bled all 4 corners and it seems to be doing a lot better now.

Gave it a bit of a heavy-duty clean since the car seems to have been sitting for what seems like 6-8 months prior to me buying it.











I need to get rid of the stupid sound system that's in it. I'm in the minority of being someone who doesn't like aftermarket systems.

[justinotha]

Cheers, I'll be following along. I commented on your post about having inspection issues on the C5 FB group. I'm also bringing an s6 i got on the super cheap back to life, it's just been slow going since we bought a new house immediately after i picked mine up. Same color, but an 02 with 160k.

[R490]

Cheers, I'll be following along. I commented on your post about having inspection issues on the C5 FB group. I'm also bringing an s6 i got on the super cheap back to life, it's just been slow going since we bought a new house immediately after i picked mine up. Same color, but an 02 with 160k.

Good stuff!

Same deal for me, it's going to be a little bit slow and depend highly on what direction I want to take with it. Do you have anything planned for the car?

[justinotha]

Good stuff!

Same deal for me, it's going to be a little bit slow and depend highly on what direction I want to take with it. Do you have anything planned for the car?

Mostly looking to make it a ski trip / bad weather car. My daily driver B6 Avant is pretty low and doesn't have enough legroom to fit 4 adults truly comfortably on that type of journey.

I picked up the car VERY cheap, but in running and driving condition. It definitely needs brakes, suspension, a timing belt, and probably some other mechanical odds and ends. It was really dirty inside and out, as it was a 4th car / winter beater for the previous owner. I have many hours into removing 20 year old yellow'd PPF from the whole front end and deep cleaning the interior. All in all the car outshines the price paid at this point.

[R490]

Mostly looking to make it a ski trip / bad weather car. My daily driver B6 Avant is pretty low and doesn't have enough legroom to fit 4 adults truly comfortably on that type of journey.

I picked up the car VERY cheap, but in running and driving condition. It definitely needs brakes, suspension, a timing belt, and probably some other mechanical odds and ends. It was really dirty inside and out, as it was a 4th car / winter beater for the previous owner. I have many hours into removing 20 year old yellow'd PPF from the whole front end and deep cleaning the interior. All in all the car outshines the price paid at this point.

Nice! I think that's about the same goal as with mine. I probably overpaid a little for mine after getting into it a little deeper, but because of the rarity I can justify it a little bit more. My office is going to be eight minutes away from my house, so it'll primarily be a ski trip car for me as well.

[ShelbyM3]

If either of you gents needs an almost new belly pan, there’s one on Facebook Marketplace right now for $100. I googled the part number listed, because it’s not stated. Not mine.
Congrats to both of you. I also recently got a C5 with a V8, just an Allroad.

https://m.facebook.com/marketplace/i.../?ref=newsfeed


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[R490]

If either of you gents needs an almost new belly pan, there’s one on Facebook Marketplace right now for $100. I googled the part number listed, because it’s not stated. Not mine.
Congrats to both of you. I also recently got a C5 with a V8, just an Allroad.

https://m.facebook.com/marketplace/i.../?ref=newsfeed


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Nice find! Luckily, mine came with a brand new belly pan. I just haven't put it on, until I get to know the car a bit better (and it's least favorite fluid).

[R490]

Does anyone have a good DIY on headliner removal? One of my sunroof drains has started leaking in the back and I'll have to replace it.

[jbain2]

I wish I did. I pulled a couple a few years ago. There are a ton of clips and there are screws in the c-pillar areas.

You may be able to get at the drains without completely undoing the headliner. But you need to support it so it doesn’t crease.


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[ShelbyM3]

I’ve always used a small steel braided cable to fish my sunroof drains. Got it at an Ace Hardware years ago. Works wonderfully. I’d recommend fishing your drains and ensuring they’re free and clear before you replace the headliner. On my son’s MKIV Jetta, we cleared the drains and thought we had it all good only to realize the drain tube had popped off the sunroof and although the line was clear he still had water staining. Ugh. I also live in Portland, OR where raining is 3/4 of our seasons…
If you plan on junking the current headliner, use it as reference. I also am unsure of the process for a C5. My new to me 4.2 Allroad has a saggy headliner, so I’m also curious what the process looks like.


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[R490]

I wish I did. I pulled a couple a few years ago. There are a ton of clips and there are screws in the c-pillar areas.

You may be able to get at the drains without completely undoing the headliner. But you need to support it so it doesn’t crease.


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That's what I was thinking, since the split is in the d-pillar. I just really want to not break stuff.

- - - Updated - - -

I’ve always used a small steel braided cable to fish my sunroof drains. Got it at an Ace Hardware years ago. Works wonderfully. I’d recommend fishing your drains and ensuring they’re free and clear before you replace the headliner. On my son’s MKIV Jetta, we cleared the drains and thought we had it all good only to realize the drain tube had popped off the sunroof and although the line was clear he still had water staining. Ugh. I also live in Portland, OR where raining is 3/4 of our seasons…
If you plan on junking the current headliner, use it as reference. I also am unsure of the process for a C5. My new to me 4.2 Allroad has a saggy headliner, so I’m also curious what the process looks like.


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That's great advice- I thought about doing that, then I realized that the hose is split or leaking. Fun times. For now, I just put painters tape around the sunroof.

[Audibot]

On the rear sunroof drains, also check where they drain out in the wheel wells (pull off the wheel liner). It's really easy for them to get caked up and then not drain because they are very narrow. I've cut mine open a bit on the allroad just to ensure I don't have this issue. My fronts, of course, are a different story...

[R490]

On the rear sunroof drains, also check where they drain out in the wheel wells (pull off the wheel liner). It's really easy for them to get caked up and then not drain because they are very narrow. I've cut mine open a bit on the allroad just to ensure I don't have this issue. My fronts, of course, are a different story...

It's draining out of there, but it's also draining out of here, and down the c-pillar directly onto the amp.

[Audibot]

In addition to leaking from that point (my B7 had that), it could also be backing up because it's clogged and then overflowing. At least a thought. I think I had used some clear silicone to seal that area.

[R490]

In addition to leaking from that point (my B7 had that), it could also be backing up because it's clogged and then overflowing. At least a thought. I think I had used some clear silicone to seal that area.

Very true, I'll have to go through the pain of getting the rear part of the headliner off first. But yeah, that's for sure a possibility.

I might make a video on it, since there's barely anything on the internet for full headliner removal.

[Calif_Kid]

I've never had to pull down a headliner, but I did a quick search and found a few links that might help, although they might not be for an Allroad or S6. Good luck!! - Jim

https://www.youtube.com/watch?v=vfxErJgrkxU

https://www.youtube.com/watch?v=Dcxo14u5Pos - video is for A6 4F Allroad

https://www.audiworld.com/tech/int.html and around 3/4 down, in the A6 section, you will find 'Headliner Removal and Replacement' link by Boston Driver from 2007

https://www.audiworld.com/tech/int67a.shtml

https://www.audiworld.com/forums/a6-...-long-1723569/ The pictures don't show up directly in the post, but if you paste them into Word, then they still exist and will appear.

[LZ9ROAD]

https://www.diyauto.com/manufacturer...-boston-driver

same exact method for avant, just gets a little different once you get to the rear, but its not anything too crazy. Would recommend re-greasing the sunroof track and mechanism, so you don't have to deal with it again after the drains are unclogged.

Glass comes out without removing anything regarding the headliner, you just tilt it up and you will see the retention hardware for it and it comes out the top. It will make it 100% easier to not completely ruin the sunroof panel Lining Retaining Clip Surround Trim (4B0867561), as you will be able to get at it from a better angle. This piece is VERY important to keep it affixed to the roof properly, ask me how I know.....

It's not too difficult, but remember the headliner pillars are not made from the best material, so I noticed they tend to bend and crease the fabric if you aren't careful with removal, especially on the rear hatch portion which is photo on post #30.

I absolutely hate the visor clips, I broke all of them, find a better method for those or just go slowly I guess.

If you have any ideas like a radar detector or something mounted on the windshield, nows the time when it's pulled, makes life MUCH easier for good clean routing AWAY from the curtain airbags.

[R490]

So I've got it all stripped down, but I can't find the sunroof drains for the life of me. The Irwin manual says they drain out of the back of the headliner, but I can't see them at all.

[Calif_Kid]

I know that the model of the car doesn't match, but https://youtu.be/0we2J_asBiM?si=jaQUkaC36yT26eZW&t=79 shows some drain hoses exiting out the C or D pillar.

[jbain2]

They are pretty easy to spot once you know what you are looking for. I use a long piece of heavy gauge trimmer wire to fish mine out. Works great.

Check out this post on quattroworld.

https://forums.quattroworld.com/a6/threads/816.phtml


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[R490]

Thanks all for the advice.

I eventually found it runs down the c-pillar. But it's NOT leaking from the fitting I expected it to be leaking from. It's leaking from the far side of the plastic thing. Looks like I have to drop the headliner the entire way to access it. Really not looking forward to it. I want to fix the headliner sag too, but I'm on a bit of a crunch because I start my new job in ten days.





Hands down the most tedious thing I've ever had to do to any Audi and I'm only 1/4 way done so far. I'm trying to not break anything, but some things are so brittle. Looks like somebody has been in here before me, broken a bunch of crap and made a mess of things, so I guess I have an excuse.

[Audibot]

The white piece? That's bonded on, so perhaps that's failed over the years.

[R490]

The white piece? That's bonded on, so perhaps that's failed over the years.

Not my picture, but from the top of the plastic thing. I can't see where without removing the headliner. Bonded on?