Front bumper and Parking Sensor removal
 

Hey guys, I decided to write up a guide on how to remove the front bumper. I had to take mine off in order to replace a faulty parking sensor. For some reason the front right sensor kept causing a malfunction in the PDC system. VCDS brought up the following error code:

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Then I had a quick look at the measuring blocks and noticed that the sensor was performing below specifications compared to the others…

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So I figured the best bet is to replace the sensor completely. I acquired a genuine one from ebay brand new primed (Part Number 7H0 919 275 C). I colour coded it to Oyster Grey and finished it off with some 2k lacquer. I kept the spray coats thin so it doesn’t affect the operation of the sensor.

Taking the bumper off on the D3 isn’t so difficult; however because Audi have over engineered this car, you have to remove quite a few items in order to get to the 3 bolts which attached the bumper to the wings on each side. You have to remove both front wheels, the front section of the wheel liners to have a good clear access to the bolts. I got myself a set of gel knee pads seeing as I will be on my knees for a long time…I strongly suggest a pair to greatly reduce any risks of injury and for your comfort too.

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1st step is to drain out the window/headlight washer tank. Reason I suggest to do this 1st as in the past when I took out the bumper I accidentally damaged the hose to the headlight washers and they snapped in half. I had to repair it by using a 4mm straight connector after dipping both ends to repair in boiling water to soften them so I can easily join them with the connector.

Make sure you have an empty 5L container to collect all the fluid. Start by removing the driver side fog light bracket.

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These two clips retain the bumper harness and washer hose together. Push it out then you’ll be able to pull it out while lifting that part of the bumper upwards.

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Have you container ready as the fluid will pour out as soon as you disconnect it.

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Draining will take 5 minutes… so while that takes place we can start jacking the car and take the wheels off. Firstly put the car in Lift Mode followed by Jacking Mode On in the setup menu of CAR. This is so that the car doesn't decide to level itself while it is being jacked up.

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Undo these two grip pins (Part number: 4A0 805 121 C, you will the following with it too: Retaining washer 4A0 805 137 A). Both sides of the wheel liners follow the same instructions.

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Undo the screws

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Undo the 4 spreader rivets with a torx screwdriver. Do not push the pin inwards too much as you will loose it for good otherwise. They can be reused once they are taken off but not if you loose the pin. It’s a good idea to keep some spares (Part number: 4D0 807 300)

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We can then go ahead and pull down the wheel liner

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Here the bolts we need to remove on each side using a Size 10mm socket. You need a ratchet with an extension to get to them properly.

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Now once the bolts are taken off, I suggest to mask the edges of the wing panel and bottom of the bumper as the securing pin from the bumper can cause damage to the paint work should you find yourself struggling to get it off.

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There are 3 more brown bolts to remove under the bumper, I didn’t get a chance to take pictures of that. You need to use a big sized flat head screw driver to get them off. It secures the bumper and the undertray to the radiator housing frame.

Also take off the 5 x torx 25 and 2 x torx 30 screws on the top of the bumper.

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Once all is that done, check if all the washer fluid has been drained and set aside. You can start taking the bumper off by pulling out the bottom by the wing panel on both sides. After that pull the bumper forwards but watch out for the harness connectors. Have a flat head screwdriver to prise them out of the bracket on the bumper so you can disconnect them with ease.

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Faulty sensor to be replaced (Front right one). Unfortunately I forgot to take pictures of this step however it’s very easy. Just pull up the tabs holding the sensor down and slide it out then disconnect the connector. Installation is in reverse… just slide it back in till it clicks into place.



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Once all that was done, I fired up VCDS and turned on the PDC system. Measuring blocks showed everything in order.

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Then it was the task of putting everything back together which is all done in reverse order.

If I missed anything guys, let me know and I’ll add it. I hope this guide comes handy for others.

Well done.
Really useful for a newbie.
When I first had my 8 I gave up dropping the bumper and managed to get my hand up to the sensor but please do not ask me to repeat the rather loud and nasty words that I used. +++

Thanks - great write up and pictures, added to sticky at the top of this section for future reference +++
My only point to add is that lift mode should be enabled and then jacking mode set to "on" before you start jacking due to the air suspension sensors needing to be told of the upcoming jacking that is about to take place

Edited.. thanks for pointing it out :)

good write up budz. one of my sensor I replaced is playing up again (fleabay job) just word of advice to others dont put copy sensors as they are bad quality. How much was the original one you purchased?
ta

Thanks neeldub, that's a great article and pictures.
I need to replace my low-tone horn fanfare and this info. will be what I use to get the bumper off. Although I see from your photo I may be able to give it a sharp prod through a hole in the upper grill and maybe it will fix it as it started off just sounding like a strangled duck.

mine just did that too, just in time for the duck hunting season lol

I was able to buy a brand new sensor for £30 on ebay.. Part Number 7H0 919 275 C Genuine VAG

i got an original on ebay too, think that was around the same price as neeldubs

i still have it somewhere, when i went to fix it turned out to be a wire off.

Hopefully my next guide will be on how to remove the rear bumper :)

Thanks, great write-up. I'm going to have to remove my own FL front bumper to replace at least one of the parking sensors and also to repair some damage when the bumper was grounded on a kerbstone.
I'm not understanding the necessity for Lift mode as well as Jacking Mode when lifting the car? I've only ever used Jacking Mode. Is the idea of using Lift Mode so as to have more room to work while removing the wheels?

Yes lift mode lifts the car up higher either for working or for driving over tricky ground or through water etc but will return back down to normal height when the car gets to over 40mph.

Jacking mode merely locks off the suspension from a feedback point of view to the controller until youve finished working on the car so that it doesnt confuse the air suspension and make it try to cope with changes it would be detecting from being jacked up.

I always try to use lift mode before working, then jacking mode to lock it off and the reverse of that when finished +++

I always use both as the extra lift makes it easier to get the jack under and then as said above 'jack mode' locks it off. Lift mode might be more useful on S8/Sport versions where the car has a lower stance

Did this yesterday swapping a front bumper!

You need a LONG 10mm extension to get those main 3 bolts per side. Made things way easier when I borrowed one!
I also found the top bolt on both sides had a 16mm nut too. don't know if this was an addition or mine being a 2005 PF 4.2 petrol model made a difference?

In my case things were not completely successful as the silver bumper was the wrong silver and only noticed once part fitted, the old one had damage and grills lost/popped due to an Ikea car park kerb where the suspension settled and dragged over, plus a few other issues!!!

Couple of Axel stands are recommended and not trying to do the whole thing in an afternoon when you get a stuck under bonnet nut because someone had rounded the star drive, the other one had a machine cap allen bolt, so i'm guessing that someone had killed that one previously.

On the upside I had two iffy parking sensors on the old bumper and that now works nicely though I lost headlight washers and I'm guessing i'll be repeating this in the future when I find the correct colour bumper.

Good and helpful thread though +++