DIY: C7 A6 Front Bumper Removal & StoneCarbon2009 RS6 Style Grille Install (Video)

[AudiC7Owners]

Hey Guys!

So, I have spent months looking for all the information possible on removing a bumper from a C7 A6, and how to install a StoneCarbon2009 RS Style grille with all the fixings (Night Vision, Parking Sensors, Parking Camera, etc). I could only find bits of information sparingly, so I took all the hodgepodge info I could scrounge up and put the rest of the pieces together myself as I tackled this project. With the help of a friend, I was able to record most everything and put together an install video.

HUGE shoutout to Enigma1406 and his thread on installing an OEM RS6 Grille to his S6. That was a big help in terms of steps to follow.

Tools List:
-T25 & T15 Torx Bits/drivers/etc. These will unscrew everything you need to
-Drill for ease of removal
-10mm Socket with extensions for bolts holding the bumper on, as well as remove negative terminal from battery
-Dremel & Cutting wheels/grinder to modify your Ebay Grille
-Protective Glasses for when you dremel... trust me, just wear them.
-Very Small flathead screwdriver for removing electrical connections and clips
-Zip Ties to help with removal of OEM Grille (You'll see)
-Plastic Trim Removal tools
-Work light of some kind
-A friend you bribed to help you do this
-Beer
-Music

Noteworthy Information:

-As always, just play it safe and remove the negative terminal from the battery to insure you don't accidentally turn the vehicle on while your electrical sensors are unplugged and risk having to recalibrate your system.

-Having a second pair of hands is SUPER helpful to hand you tools, hold back fender liners, hold a light, etc. I highly suggest bribing someone with beer or food or both to help you out.

-The eBay grille from StoneCarbon doesn't require much modification other than cutting out the camera mount it has in it so you can retrofit your camera mount to it. Unlike installing the OEM RS6 grille, you do NOT have to trim any tabs on the grille, or trim any part of your bumper. It pops in nice and tight and flush.

-Cutting the grille to retrofit your oem camera mount is tricky. Cut small amounts, and constantly reference the mount until you get the right fit. Don't make large or deep cuts... it's better to have to cut more than to have cut too much at all.

-After you get it to where the rear camera mount can be screwed into the new grille, you can mount your camera into it. The only downfall is the front shield that goes over your camera has no way to mount to the new RS style grille at all. I tried trimming it down and getting it to fit to a point that I could epoxy it or something, but it just won't work. It doesn't look bad without it, and no one is likely going to notice it at all, but I'm trying to source an oem RS6 front camera shield to use... otherwise I'm going to have a local shop retrofit something to cover it.

-The video doesn't show reassembly to the car, but it is literally just reversing the steps you did to remove the bumper and grille. It's very straight forward. The trickiest part is getting the bumper back on the teeth, but it's not bad. Having a friend to assist really helps with this.

-I don't know if this happens to everyone, but I figured I'd mention it in case it happens to you: When I plugged the battery back up, the car started right up and didn't have any CEL's or anything (I'm used to the dash lighting up like a Christmas tree after I disconnect the batter with my VW's). The car idled normally, and I backed it out of the garage and parked it. The next morning, however, I started it up and it had an extremely rough idle and the EPC light was on. I let it warm up and drove it and the lower the RPM's, the more violent the engine shook. It felt like I had a really bad motor mount. I drove for about 10 mins and it did it every time I got into lower rpms. I parked the car and shut it off for an hour, and then started it up again and it was back to normal. No shaking, no EPC light, and it has driven as normal ever since. Probably just your typical German gremlins after you disconnect the battery.

I may add to this thread as I remember things, and I'll post updates in the replies as I do. I really hope this video helps and shows in detail the steps to doing this job. If I didn't have to record what I was doing, this probably would have only taken about 3-4 hours including painting the crash bar and taking my time as it was the first time I have really worked on this car so far.

Updates:

-I just realized I kept calling the Parking Sensors on the grill the ACC Sensors. That was my bad... it was a long day. I may redo that part of the voiceover and re-upload the video.

And on to the video! Make sure you watch it with the sound on as there is a voiceover by yours truly talking about each step of the process.

Please subscribe to my youtube channel. It's brand new and this is the first video on it, but I'm hoping to continue adding C7 specific videos soon.
You can also follow my C7 Instagram page @AudiC7Owners

[AudiC7Owners]

Save this post for pictures

Direct Link to video: https://www.youtube.com/watch?v=El5k04T7ieo

[FistMeHarderDad]

Awesome writeup and great video!

[Vinng86]

Looks good!

When I did mine, I didn't unplug the garage door transmitter - you can just push the latch on the right side and take the unit out and rest it on something. I also didn't disconnect the nightvision camera's washer line, you can unscrew the 4 screws around the camera and the whole unit comes out. When I started the car for the first time, I had zero check engine lights and zero codes so maybe something's different on your car?

[AudiC7Owners]

Awesome writeup and great video!

Thanks!

Looks good!

When I did mine, I didn't unplug the garage door transmitter - you can just push the latch on the right side and take the unit out and rest it on something. I also didn't disconnect the nightvision camera's washer line, you can unscrew the 4 screws around the camera and the whole unit comes out. When I started the car for the first time, I had zero check engine lights and zero codes so maybe something's different on your car?

Yea, you don't have to remove it, but I did just to be sure... i eventually put it back on the bumper when I realized it wasn't necessary.

And yea, the first time i started the car I had no issues... the issue came the next day when I cranked it... but only for that one time. When i started it back up again it was normal... gremlins.

[Dave4501]

Are you sure that paint with primer behind the new grill will hold up to the elements? I just would hate to have to repaint the black in a few months if it didn't stick well. I do think primer is needed but never sure if the paint/primer combo is as good as using a two step (primer then paint) process.

[AudiC7Owners]

Are you sure that paint with primer behind the new grill will hold up to the elements? I just would hate to have to repaint the black in a few months if it didn't stick well. I do think primer is needed but never sure if the paint/primer combo is as good as using a two step (primer then paint) process.

We'll see I suppose. Getting the bumper off isn't very difficult at all.


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[ABlazeski]

Planning on doing this once the spring time comes great video and great write up. Good job! This video is going to help out a lot.


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[AudiC7Owners]

Planning on doing this once the spring time comes great video and great write up. Good job! This video is going to help out a lot.


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Awesome! That's why I made it... there isn't one other video that details this out there.

[gimpgutter]

Question for you guys who live in a state with mandatory front plates: how do you mount it? Does it fit in the European style plate mount that comes with grille from Stonecarbon?

If you don't put it on, it's it possible to modify the grille while it's on the car? I don't want to have to go through this process twice if I decide to forgo the plate for now.

[digdah]

OP thanks for the video. I am leaning more and more towards purchasing one. As the C8 has dropped so have the prices on parts for C7s which is a yay for me haha!!

[Vinng86]

Question for you guys who live in a state with mandatory front plates: how do you mount it? Does it fit in the European style plate mount that comes with grille from Stonecarbon?

If you don't put it on, it's it possible to modify the grille while it's on the car? I don't want to have to go through this process twice if I decide to forgo the plate for now.

It won't fit in the euro style plate mount so you have to find your own solution. I drilled it into the bottom bar above the quattro and used bolts with a wide washer for the top screws. Here in Ontario we're required to have front license plate and I live next to a police station...so no choice for me lol.

Here's highres image of how it looks on my car:

[gimpgutter]

It won't fit in the euro style plate mount so you have to find your own solution. I drilled it into the bottom bar above the quattro and used bolts with a wide washer for the top screws. Here in Ontario we're required to have front license plate and I live next to a police station...so no choice for me lol.

Here's highres image of how it looks on my car:

Thanks for posting that. I'm not thrilled with the look (you did a good job). The placement is tough since it fills up all of the gap between logo and the Quattro area. I might just skip it.

[AudiC7Owners]

OP thanks for the video. I am leaning more and more towards purchasing one. As the C8 has dropped so have the prices on parts for C7s which is a yay for me haha!!

You're Welcome! I spent weeks searching for a video and couldn't find one so I figured it would be a good opportunity to make one.

Thanks for posting that. I'm not thrilled with the look (you did a good job). The placement is tough since it fills up all of the gap between logo and the Quattro area. I might just skip it.

They make offset license plate holders for your front bumper... not the most ideal choice, but it could work.

[Vinng86]

They make offset license plate holders for your front bumper... not the most ideal choice, but it could work.

You're referring to the tow hook license plate holders right? I hate them because they introduce a new problem - they ruin the symmetry, lol.

[AudiC7Owners]

You're referring to the tow hook license plate holders right? I hate them because they introduce a new problem - they ruin the symmetry, lol.

You could always get the solid honeycomb grill without the quattro text at the bottom. That would probably be your best option.

https://www.ebay.com/itm/for-Audi-A6...FeA:rk:28:pf:0

https://www.ebay.com/itm/For-AUDI-A6...KKb:rk:29:pf:0

[s4nicetry]

Nice video, the tie wraps are definitely a life saver trying to separate the grill.

[gimpgutter]

Well, I just finished putting in the Stonecarbon grille on my 2013 S6. The process went reasonably well, but I did run into some hiccups along the way.

1) Highly recommend safety glasses when dealing with the wheel surround. I got a face full of nasty dust. This is just good practice anyway.
2) I had to modify the Stonecarbon grille to fit on my S6. See the photos below for a guide. Basically, there are existing horizontal fins in line with the Audi logo. On the new Stonecarbon grille, there is a plastic piece that extends down and interferes with the fins. I used a Dremel to make 4 notches (2 on either side) to avoid these fins.
3) My parking (or is it ACC) sensors didn't have covers like you mentioned in the video. They are gray, so i will eventually paint them. Apparently the radar band they use can penetrate paint without issue.
4) Perhaps it's my stupidity, but I had a difficult time locating the correct spot for the zip ties. In hindsight, it makes sense, but you may want to insert a closeup of where you separated from the existing grille. I ended up prying my chrome surround (which was already damaged, so no big deal), instead of the grille assembly itself.
5) The Torx screws under the car are actually T20, at least on mine. I think I used that for the wheel surrounds, as well.
6) My wife insisted I put a front license plate on. She is the easiest going person I know and never takes a stand on anything, so I figured I'll listen to her this time. I ended up using an assembly pieced together from stuff at Home Depot. I wish I had a true fastener store around me, or bought things online in advance. I don't have nightvision, so I could git the plate entirely between the Quattro text and the Audi logo, unlike Vinng86
- I used a 1/4" x 20 tpi x 1-1/4" long panhead stainless screws.
- I painted the old license plate frame black. I used plastidip, but a glossy automotive paint would have been better. Or just go to Autozone and get a 5 dollar one already in black.
- The order of hardware is as follows: screw, license plate frame, license plate, grille, rubber washer (1/4" inner diameter, 1-1/4" outer diameter), metal washer (same size), locking washer, then nut. Any longer and the screws would have interfered with the grille support. The 1-1/4" OD washers span the hexagons and give a good fit. What sucks is that I can't change the license plate without getting to the back nuts. I couldn't think of another solution given the hexagon pattern.

[Vinng86]

Good stuff! That huge lip must be very new 'cause I don't remember having such a lip. Stonecarbon sells multiple different grilles for the same platform though, so maybe you got a different one than I did.

Those gray circles are 2 of your 4 parking sensors on the front. I think KwikStix misspoke when he said "covers", they're more like "holders" as the front of the sensor is exposed.
The ACC modules are also the two black dome things where fog lights usually are on the left/right.

[AudiC7Owners]

Well, I just finished putting in the Stonecarbon grille on my 2013 S6. The process went reasonably well, but I did run into some hiccups along the way.

1) Highly recommend safety glasses when dealing with the wheel surround. I got a face full of nasty dust. This is just good practice anyway.
2) I had to modify the Stonecarbon grille to fit on my S6. See the photos below for a guide. Basically, there are existing horizontal fins in line with the Audi logo. On the new Stonecarbon grille, there is a plastic piece that extends down and interferes with the fins. I used a Dremel to make 4 notches (2 on either side) to avoid these fins.
3) My parking (or is it ACC) sensors didn't have covers like you mentioned in the video. They are gray, so i will eventually paint them. Apparently the radar band they use can penetrate paint without issue.
4) Perhaps it's my stupidity, but I had a difficult time locating the correct spot for the zip ties. In hindsight, it makes sense, but you may want to insert a closeup of where you separated from the existing grille. I ended up prying my chrome surround (which was already damaged, so no big deal), instead of the grille assembly itself.
5) The Torx screws under the car are actually T20, at least on mine. I think I used that for the wheel surrounds, as well.
6) My wife insisted I put a front license plate on. She is the easiest going person I know and never takes a stand on anything, so I figured I'll listen to her this time. I ended up using an assembly pieced together from stuff at Home Depot. I wish I had a true fastener store around me, or bought things online in advance. I don't have nightvision, so I could git the plate entirely between the Quattro text and the Audi logo, unlike Vinng86
- I used a 1/4" x 20 tpi x 1-1/4" long panhead stainless screws.
- I painted the old license plate frame black. I used plastidip, but a glossy automotive paint would have been better. Or just go to Autozone and get a 5 dollar one already in black.
- The order of hardware is as follows: screw, license plate frame, license plate, grille, rubber washer (1/4" inner diameter, 1-1/4" outer diameter), metal washer (same size), locking washer, then nut. Any longer and the screws would have interfered with the grille support. The 1-1/4" OD washers span the hexagons and give a good fit. What sucks is that I can't change the license plate without getting to the back nuts. I couldn't think of another solution given the hexagon pattern.

It must be an S6 bumper thing with those fins behind the grille that you have to trim, because my prestige bumper did not have those at all. At least it didn't require much trimming. Your custom license plate looks really good for throwing it together yourself.

[Prlme]

Where did you source your replacement camera? My lense cover is so chipped you can barely see anything

[s4nicetry]

Where did you source your replacement camera? My lense cover is so chipped you can barely see anything

So is mine, drives me nuts. I'm definitely putting some protective film over my replacement when I get one.

[AudiC7Owners]

I got mine on eBay, but it didn't match up with my plug perfectly... Think it was slightly different for vw's. Gonna try a different one acs I'll report back


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[itdoesitallroad]

Just ordered mine from stonecarbon. I have and 2013 S6 with parking cameras and night vision. Did you have a clear view with you top down parking camera view. I would think if the front camera is not exactly in it's original position it would throw the view off.

[Vinng86]

Just ordered mine from stonecarbon. I have and 2013 S6 with parking cameras and night vision. Did you have a clear view with you top down parking camera view. I would think if the front camera is not exactly in it's original position it would throw the view off.

The front camera mounts to a bracket which mounts to the back of the audi rings holder. The stonecarbon grille has the same hole so when you mount it, it's in the exact same position. I had no issues with the top down parking view, it was perfect.

[AudiC7Owners]

The front camera mounts to a bracket which mounts to the back of the audi rings holder. The stonecarbon grille has the same hole so when you mount it, it's in the exact same position. I had no issues with the top down parking view, it was perfect.

No issues at all either, but you you have to trim the Stone Carbon grille in order to mount it to the back of the rings as shown in the video.

[chyates]

So I need some opinions, I am getting ready to order the grill from stonecarbon.

I have a 16 Misano red S6, and trying to decide which color option to go with

Option 1 Silver trim and silver quattro lower grill
Option 2 Black trim and silver quattro lower grill
Option 3 All Black with quattro lower grill

https://www.google.com/search?q=audi...ba22G6OIEBUoM:

[Vinng86]

Do you have black optics package (or plan to go black)? If so, go black trim. I think black will definitely go well with your red s6 regardless, it's a classic color combo.

You may want silver quattro lettering because black may not contrast enough against the "noisy" honeycomb mesh for you to actually read it at a distance.

[chyates]

I don't have the BO package so today it has the chrome around the grill like the link to RS6 picture..

[Nemesis tl-s]

Are you sure that paint with primer behind the new grill will hold up to the elements? I just would hate to have to repaint the black in a few months if it didn't stick well. I do think primer is needed but never sure if the paint/primer combo is as good as using a two step (primer then paint) process.

I did this a few months ago and used black truck bed liner spray from Pep Boys. I thought it would hold up better to rocks and other road debris.

[AudiC7Owners]

I did this a few months ago and used black truck bed liner spray from Pep Boys. I thought it would hold up better to rocks and other road debris.

Not a bad idea... I'll probably do that if I have to redo it.

[s4nicetry]

I did this a few months ago and used black truck bed liner spray from Pep Boys. I thought it would hold up better to rocks and other road debris.

I used bed liner as well, seems to be holding up good.

[JakesAudiA7]

im in this situation right now... the parking camera doesn't move over nor do the parking sensors, so ok i see cutting the grill to make the camera fit.. (Even if the front piece cant go back on), but how do i get the Parking sensors to stay in place if there is no housing for them to stay in.... HELP!!!!!!!!!!

[JakesAudiA7]

im in this situation right now... the parking camera doesn't move over nor do the parking sensors, so ok i see cutting the grill to make the camera fit.. (Even if the front piece cant go back on), but how do i get the Parking sensors to stay in place if there is no housing for them to stay in.... HELP!!!!!!!!!!

Body shop wanted to avoid any cutting and ordered the correct factory parts to add to the grille.. I dont have a Stonecarbon grille, but all this cutting is crazy...

[AudiC7Owners]

im in this situation right now... the parking camera doesn't move over nor do the parking sensors, so ok i see cutting the grill to make the camera fit.. (Even if the front piece cant go back on), but how do i get the Parking sensors to stay in place if there is no housing for them to stay in.... HELP!!!!!!!!!!

Body shop wanted to avoid any cutting and ordered the correct factory parts to add to the grille.. I dont have a Stonecarbon grille, but all this cutting is crazy...

Do you have a picture of the grille? Sounds like you may have not bought the correct grille (needed to get one with the parking sensor housings built in)

[JakesAudiA7]

Do you have a picture of the grille? Sounds like you may have not bought the correct grille (needed to get one with the parking sensor housings built in)

Your exactly correct, any ideas where I can purchase one for a 2018 S7 with the sensors housing already built in plus the correct!!!! Camera bracket.... I left the Aftermarket grill at the body shop... so no pics... ill get it on monday.

[AudiC7Owners]

Your exactly correct, any ideas where I can purchase one for a 2018 S7 with the sensors housing already built in plus the correct!!!! Camera bracket.... I left the Aftermarket grill at the body shop... so no pics... ill get it on monday.

https://www.ebay.com/itm/RS7-Style-B...oAAOSwJ7RYUQFB

Might need to message them to verify it's ready for night vision.


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[ProgressiveB6A4]

@KwikStix

Reviving this thread, sorry! But I noticed your A6 has the thermal camera AND the ACC (based on the fact that you don't have fog lights and have the radar bulbus black things).

What was your perspective on potentially knocking out of alignment the ACC, and having to potentially get it re-calibrated by audi (some 8 hour job and $1K ish dollars Im sure you have heard).

Obviously sounds like your ACC was just fine, in fact everything was fine after installation, but just wanted to know your thoughts, perspective, and recommendations towards modifying the grille/bumper/removing bumper and the ACC.

Thanks!!
Scott

- - - Updated - - -

Reviving this thread, sorry! But I noticed your A6 has the thermal camera AND the ACC (based on the fact that you don't have fog lights and have the radar bulbus black things).

What was your perspective on potentially knocking out of alignment the ACC, and having to potentially get it re-calibrated by audi (some 8 hour job and $1K ish dollars Im sure you have heard).

Obviously sounds like your ACC was just fine, in fact everything was fine after installation, but just wanted to know your thoughts, perspective, and recommendations towards modifying the grille/bumper/removing bumper and the ACC.

Thanks!!
Scott

[Nemesis tl-s]

In my case I put the grill on without removing the front bumper. so I didn't have to worry about messing up the sensors for the adaptive cruise control. However, there are several threads on this forum that help you realign the sensors without going to the stealership.

[AudiC7Owners]

@KwikStix

Reviving this thread, sorry! But I noticed your A6 has the thermal camera AND the ACC (based on the fact that you don't have fog lights and have the radar bulbus black things).

What was your perspective on potentially knocking out of alignment the ACC, and having to potentially get it re-calibrated by audi (some 8 hour job and $1K ish dollars Im sure you have heard).

Obviously sounds like your ACC was just fine, in fact everything was fine after installation, but just wanted to know your thoughts, perspective, and recommendations towards modifying the grille/bumper/removing bumper and the ACC.

Thanks!!
Scott

- - - Updated - - -

Reviving this thread, sorry! But I noticed your A6 has the thermal camera AND the ACC (based on the fact that you don't have fog lights and have the radar bulbus black things).

What was your perspective on potentially knocking out of alignment the ACC, and having to potentially get it re-calibrated by audi (some 8 hour job and $1K ish dollars Im sure you have heard).

Obviously sounds like your ACC was just fine, in fact everything was fine after installation, but just wanted to know your thoughts, perspective, and recommendations towards modifying the grille/bumper/removing bumper and the ACC.

Thanks!!
Scott

As long as you follow the DIY video I posted you will be good... that means unplugging the battery before you start. If you turn the car on while any of the cameras are unplugged, you will cause their alignment to mess up... but as long as no power is there until you plug everything back up you will be fine.