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Bumper Cover Repair With ADAS: Audi - UPDATE
I-CAR · March 10, 2026 · Audi
Summary
This article outlines Audi's strict guidelines for bumper cover repairs on vehicles equipped with ADAS sensors. It details specific restrictions on paint thickness (max 150 microns), plastic repairs, filler application, and spot repairs within 25 cm of radar sensors, as well as requirements for sanding the radar field of vision down to the plastic.
What to do on the job
Adhere to Audi's bumper repair limits near radar sensors: do not exceed 150 microns of paint, do not perform plastic repairs or apply filler within 25 cm of the sensor area, sand the entire radar field of vision down to raw plastic before refinishing, and avoid three-coat paint systems or spot repairs in these zones.
How to use it
Use this document to justify the labor and material costs associated with sanding the bumper cover down to raw plastic in the radar field of vision, measuring paint mil thickness, and performing necessary pre-paint sanding checks. It also serves as official documentation to defend why a bumper cover must be replaced rather than repaired if damage, filler, or plastic repairs are located within 25 cm of a radar sensor, or if a three-coat paint process is required.
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