Exhaust Install

STāSIS Engineering
S4 DSG 3.0T / S5 3.0T Cabriolet / A7 3.0T
Exhaust Installation Guidelines
SE-022-023-024
S4 DSG S5 A7 3.0T Exhaust
Exhaust Kit Installation
Applications
Description
S4 DSG B8 3.0T Exhaust w/Downpipe
S5 B8 3.0T Cabriolet Exhaust w/Downpipe
A7 3.0T Exhaust w/Downpipe
Instructions
1
Before removing any parts, jack the vehicle up, and place the vehicle on four stable jack stands or use a
professional vehicle lift.
2
Remove the mid and rear undertrays.
S5/A7 - remove rear support bars.
Support the exhaust and remove the two
exhaust muffler hanger nuts (one per
side), 13mm socket.
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3
Gently pry the two center exhaust rubber
hangers of off the exhaust. Use a
lubricant (i.e. WD-40) if required.
4
Remove the center chassis cross brace
5
Loosen the 4 13mm exhaust clamp nuts #12.
Remove entire rear muffler assembly #3 and
#4 in one piece.
Remove the front undertrays and downpipe
flange nuts #8. Remove downpipes #10 and
gaskets #9 from both sides.
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6
For proper installation and fitment, please
follow the instructions in the correct
sequence listed-
Hardware supplied:
A7: Replacement nuts for factory studs
and new gaskets
S4/S5: Allen bolts, corresponding nuts,
offset crows foot socket, and exhaust
gaskets.
Install passenger side down-pipe first.
Do not torque flange nuts and bolts at
this time! Finger tighten only!
7
Slide drivers side down-pipe over
passenger side down pipe and install to
flange using the hardware and gaskets
provided.
Note orientation of the clamp before
installation, do not tighten the clamp at
this time.
Do not torque flange nuts and bolts at
this time! Finger tighten only!
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8
Center downpipes before tightening flange
nuts and bolts.
Torque – 23 Nm
Warning: Insure that the mid-pipes are
completely centered before tightening
flange bolts. If the downpipes are not
centered, the exhaust system will have
interference issues once all components
are installed.
The “S” reinforcement bracket on the
crossover section should be completely
horizontal. If the bracket is at an angle to
the ground, twist down pipes until bracket
is horizontal before tightening the flange
bolts.
Support down pipes and tighten the passenger
side downpipe clamp.
Warning: Insure proper clamp placement!
Align all clamps to the edge of the outer pipe.
If the clamp is installed inboard, insufficient
clamping force will result in exhaust slippage
and alignment issues.
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8
Install mid-muffler onto down-pipes and
slide exhaust hanger brackets into the
rubber hangers with lubricant. Make sure
muffler and pipes are centered with
adequate space around all components.
Slide mid-muffler forward until rubber
hangers are canted forward (towards the
front of the car) as shown. This allows for
exhaust expansion without stretching the
hangers.
Mid muffler pipe should be approximately
¼” to ½” from the corner of the center
tunnel of the vehicle. Clearance will
increase due to thermal expansion once
exhaust system heats up.
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9
Note clamp orientation, do not tighten
clamps at this time.
10 Install foam padding in the four locations
shown to center the exhaust mid-section.
Do not tighten clamps at this time.
Warning: Foam pads must be removed
after the exhaust is completely installed.
Failure to remove pads will result in the
melting of the pads onto the exhaust
system.
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10 Install drivers side intermediate pipe with
the clamp orientation as shown.
Do not tighten clamp at this time
Install passenger side intermediate pipe
with the clamp orientation as shown.
Do not tighten clamp at this time
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11 Remove exhaust hanger bracket off of the
stock exhaust and slide with lubricant into
the drivers side muffler hanger.
Note: S4/S5 muffler shown, A7 has single
tip outlet
Install drivers side muffler into
intermediate pipe, do not tighten clamp at
this time.
Install 13mm nut on exhaust hanger
bracket. Slide muffler forward until rubber
hanger is canted forward (towards the
front of the vehicle) to account for thermal
expansion (as shown).
13 Ensure all pipes are centered and clear of
any components. Tighten the forward
exhaust clamps on the mid muffler.
Warning: Insure proper clamp placement!
Align all clamps to the edge of the outer pipe.
If the clamp is installed inboard, insufficient
clamping force will result in exhaust slippage
and alignment issues.
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14 Locate drivers side muffler so that it is
centered in the valence cavity and pushed
forward so that the STaSIS logo is just
visible next to the valence (looking from
the top down)
Tighten the drivers side intermediate pipe
clamp at this time.
Warning: Insure proper clamp placement!
Align all clamps to the edge of the outer pipe.
If the clamp is installed inboard, insufficient
clamping force will result in exhaust slippage
and alignment issues.
Tighten the drivers side mid muffler clamp
15 Remove exhaust hanger bracket off of the
stock exhaust and install on the
passenger side muffler hanger.
Install passenger side muffler onto
intermediate pipe. Note clamp orientation.
Do not tighten clamp at this time.
Tighten 13mm nut for the passenger side
exhaust hanger bracket
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16 Match tip fitment to the driver side muffler.
13mm nuts for the OEM exhaust hanger
brackets can be loosened and hanger can
be rotated to accommodate side to side
movement.
Tighten intermediate pipe clamp.
Warning: Insure proper clamp placement!
Align all clamps to the edge of the outer pipe.
If the clamp is installed inboard, insufficient
clamping force will result in exhaust slippage
and alignment issues.
Tighten passenger side muffler assembly
clamp.
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17 Install center support bracket with
hardware provided. Mufflers can be
spread apart slightly while tightening to
accommodate tip alignment.
If brackets do not line up, loosen muffler
clamps and readjust as necessary.
Remove all foam locating pads before
running vehicle!
18 S5/A7 - Re-install rear support bars, check for clearance between exhaust system and support bars.
Loosen clamps and adjust pipes if additional clearance is needed. Double check tip alignment once all
clamps have been retightened.
All vehicles – Re-install cross brace and all undertrays. Test drive and check for rattles. Re-adjust as
necessary to provide proper clearance.
Exhaust Post Installation Checklist
Exhaust
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o
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During and after install, using isopropyl alcohol, wipe off all assembly and shipping
particles from the exhaust. If dust is not wiped off, once the exhaust gets hot, the
particles burn onto the stainless steel finish and become permanent.
Ensure the exhaust tips on both sides protrude from the bumper evenly and are not
touching any body panels.
Apply anti seize to all assembly bolts to allow for ease of removal.
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