Signature Series Vehicles A3 Installation Guidelines

STāSIS Engineering

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Table of Contents

Page Torque specs 3 Suspension

Front and Rear Suspension 4 Rear Anti-Roll Bar (Challenge Series) 11

Braking Touring Brake Kit 13 Challenge Brake Kit 16 Bed-In Procedure 20

Exhaust Exhaust Kit 21

Differentials A3 Front Differential 22

Post Installation Checklist 23

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A3 TORQUE VALUES

Suspension Front strut to upper mount 44.3 ft-

lbs Front strut upper mount to body 11 ft-lbs

+90º Front strut /bearing housing pinch bolt 52 ft-lbs

+ 90º Coupling rod end to strut 48 ft-lbs Ball joint to control arm 55 ft-lbs Outer CV/wheel bearing bolt 147 ft-lbs

+ 180º Rear damper to upper mount 18 ft-lbs Rear damper upper mount to body 37 ft-lbs

+ 45º Rear damper to upright 132 ft-lbs

Rear sway bar link to sway bar 30 ft-lbs Rear sway bar mounts 15 ft-lbs Brakes Rotor set screw 44 in-lbs STaSIS touring bracket to caliper 113 ft-lbsSTaSIS touring bracket to upright 143 ft-lbsSTaSIS Challenge bracket to upright 92 ft-lbs STaSIS Challenge caliper to bracket 70 ft-lbs Brake line to caliper 14 ft-lbs Exhaust Down pipe to mid pipe slip clamp 17 ft-lbs Hangers to body 17 ft-lbs Mufflers to mid pipe 17 ft-lbs Muffler adjustment bracket 17 ft-lbs Front Diff Ring gear to Diff 52 ft-lbs

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A3 Suspension Fixed Height Suspension Kit

Parts List Qty Description Part Number 2 Front Damper MkV SA01.2006.03 2 Rear Damper MkV SA01.2006.04 1 Spring Set MkV

SP04.0002.00

Special Tools Required

Qty Description Part Number 1 Torque Wrench VAG 1332 1 Spreader 3424 1 Engine/transmission jack VAG 1383 A 1 Wheel hub support T10149 1 Spring compressor VAG 1752/1 2 Spring holders VAG 1752/3

Please read ALL instructions prior to attempting installation. Please torque all fasteners to

specifications.

Front Removal 1 Before removing any parts, park the car on a

secure, stable, and level surface and loosen (but do not remove) the wheel lug nuts. Jack the vehicle up, and place the car on four stable jack stands or use a professional vehicle lift. We recommend having two people available for certain steps of the installation.

2 Remove wheel trim; pull trim cap off light-alloy wheels (using puller in vehicle tool kit). Remove wheel

3 Loosen hex-combination bolt for drive axle. 4 Remove Wheel

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5 Remove upper coupling rod hex nut - arrow - from suspension strut.

6 Disengage wheel speed sensor wire from suspension strut.

7 Remove nuts -arrows - .

8 Pull out wheel bearing housing with lower ball

joint out of control arm.

9 Fasten drive axle to body with wire. Note: Drive axle must not hang down, otherwise inner joint will be damaged by over bending

10 Reattach lower ball joint to control arm to prevent assembly from hanging freely.

11 Secure Engine / transmission jack VAG 1383 A with wheel hub support T10149 to wheel hub using wheel bolt

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12 Remove wheel bearing housing / suspension strut bolt connection -arrow-

13 Insert Spreader 3424 into slot of wheel bearing housing and turn ratchet 90 degrees and remove ratchet.

14 Press brake disc by hand in direction of

suspension strut Otherwise, strut tube may be canted in hole of wheel bearing housing

15 Pull off wheel bearing housing downward from strut tube using Engine/transmission jack VAG 1383 A and lower until strut tube hangs free

16 Tie wheel bearing housing with wire at sub frame.

17 Remove wiper arm and plenum chamber cover in engine bay

18 Remove hex bolts - arrows- for top strut mounting and remove suspension strut.

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Front Installation 19 Re-using OEM parts 2-3-5-6-9 and 10.

Insert STaSIS strut with supplied spring into the OEM upper mount (wider coils on bottom perch), one of two markings - arrows - must point in direction of travel. Tighten upper nut to 60 Nm (44.3 lb-ft)

20 Tighten hex bolts - arrows- for top strut mounting

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21 Secure Engine / transmission jack VAG 1383 A with wheel hub support T10149 to wheel hub using wheel bolt

22 Re-insert drive axle into wheel bearing

housing by disconnecting the control arm - arrows – and reassembling. NOTE: Ensure that boot is not damaged or twisted

23 Carefully lift wheel bearing housing using

transmission jack far enough until bolt for suspension strut/wheel bearing housing can be inserted

24 Press brake disc by hand in direction of suspension strut while lifting

25 Remove spreader 3424 26 Tighten wheel bearing housing/suspension

strut bolt connection -arrow-

27 The remainder of the installation is

performed in reverse order of removal

28 Install Wheel and tighten Note – do not fully tighten bolts until vehicle is unsupported and sitting at ride height.

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Rear Removal 1 Remove wheel 2 Remove wheel housing liner 3 Remove coil spring, using spring

compressor. CAUTION! Make sure that coil spring is correctly seated in spring retainer. 1 - Spring compressor V.A.G 1752/1 2 - Spring holders V.A.G 1752/3

4 Remove bolts holding upper damper mount

5 remove bolt holding damper

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Rear Installation 6 Assemble STaSIS damper (1) with OEM

parts 2 -7 1 – STaSIS damper 2 – Audi Protective Cap 3 – Audi Protective Tube 4 – Supporting Ring 5 – Buffer Stop 6 – Damper Mount

7 Install damper assembly and torque to:

Bolt #4 – 180 Nm (132 ftlb) Bolt #5 – 50 Nm (37 ftlb) + additional 45° turn Note – Bonded rubber bushings can only be turned to a limited extent. The mountings of the suspension links must only be tightened when the suspension is in the curb weight position.

8 Reinstall the wheel housing liner 9 Install Wheel and tighten

Note – do not fully tighten bolts until vehicle is unsupported and sitting at ride height.

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A3 Suspension Rear Anti-Roll Bar (Challenge Series Only)

Parts List

1 MkV Rear anti-roll bar SA15.1107.00 Special Tools Required

1 Torque Wrench VAG 1332 Please read ALL instructions prior to attempting installation. Please torque all fasteners to specifications.

Removal

1 Remove Rear Wheels 2 Remove Nut -1- and pull coupling rod -2-

out of anti-roll bar (ARB)

3 Remove bolts -arrows- for ARB bracket

4 Remove ARB

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Installation 5 Apply silicone grease to the inside of the new

ARB bushings

6 Install the bushing on the inside of the stops welded to the ARB

7 Install the STaSIS ARB using the OEM clamps

and bolts to subframe - bolt torque: 20Nm (15 ftlb)

8 Attach end-links to STaSIS ARB rearward holes, using OEM bolts - bolt torque: 40 Nm (30 ftlb)

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A3 Brakes Touring Brake Kit Parts List

Qty Description Part Number 1 Rotor Alcon 345x26 RH BR01.1025.00

Assembly 1 Rotor Alcon 345x26 LH BR01.1024.00

Assembly 1 Bracket Touring RH BR04.1012.00 1 Bracket Touring LH BR04.1013.00 1 Modified backing plate RH BR07.3001.00 1 Modified backing plate LH BR07.3000.00 2 Lowhead SHCS Torx HA04.0001.00 4 M14 Wedge Lock Washer HA02.1400.00 2 Flat Washer HA02.0611.00 6 SHCS M14x1.5x35 12.9 Zinc HA04.0003.00

Special Tools Required

Qty Description 1 T30 Torx bit 1 T55 Torx bit 1 Brake pad spreader

Installation Guidelines • The brackets are side-specific, labeled “L” for driver side and “R” for passenger side • The rotors are side-specific, rotational direction is labeled

• Torque all fasteners to specification. Do not use impact wrench.

• Ensure all ABS sensor and Pad wear sensor plugs are reconnected.

• Drive the car at low speeds for a few miles to check brake operation before beginning brake bedding procedure.

• During bedding do not thermally shock the rotors with aggressive braking before the rotors have come

up to temperature. Cracks on new rotors can form due to thermal shock. Gradually increase brake pressures as instructed in the bedding procedure.

• After bedding brakes re-torque wheel nuts to proper torque specifications. • If vibration occurs during normal usage, check for abnormal pad wear deposits on the rotor. Double

check all fasteners and repeat the bedding process 2-3 cycles until the pad deposits on the rotor becomes uniform.

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Instructions

1 Sort the parts in the brake kit for the right and left side. Caliper mounting brackets are NOT universal.

2 Raise vehicle and remove the front wheels. 3 Remove the caliper.

Disconnect the brake pad wear sensor wire from the driver’s side front brake inner pad. Remove caliper mounting bolts (the bolts holding the caliper mounting bracket to the upright). Remove caliper and support it so that the brake line is not under tension.

4 Remove the brake rotor. Clean the hub, removing all rust from the rotor mounting surface, the rotor pilot and wheel pilot. Apply some anti-seize to the pilot surface to prevent rotors and wheels from sticking in the future. Do not get any anti-seize on the rotor mounting surface of the hub.

5 Attach brake bracket to caliper as shown (the brake line will still be attached to the caliper, so make sure to support the caliper with a bungee cord). Install the SHCS Lowhead Torx bolt in the top hole, and the M14x1.5x35 bolt with the Flat washer in the lower hole.

Outboard view:

Inboard view:

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6 Attach the bracket to the upright at only the bottom hole using a M14x1.5x30 bolt with a M14 Wedge Lock Washer. Do not completely tighten the bolt. Putting the bracket in the position shown will make it much easier to torque the bolts from the previous step. Torque the bracket to caliper bolts to 113 ft.-lbs.

7 Detach the bottom bolt that is holding the bracket

to the upright. Replace brake rotor backing plates with the STaSIS modified plates. Install the new rotor making sure it is free of dirt and grease. Tighten the rotor retaining bolt to 48 in-lbs.

8 Install the caliper/bracket unit using the

M14x1.5x35 bolts with the wedge lock washers. Torque the bolts to 143 ft.-lbs. If the caliper won’t fit over the rotor, use a pad spreader to allow the caliper to fit over the rotor.

9 Make sure that the brake rotor spins freely and that the rotor is flush on the hub.

10 Check the clearance between the wheels and the new brake calipers. Make sure that there is at least 1/8” (0.125”) between the wheel and the caliper.

11 Verify that all brake bolts are tight. Install Wheel and tighten Note – do not fully tighten bolts until vehicle is unsupported and sitting at ride height.

12 Test drive the car using the brakes gently.

13 WARNING: Do not aggressively test the brakes until they are properly bedded.

14 Bed the pads and rotors. See the Bedding Procedure attached to these installation instructions. After brakes are fully bedded recheck wheel lug bolt torque.

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A3 Brakes

Challenge Brake Kit

Parts List: Qty Description Part Number

1 Rotor Alcon 355 x 28mm RH BR01.1018.00 Assembly

1 Rotor Alcon 355 x 28mm LH BR01.1019.00 Assembly

4 Spacer 13-14” BR05.5001.00

4 SHCS M12x1.75x70 12.9 Blue HA01.1207.75

4 Serrated Belleville Washer HA03.0201.00

1 Caliper Alcon Mono4 RH Leading 28mm

BR03.1012.00

1 Caliper Alcon Mono4 LH Leading 28mm

BR03.1013.00

2 Bracket A3 13” Mono 4 BR04.2001.05

1 Line Kit Alcon A3 Front BR20.1006.00

1 Pad Mono4 SBS Pro-Track BP01.3001.00

1 Fluid Motul 5.1 BP99.1000.00

Installation Guidelines

Please follow these guidelines when installing the front brake kit. • Tighten hydraulic connections with a line wrench. • Bleed brakes properly to assure proper brake operation; the use of a power bleeder is

recommended. • The rotors are side-specific, rotational direction is labeled • Torque all fasteners to specification. Do not use impact wrench. • Ensure all ABS sensor and Pad wear sensor plugs are reconnected. • Drive the car at low speeds for a few miles to check brake operation before beginning brake bedding

procedure. • During bedding do not thermally shock the rotors with aggressive braking before the rotors have come

up to temperature. Cracks on new rotors can form due to thermal shock. Gradually increase brake pressures as instructed in the bedding procedure.

• After bedding brakes re-torque wheel nuts to proper torque specifications. • If vibration occurs during normal usage, check for abnormal pad wear deposits on the rotor. Double

check all fasteners and repeat the bedding process 2-3 cycles until the pad deposits on the rotor becomes uniform.

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Instructions

1 Sort the parts in the brake kit for the right and left side. Brake bleeders face upward. Caliper mounting brackets are universal. Install brake pads in calipers, and the lines onto the caliper.

2 Raise vehicle and remove the front wheels. 3 Using brake cleaner, clean the brake line connection at

the body flange. Remove all dirt and debris from this area and from the line connection threads so that no dirt will get into the new brake line when it is installed.

4 Remove the caliper. Disconnect the brake pad wear sensor wire from the driver’s side front brake inner pad. Remove caliper mounting bolts (the bolts holding the caliper mounting bracket to the upright). Save these bolts as they will be reused. Remove caliper and support it so that the brake line is not under tension.

5 Remove the brake rotor. Clean the hub, removing all rust from the rotor mounting surface, the rotor pilot and wheel pilot. Apply some anti-seize to the pilot surface to prevent rotors and wheels from sticking in the future. Do not get any anti-seize on the rotor mounting surface of the hub.

6 Remove the OEM rotor backing plates, they will not be reused. Install caliper mounting brackets using the stock mounting bolts and torque to 92 ft-lb. The bracket will mount to the outside face of the upright with the angle flange going over the mounting ears in the upright. The OEM bolts will fit through the upright from the backside and thread into the bracket.

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7 Install the new rotors making sure they are free of dirt and grease. Tighten the rotor retaining bolt to 48 in-lbs.

8 Install brake line with the banjo bolt and crush washers

into the caliper. To determine brake line orientation, tighten finger tight until the caliper is mounted.

9 Place the caliper with the brake pads installed onto the

caliper mounting bracket and install the caliper mounting bolts M12 x 1.75, making sure to put anti-seize on the threads. Torque to 70 ft-lb. If the caliper will not go over the rotor because the pads are too close together, push the pads back using a pad spreader. IMPORTANT: Check the caliper mounting bolts for wear each time the brake pads are replaced, and make sure to put anti-seize on the threads when re-installing the calipers. Note: When rotating, the rotor must always pass the small caliper piston first. Therefore in a trailing caliper application like we have here, the small caliper piston will be at the bottom of the caliper. The purpose is to insure even pad wear.

10 Orient brake line on caliper so that there is no binding or stretching of the line when the upright assembly is turned from full lock left to right (checked at ride height position). Tighten banjo bolt.

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11 Replace OEM lines and attach new brake lines.

Use an 11-mm line wrench on the hard line nut and a 14-mm wrench on the flats on the flex line hose-end. Remove the stock flexible line from the hard line and completely remove the stock caliper and line from the vehicle. Install the new flexible line, using the stock spring clip under the hard line nut and clean with brake clean once tightened. Install the brake line grommet into the factory bracket on the back of the upright. Re-connect the brake pad wear sensor.

12 Make sure that the brake rotor spins freely and that the rotor is flush on the hub.

13 Bleed the brakes using fresh high-quality brake fluid. A power bleeder is highly recommended. Two bleeders are on each front caliper. Bleed the outers first until no air exits, then the inners until no air exits Wait 10-15 minutes. Power bleed again while turning the ignition on/engine off and stroke the brake pedal five times when each bleeder is open. This process will assure a proper bleed with the ABS equipped system. Tighten all bleeders securely.

14 Clean all brake line connections with brake cleaner and compressed air so that they are clean and dry. Start engine and pressurize brake system several times and check for leaks at all the brake line connections. Correct any leaks before driving the car.

15 Check the clearance between the wheels and the new brake calipers. Make sure that there is at least 1/8”(0.125”) between the wheel and the caliper.

16 Verify that all brake bolts are tight. Install Wheel and tighten Note – do not fully tighten bolts until vehicle is unsupported and sitting at ride height.

17 Test drive the car using the brakes gently.

18 WARNING: Do not aggressively test the brakes until they are properly bedded.

19 Bed the pads and rotors. See the Bedding Procedure attached to these installation instructions. After brakes are fully bedded recheck wheel lug bolt torque.

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STaSIS Bedding Procedure

After installing new pads, rotors, or both, it is necessary to properly bed the pad to the rotor before using the brakes to their full capacity.

What is bedding?

Bedding is simply the process of depositing a layer of pad material (often called the transfer layer or transfer film) onto the surface of the rotor. The frictional characteristics of the pad/transfer layer interface are far better than those of a pad/rotor interface. It is therefore crucial to bed pads properly to ensure the reliability, performance, and longevity of your STaSIS/ALCON brake system.

When should I bed pads and rotors?

Bedding is recommended whenever you install new pads or rotors, or experience vibrations while braking. Vibrations felt through the brake pedal are almost always a result of uneven pad deposition, which is remedied by re-bedding the existing components.

Bedding Process

1. Find a suitable road. You will need a relatively straight road with minimal traffic where you can safely (and legally!) reach speeds up to 65 MPH.

2. Bring the car up to approximately 65 MPH. Gently apply constant pressure (about 10%) to the brakes, bringing the car down to about 20 MPH.

3. Accelerate briskly back to 65 MPH. Apply the brakes again, however this time use more force (about 20%).

4. Repeat steps 2 and 3, each successive time applying more pressure. Your last two brake applications should engage or nearly engage the ABS system.

5. Drive for awhile using absolutely minimal brake application to cool the rotors to ambient temperature.

6. Once the system has cooled, repeat the entire process. After completing two heat cycles on the rotors, check the rotors for an even, slightly hazy coating (often with a slight blue tint). Any spotting or blotches indicate uneven pad deposition. Repeat the process until the rotor surface is even.

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A3 Exhaust Exhaust Kit Installation

Parts List Qty Description Part Number 1 A3 Sig Series 2.0T FWD Exhaust EX01.A320.00

1 Downpipe Adapter 1 Front Muffler Assembly 1 Rear Assembly 1 Dual Tip 2 2.5” Band Clamp 1 Front Double hanger/clamp 1 Bottle of exhaust sealant 2 Rubber Hanger Retaining Clips

Instructions

1 Remove cross member just below factory clamping sleeve.

2 Unbolt rear hangers and support rear muffler. 3 Loosen clamping sleeve, unhook front and middle rubber hangers

and remove factory exhaust. Clamping sleeve will be reused.

4 Loosely install front double hanger onto the flared side of front muffler assembly (hangers leaning toward back of car). Install downpipe adapter into flared end of front muffler assembly.

5 Re-install clamping sleeve on end of downpipe. Install front muffler assembly into clamping sleeve while inserting front double hook hanger and middle hook hanger into rubber hangers on car. Secure front double hanger but do not fully tighten yet.

6 Remove rear rubber hangers from stock exhaust and reinstall onto car.

7 Install 2.5” clamp over front end of rear muffler assembly. Install rear assembly onto back of front muffler assembly and into rear rubber hangers. Secure 2.5” band clamp but do not fully tighten yet.

8 Install dual tip onto end of rear muffler assembly with band 2.5” clamp.

9 After you get ½” to ¾” clearance to all chassis points start tightening clamps. Start at clamping sleeve and work your way back.

10 Test drive and check for rattles. Re-adjust as necessary to provide proper clearance.

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A3 Differential A3 Front Differential Installation (Challenge Series Only) Parts List: Qty Description Part Number

1 Front LSD MkV DL01.0007.0012 Ring gear bolts

Removal

1 Remove the differential following factory specified procedures

2 Using a 21/64” drill bit, drill rivet from differential side, opposite ring gear side. Drill out to ¾” depth from the face of the rivet

3 Using a 1/2” drill bit, remove the rivet head

4 Using a 5/16” drift, tap out the remainder of the rivet

5 Follow steps 2 to 4 for all rivets

6 Remove ring gear from differential

Installation

7 Clean ring gear and heat to factory specification

8 Slip ring gear onto STaSIS differential

9 Place two bolts 180° apart, and hand-tighten two nuts onto each bolt

10 After allowing the ring gear to cool, install the remainder of the bolts

11 Remove the two nuts, install locking plates and all nuts

12 Torque nuts to 52 ft-lb

13 Using a large drift, tap the back of the bolt (round head) to ensure that bolt is seated

14 Recheck torque 15 Reinstall differential and transmission following factory

procedures

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S5 Suspension A3 Signature Series Post Installation Checklist Suspension

o Check and re-torque front outer CV joint bolts after damper installation

o Apply a large amount of grease into the anti-roll bar bushings to prevent possible squeaking.

o Ensure all rear suspension and anti-roll bar mounting bolts were tightened with the suspension compressed to the curb weight position.

o Check alignment after driving the car for a few miles, as the rubber bushings will cause the car to settle.

Brakes

o Ensure all ABS sensor and Pad wear sensor plugs are reconnected

o Ensure brake line grommet is properly clipped. Cycle steering from full lock left to full lock right (with the suspension compressed to the curb weight position) and inspect for possible binding on the brake line.

o After bleeding brakes, cycle pressure to the pedal and double check all bleed screws and brake line connections for possible leakage.

o Drive the car at low speeds for a few miles to check brake operation before beginning brake bedding procedure.

o During bedding do not thermally shock the rotors with aggressive braking before the rotors have come up to temperature. Cracks on new rotors can form due to thermal shock. Gradually increase brake pressures as instructed in the bedding procedure.

o After bedding brakes re-torque wheel nuts to proper torque specifications.

o After installation and bleeding is completed double check brake fluid level.

o If vibration occurs during normal usage, check for abnormal pad wear deposits on the rotor. Double check all fasteners and repeat the bedding process 2-3 cycles until the pad deposits on the rotor becomes uniform.

Exhaust

o During and after install, 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.

o Ensure the exhaust tips protrude from the bumper evenly and are not touching any body panels.

o Apply anti seize to all assembly bolts to allow for ease of removal.