AWE 3020-31022 Touring Edition Exhaust System Instruction Manual

AWE 3020-31022 Touring Edition Exhaust System

**Thank you for purchasing the AWE Touring Edition Exhaust System for the

B9 Audi 3.0T SQ5.**

For up to the minute fitment information, be sure to visit the Audi B9 (80A) SQ5 section of the AWE website.
As always, AWE Performance Specialists are standing by for any questions, at 215-658-1670, or email usperformance@awe-tuning.com
Let’s go!

Parts Lists

INSPECT ALL PARTS PRIOR TO DISASSEMBLY OF VEHICLE;IF DAMAGED OR MISSING, PLEASE CONTACT THE PLACE OF PURCHASE IMMEDIATELY.

Non-Resonated Touring Edition Exhaust

Resonated Touring Edition Exhaust

INSTALLATION

Step 1

**** Installation of the AWE Performance Exhaust System is the reverse of the removal OEM exhaust.
Always refer to the manufacturer service manual for precise torque specifications on all OEM fasteners.

Under the hood, remove the plastic engine cover and turbo heat shield, to expose the turbo and catalyst.

CAUTION: The catalyst may be HOT, allow adequate time to cool down before disassembly. Severe burns and injury will occur if skin comes into contact with a hot exhaust.

Before removing the factory exhaust, soak the fasteners that hold the exhaust in place with a penetrating oil.
Start by removing the two (2) 12mm nuts on the driver side flange along with the two (2) 12mm nuts on the passenger side flange, as shown by the arrows in Figure 1-1 and 1-2. Four (4) of the flange nuts in total can be accessed from the engine bay; the remaining two (2) flange nuts are better accessed from the underside of the vehicle.

Step 2

The remainder of the removal process takes place under the car. Removing the belly pan is accomplished by removing the fasteners as shown by the arrows in Figure 2.
Four (4) quick release fasteners, at Arrows A in Figure 2.
Six (6) quarter-turn fasteners, at Arrows B in Figure 2.

NOTE: Before removing any braces or hanger supports, be sure the exhaust is supported either by a second set of hands or support stands.

Step 3

Some of the fasteners will need to be removed on the underbody panels to access all of the bolts that secure the cross-brace in place, shown by the arrows in Figure 3. Remove the 16mm bolts that secure the cross-brace
The mid-muffler hanger bracket is also held into place under this cross brace. Once removed, set aside the hanger and bracket for reuse on the AWE X-pipe section (part A77).

Step 4

Unplug the factory valve control motor, as shown by Arrow A in Figure 4.
Plug the included valve simulator into the factory valve control harness, as shown by Arrow B in Figure 4.
Secure the harness out of the way of any potentially hot exhaust parts, as shown in Figure 4.

Step 5

Starting from the rear of the car, support the OEM rear mufflers and loosen the four (4) 13mm bolts that secure the sleeve clamps into place, as shown by the arrows in Figure 5.
Remove the OEM rear muffler sections from the car.

Step 6

Some models are equipped with an additional cross-brace, located in front of the transmission, as shown in Figure 6. This brace will need to be removed to be able to remove the factory downpipes from the vehicle.
Loosen and remove the 16mm bolts, as shown by Arrow A
Loosen and remove the 18mm bolts, as shown by Arrow B
Loosen and remove the 13mm bolts, as shown by Arrow C
Set brace aside to be reinstalled at the final step.

Step 7

Loosen and remove the last remaining 12mm nut from the driver and passenger side exhaust flange at the catalytic converter, as shown by Arrow A in Figure 7.
Loosen and remove the 13mm bolts that secures each downpipe to the support bracket, driver side shown by Arrow B in Figure 7.

Step 8

Properly support the OEM mid mufflers and downpipe sections before complete removal.
Remove the four (4) 10mm triple square bolts that hold the hanger brackets onto the cross brace; driver side shown by the arrows in Figure 8.
The OEM exhaust can now be completely removed from the car allowing the AWE Touring Edition exhaust to be installed in the reverse order of removal.
Transfer the OEM hanger bushings and brackets onto the corresponding AWE Performance Exhaust parts.

Step 9

Install the downpipe upper sections (part A67 & A68) using the included flange gaskets and mounting hardware to secure them to the outlet flange of the factory catalyst.
Reinstall the mounting bracket and hanger hardware for both driver and passenger sides, as shown in Figure 9-1.
Reinstall and torque the flange nuts to manufacturer specification along with the spring-bolt into the support bracket. Be careful not to overtighten the spring-bolt.
NOTE: Spraying an assembly lube into the hanger bushings will make installation easier.
Figure 9-2 shows the proper orientation of the downpipe bracket on the driver side of the vehicle. The components from the OEM downpipe bracket will be reused here.
For the passenger side bracket, mirror this assembly.

Step 10

Place two (2) 2.5” Accu-Seal clamps over each inlet side of the downpipe lower sections (resonated parts B06 & B07, Non-resonated parts A69 & A70), install into place as shown on the resonated system in Figure 10. Be sure to fully seat the pipes over the corresponding downpipe upper sections outlet pipe.
Do not torque any of the clamps into place until the entire system has been installed and adjusted.

Step 11

Place two (2) 2.5” Accu-Seal clamps over the inlets of the X-pipe section (part A77) and install into place.
Transfer the OEM hanger bracket and bushing assembly onto the correlating hanger post on the exhaust.
Reinstall the cross brace with the included eight (8) cross brace spacers placed between the chassis and the brace, as shown by the arrow in Figure 11.
NOTE: Installing the hanger before installing the cross brace will make installation easier. Two (2) of the spacers will be placed between the hanger bracket and cross brace to maintain the factory.

Step 12

Place a 2.5” Accu-Seal clamp over the inlet of the passenger axle tube (part A72) and install onto the X-pipe section, as shown by Arrow A in Figure 12. This pipe must be installed first due to the shape of the pipes.
Place a 2.5” Accu-Seal clamp over the inlet of the driver axle tube (part A71) and install onto the mid-muffler section, as shown by Arrow B in Figure 12.

Step 13

Place a 2.5” Accu-Seal clamp over the inlet of the driver and passenger rear sections (A75 & A76) and install onto each of the axle pipe sections, as shown by the arrows in Figure 13.

Step 14

It is crucial to install each section and Accu-Seal clamp correctly to prevent loose joints and exhaust leaks between the tubing connections.
Arrow A in Figure   14 shows the expanded pipe and the preinstalled Accu-Seal clamp being brought up to the corresponding pipe.
Arrow B in Figure 14 shows the overlapping pipe installed correctly over the corresponding pipe.
Arrow C in Figure 14 shows the Accu-Seal clamp being brought to the edge of the expanded pipe.

NOTES:

• Do not torque any Accu-Seal clamp until the entire exhaust has been installed and adjusted.
• Torque specification is a minimum of 40 ft/lbs.

CARE

Once installed properly, your AWE Performance Exhaust will provide years of trouble free performance.

The exhaust volume and sound will settle with usage; 800-1000 miles is required to break-in new exhaust systems.

Also please note that the rear 180Technology® resonator has a small drain hole to allow condensation to escape. Water drops from this area are normal.

Periodic cleaning of exhaust tips is necessary to maintain proper finish, especially in areas prone to road salt and caustic deicing solutions. Use a mild soap and water solution or car wax to clean the finish. Avoid using metal polishes, as they can scratch the finish.

WARRANTY

Up-to-date warranty information is found HERE.

CUSTOMER SUPPORT

Any questions or comments, please do not hesitate to contact us:

AWE
215-658-1670
performance@AWE-Tuning.com

References

• Chiptuning & Motortuning von DTE Systems | Chiptuning No1
• AWE Exhaust Suite for Audi B9 SQ5 3.0T - AWE
• Warranty, return, cancellation policies - AWE

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