APR CBK0051 Catback Exhaust System Instruction Manual

APR CBK0051 Catback Exhaust System

Product Information

• Product   Name: APR RSQ8 Catback Exhaust
• Model Number: CBK0051
• Compatibility: North American specification Audi RSQ8, similar models like the Urus

Specifications

• Material: Fiber-reinforced plastic, metal
• Screw Sizes: 10mm, 13mm, 16mm, T25, T45
• Number of Screws: 4 (10mm nuts), 4 (push-pin style fasteners), 2 (T25 screws), 10 (16mm screws and nuts), 4 (13mm exhaust clamps), 3 (T45 screws), 15 (T25 screws), 11 (T25 screws)

Product Usage Instructions

Section 1: Preparation

1. Raise and support the vehicle using jack stands or a lift.

2. Remove the noise insulation cover under the rear cross brace.
   There are four 10mm nuts, four push-pin style fasteners, and two T25 screws. Note how it interfaces with the other covers around it.

3. Remove ten 16mm screws and nuts from the metal cross brace exposed when the noise cover was removed. Note how it interfaces with the covers around it.

Section 2: Disassembling the Factory Exhaust

4. Remove the rubber hangers with brackets from the factory exhaust, noting their orientation.
5. Loosen the four 13mm exhaust clamps from the four exhaust tip pipes, and remove the pipes from the car.
6. Unplug the electrical connectors on both exhaust valve motors, located on both the left and right side of the rear muffler.

Section 3: Removing Components

7. Support the rear muffler assembly with a transmission jack.
8. Loosen the four 13mm nuts on the two sleeve clamps just behind the removed metal cross brace. With an assistant to hold the front of the rear section of the exhaust, slide the sleeve clamps towards the front of the car.
9. Remove three T45 screws from the center of the fiber-reinforced plastic undertray. Remove fifteen T25 screws from the perimeter of the undertray, and then remove it from the car. Note how the undertray interfaces with the surrounding panels on the car.
10. Remove eleven T25 screws from the middle noise cover panel under the car, and remove the panel from the car.
11. Remove the two 10mm nuts and one 10mm bolt from the metal heat shield on the left inside wheel well, just behind the left axle. Remove the panel from the car.
12. To remove the same metal heat shield from the right inside the wheel well, you must first move the high-voltage cables if the car is equipped with the sway stabilization feature. Remove the 10mm screw holding the cable bracket from the bottom of the right frame rail.
13. On the back side of the high-voltage cable bracket, spin the clamping washer off the threaded stud on the bottom of the frame rail. Move the cable assembly out of the way.
14. Remove the three T25 screws from the metal heat shield on the right inside the wheel well, just behind the right axle. Remove the panel from the car.

FAQ

Q: Are these instructions applicable to other car models?

A: These instructions were written for a North American specification Audi RSQ8, but other models like the Urus are similar.

Q: What tools do I need to install the kit?

A: These instructions assume that you have basic mechanical skills and several varieties of basic hand tools in order to install the kit. If you have any questions about the installation, feel free to contact your APR representative.

Q: How should I organize the fasteners during disassembly?

A: It is recommended that you get some kind of compartmented tray to organize the fasteners, such as a fishing tackle box or several large ice cube trays. Be sure to keep all fasteners so they can be reused unless otherwise noted in the instructions.

Notes:

• These instructions were written for a North American specification Audi RSQ8, but other models like the Urus are similar.
• When disassembling the car, be sure to keep all fasteners so they can be reused. It is recommended that you get some kind of compartmented tray to organize the fasteners, such as a fishing tackle box or several large ice cube trays. Fasteners that are not reused for reinstallation are noted in the instructions. All directions used in this manual (right, left, front, etc.) are based on if you were sitting in the driver’s seat of the car.
• These instructions assume that you have basic mechanical skills and several varieties of basic hand tools in order to install the kit. If you have any questions about the installation, feel free to contact your APR representative.

INSTALLATION INSTRUCTION

1. Raise and support the vehicle. While this can be done on jack stands, a lift is highly recommended. Remove the noise insulation cover under the rear cross brace. There are four 10mm nuts, four push-pin style fasteners, and two T25 screws. Remove the cover, noting how it interfaces with the other covers around it.
2. Remove ten 16mm screws and nuts from the metal cross brace exposed when the noise cover was removed. Remove the metal cross brace, noting how it interfaces with the covers around it.
3. Remove the rubber hangers with brackets from the factory exhaust, noting how the orientation of the brackets.
4. Loosen the four 13mm exhaust clamps from the four exhaust tip pipes, and remove the pipes from the car.
5. Unplug the electrical connectors on both exhaust valve motors, on both the left and right side of the rear muffler.
6. Support the rear muffler assembly with a transmission jack.
7. Loosen the four 13mm nuts on the two sleeve clamps just behind the removed metal cross brace. With an assistant to hold the front of rear section of the exhaust, slide the sleeve clamps towards the front of the car.
8. Remove three T45 screws from the center of the fiber-reinforced plastic from the undertray. Remove fif-teen T25 screws from the perimeter of the undertray, and then remove it from the car. Note how the under-tray interfaces with the surrounding panels on the car.
9. Remove eleven T25 screws from the middle noise cover panel under the car, and remove the panel from the car.
10. Remove the two 10mm nuts and one 10mm bolt from the metal heat shield on the left inside wheel well, just behind the left axle. Remove the panel from the car.
11. To remove the same metal heat shield from the right inside wheel well, you must first move the high voltage cables if the car is equipped with the sway stabilization feature. Remove the 10mm screw holding the cable bracket from the bottom of the right frame rail.
12. On the back side of the high voltage cable bracket, you must spin the clamping washer off the threaded stud on the bottom of the frame rail. The cable assembly can then be move out of the way.
13. Remove the three T25 screws from the metal heat shield on the right inside wheel well, just behind the right axle. Remove the panel from the car.
14. On the left downpipe, remove the 10mm triple square fastener from the top of the spring-loaded hanger assembly.
15. On the right downpipe, remove the 10mm triple square fastener from the top of the spring-loaded hanger assembly.
16. On the left downpipe, remove the three 12mm nuts holding the left downpipe to the left catalyst, as accessed from underneath.
17. On the left downpipe, remove the two 10mm triple square screws from the exhaust hanger near under the car, and then remove the left downpipe and gasket from the car.
18. On the right downpipe, remove the three 12mm nuts holding the right downpipe to the right catalyst, as accessed from underneath.
19. On the right downpipe, remove the two 10mm triple square screws from the exhaust hanger near under the car, and then remove the right downpipe and gasket from the car.
20. Swap the rubber hanger from the stock left downpipe to the APR left downpipe.
21. Install the APR downpipe onto the car. Install the two 10mm triple square screws to the exhaust hanger, and torque the screws to 20Nm (177 in-lbs).
22. Connect the left APR downpipe to the left catalyst with the supplied 12mm nuts and the new supplied gasket. Tighten the three nuts to 23Nm (204 in-lbs).
23. Install the factory spring and 10mm triple square bolt onto the factory spring hanger on the left down-pipe. Use one of the supplied nuts on the back side of the APR down-pipe bracket to hold the factory bolt. Tighten the 10mm triple square to 23Nm (204 in-lbs).
24. Swap the rubber hanger from the stock right downpipe to the APR right downpipe.
25. Install the APR downpipe onto the car. Install the two 10mm triple square screws to the exhaust hanger, and torque the screws to 20Nm (177 in-lbs).
26. Connect the right APR down-pipe to the right catalyst with the sup-plied 12mm nuts and new supplied gasket. Tighten the three nuts to 23Nm (204 in-lbs).
27. Install the factory spring and 10mm triple square bolt onto the fac-tory spring hanger on the right down-pipe. Use one of the supplied nuts on the back side of the APR down-pipe bracket to hold the factory bolt. Tighten the 10mm triple square to 23Nm (204 in-lbs).
28. Reinstall the metal heat shield on the right inner wheel liner with the three original T25 screws, tightening the screws to 5Nm (44 in-lbs).
29. Reinstall the clamping washer on the back of the high-voltage wiring harness bracket. The washer can be either spun into place or pushed in place.
30. Reinstall the 10mm screw on the front of the high-voltage wiring harness bracket. Tighten the 10mm screw to 9Nm (80 in-lbs).
31. Reinstall the metal heat shield on the left inner wheel liner with the three original 10mm screws, tightening the screws to 5Nm (44 in-lbs).
32. Reinstall the middle noise cover panel with the eleven T25 screws. Tighten the screws to 3Nm (27 in-lbs).
33. Reinstall the fiber-reinforced plastic undertray. Make sure the panel fits to the surrounding panels as it did before. Install and tighten the three T45 screws to 6Nm (53 in-lbs). Install the fifteen T25 screws to the perimeter of the undertray, and tighten those screws to 3Nm (27 in-lbs).
34. Place the two APR rear muffler sections on the floor or workbench as shown.
35. Secure the two mufflers together as shown with the two supplied 13mm bolts and two of the 12mm nuts.
36. Remove six 10mm screws holding both exhaust valve motors to the factory exhaust, and remove the motors from the exhaust.
37. Remove both rubber exhaust hangers with their brackets from the factory exhaust, noting their orientation.
38. Install both rubber hangers onto the APR rear muffler assembly in the same orientation as stock. The brackets on the rubber hangers should be on the outside from the rear mufflers.
39. Install the supplied D-shaped adapter onto the exhaust valve bracket on the APR exhaust as shown. The loop on the bottom of the D-shaped adapter goes into the slot on the end of the APR exhaust valve. Pivot the adapter so that is fully clockwise and touching the left stop on the APR bracket.
40. Install the factory exhaust valve motor onto the APR bracket, making sure the slot on the bottom of the motor connects to the top of the D-shaped adapter. Install the three factory 10mm screws and tighten to 10Nm (88 in-lbs). Repeat this pro-cess for the exhaust valve motor on the opposite side.
41. With an assistant, raise the APR muffler assembly into place, making sure muffler outlets sit inside the exhaust tips. Use a transmission jack to support the exhaust in place.
42. Install the two 13mm factory screws to secure the rubber exhaust hanger brackets to the car. Tighten the 13mm screws to 20Nm (177 in-lbs).
43. Reconnect the factory wiring harnesses to both factory exhaust valve motors.
44. Install the APR forward center pipes of the exhaust to the previ-ously installed downpipes with two of the supplied sleeve clamps. Lightly tighten the 15mm nuts on the sleeve clamps to hold the forward center pipes in place.
45. Install the previously removed center exhaust hangers onto the APR middle center pipes as shown.
46. Install the APR middle center pipes of the exhaust to the previously forward center pipes with two of the supplied sleeve clamps. Lightly tighten the 15mm nuts on the sleeve clamps to hold the middle center pipes in place.
47. Reinstall the metal cross brace on the car, making sure it interfaces with the surrounding panels as it did before. Install the ten 16mm bolts and tighten them to 49Nm (36 ft-lbs).
48. Install the APR rear center pipes of the exhaust to the previously installed middle center pipes with two of the supplied sleeve clamps. Use two more sleeve clamps to con-nect the rear center pipes to the APR rear muffler assembly. Connect the hanger bracket from the rear center pipes to the rubber hanger that should still be attached to the car. Lightly tighten the 15mm nuts on the sleeve clamps to hold the middle center pipes in place.
49. Working from the front of the car to the back, adjust the position of the position of the exhaust on the car. Once positioned well, fully tighten the 15mm nuts on all sleeve clamps to 35Nm (26 ft-lbs).
50. Reinstall the noise insulation cover under the metal cross brace, making sure it interfaces correctly with the surrounding panels. There are four 10mm nuts, four push-pin style fasteners, and two T25 screws.

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